Power cables place high demands on both performance and the production process. In the case of submarine and underground cables, reliable energy transmission to the point of use is critical, which means that product quality directly affects the safety of electricity supply. Sikora states that its X-Ray 8000 system has been regarded as the global industry standard in CV lines for more than 30 years, with more than 2,000 systems installed. In the latest version, X-Ray 8000 Advanced, the system is designed to control cable dimensions directly after the extruder, in the CV tube. The device measures parameters such as wall thickness, eccentricity, diameter and ovality. The data is intended to be available within a very short time, allowing rapid centering adjustment and dimensional control against target values at an early stage of the process. The solution is positioned as a tool for production stabilization and for reducing quality deviations in power cable manufacturing.
Compared with conventional systems available on the market, X-Ray 8000 Advanced uses High-Speed Technology, HST. The system is equipped with 16 measuring sensors, which shortens measuring distances and, according to the manufacturer, enables measurement at least 10 times faster than conventional solutions. As a result, measured values are available in less than 30 seconds, allowing immediate centering, while distortion-free control to the target value is said to be achieved within 100 seconds.
Continuous use of the X-Ray 8000 Advanced is intended to enable a wall thickness reduction of around 5%, which translates into significant material and cost savings. According to the company, this level of material saving corresponds to a reduction in CO2 emissions of around 375 tonnes per year. The manufacturer compares this reduction to about 125 round-trip flights between Frankfurt and New York. In this context, the system is also intended to support sustainability goals in cable production.
The X-RAY 8000 Advanced is used for quality control in CV lines
Measurement scope and line integration
System durability is intended to be ensured by XLL X-ray technology. In turn, special self-cleaning and non-toxic NTX measuring windows are intended to improve operational safety and working conditions in the CV line. In addition to the measuring system itself, a control cabinet containing an industrial PC for evaluation of the X-ray image is supplied. All measured values are visualized and logged in real time on a TFT monitor.
X-Ray 8000 Advanced can be integrated vertically in CCV and VCV lines as well as in a horizontal line for medium-voltage cables. The system can also operate in hybrid CV lines in which both XLPE and PP are used as insulation materials.
Final inspection at the end of the line
For final quality control at the end of the CV line, the X-Ray 8700 NXT system is intended to record the cable’s cold values. In combination with the X-Ray 8000 Advanced system installed at the beginning of the line, it is also possible to determine shrinkage values precisely for all three insulation layers of the cable. This arrangement is intended to ensure optimal process control and compliance with existing cable quality requirements for maximum reliability and safety.
The combination of the X-RAY 8000 Advanced at the beginning and the X-RAY 8700 NXT at the end of the CV line ensures optimal process control
