Specializing in automotive single-core and multi-core cables, battery cables and building wires, the manufacturer supplies critical components to a wide range of vehicle segments including 2- and 3-wheelers, commercial vehicles, passenger cars, tractors, and electric vehicles (EVs).

Prior to adopting Zumbach technology, the company relied on manual and destructive testing methods to verify eccentricity. Operators had to cut samples from the extrusion line and send them to a lab for analysis. This process introduced several inefficiencies which included delayed feedback between measurement and corrective action; risk of off-specification production during intervals between lab checks; and increased scrap and rework, especially during start-up and product changeovers.

To overcome these challenges, Zumbach deployed the “Odex 10” combination measuring device, paired with an inductor and the Usys Touch processor. This integrated solution enables continuous, non-contact monitoring of eccentricity directly on the extrusion line. The introduction of this solution means that the operators now benefit from:

– Live eccentricity readouts displayed on the “Usys” touch human machine interface (HMI)

– Manual die-head positional adjustments based on real-time feedback, ensuring concentricity remains within tolerance

Since Implementing the Zumbach tailored solution, the manufacturer has achieved substantial improvements across its operations:

– Real-time visibility into eccentricity measurements have eliminated the need for periodic lab checks, enabling faster set-ups and changeovers, with quicker convergence to target concentricity.

– Early detection of drift has significantly reduced scrap and rework, while consistent concentricity ensures stable, compliant quality that meets stringent automotive-grade standards across all vehicle segments, including electric vehicles.

– Intuitive HMI guidance has empowered operators by standardizing corrective actions and shortening learning curves.

This success story underscores how Zumbach’s precision measurement solutions continue to support cable manufacturers worldwide in achieving consistent quality, operational efficiency, and customer satisfaction.

The “Odex 10” is a high-precision, non-contact eccentricity sensor designed for inline monitoring of cable and wire insulation. Utilizing advanced inductive measurement technology, it continuously detects the position of the conductor within the insulation layer, providing real-time feedback on concentricity. When integrated with Zumbach’s “Usys” touch processor, operators gain immediate visual access to eccentricity values via an intuitive HMI, enabling timely manual adjustments to maintain product quality.

Cable & Wire Fair 2025, booth 4/P1-4

Zumbach Electronic AG

Hauptstrasse 93

2552 Orpund/Switzerland

Tel.: +41 32 3560400

sales@zumbach.ch

www.zumbach.com