DLN 10 Put to the Test: Accuracy and Defect Detection in Real Production Conditions

When Ghost Defects Disrupt Cable Production

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During a recent test in Europe, CERSA-MCI had the opportunity to test its latest innovation, the DLN 10 in-line measurement system, directly on an extrusion line. The instrument was installed in parallel with the existing gauges in order to evaluate its performance on a multi-conductor copper cable. The results confirmed the importance of the instrument's ability to measure the diameter of the cable.

While competing systems reported defects such as lumps and necks, the DLN 10 indicated no irregularities. Subsequent verification of the cable by rewinding and manual inspection revealed that there were in fact no defects. The anomalies identified by the other devices were actually false positives.

This result highlights a common problem in cable production: false detection of defects can lead to unnecessary downtime, wasted materials and reduced productivity. By eliminating these “ghost defects”, the DLN 10 provides manufacturers with a tool that ensures both accuracy and operational efficiency.

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How Light Shadow Projection Enables Precision Measurement

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At the core of the DLN 10 is the light shadow projection method. A collimated LED beam is projected across the product, and the shadow cast is analyzed by ultra-fast CMOS sensors. The system operates on three orthogonal axes, providing a complete characterization of diameter, non-circularity, and geometric variations in real time.

Unlike traditional systems that rely on rotating mirrors or mechanical components, the DLN 10 integrates the optical system and electronics within a compact, maintenance-free head. With an exposure time of 1 µs, the device achieves 750,000 measurements per second (250,000 per axis), ensuring accuracy even at high line speeds or under vibration.

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Key technical advantages

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The DLN 10 provides high-performance inline measurement for demanding production environments, with the following specifications:

-       High-speed data acquisition: 250,000 measurements per second per axis, across three axes (total of 750,000 measurements per second).

-       Measurement range: from 0.3 to 10.0 mm.

-       Accuracy and repeatability: ±0.005 mm accuracy and ±0.001 mm repeatability (3σ, without averaging).

-       Defect detection: capable of detecting defects as small as 0.04 mm in length and 0.005mm in height.

-       Design: compact dimensions (313 × 310 × 89 mm), weight 6.3 kg, IP54 protection, LED light source, and no moving parts.

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When connected to CERSA-MCI’s CIM software, the DLN 10 provides advanced visualization and statistical analysis, enabling operators to monitor process stability, optimize line efficiency, and ensure compliance with stringent customer specifications.

The DLN 10 represents a significant step forward in inline measurement technology for the wire and cable industry. By combining light shadow projection, ultra-fast performance, and robust industrial design, it delivers both accuracy and reliability where it matters most: on the production line.

Manufacturers looking to improve quality control, reduce waste, and avoid unnecessary downtime now have access to a system capable of redefining the standards in industrial metrology.

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Want more about DLN10 ?

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How does it work ? click here !

Inline demo click here !

Product page click here !

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