How does light shadow projection work for inline wire and cable measurement ?

Light shadow projection

‍

How can you accurately measure the diameter of a wire, cable or tube traveling at thousands of meters per minute ? How do you detect microscopic surface flaws or deviations in shape without touching the product ? The answer lies in a proven and robust technology: light shadow projection.

This non-contact optical method uses a collimated beam of light typically from a high-performance light source that is projected across the moving product. As the object interrupts the beam, it casts a precise shadow onto high-speed CMOS image sensors. By analyzing the shadow’s edges, the system can determine exact diameters and detect shape irregularities with micron accuracy.

Unlike traditional contact-based systems or scanners, light shadow technology is immune to vibration, requires no calibration between changes, and works seamlessly across various materials and surface finishes. It’s a perfectly suited method for real-time quality control in modern, high-speed manufacturing environments.

‍

‍

It is this very principle that powers the DLN10 CERSA-MCI’s latest advancement in inline measurement technology.

‍

Designed to push the boundaries of speed, precision, and versatility, the DLN 10 takes full advantage of light shadow projection and delivers unmatched performance for demanding industrial applications.

CERSA-MCI is proud to introduce the DLN10, a powerful and ultra-precise diameter measurement solution engineered to meet the needs of modern wire, cable, and tube manufacturers. Designed for real-time process control, the DLN10 combines high-speed, multi-axis diameter measurement with surface defects detection, flaw detection and non-circularity analysis, making it the ultimate solution for advanced industrial metrology.

‍

Industry-Leading Technical Performance

‍

Based on light shadow technology and ultra-fast CMOS image sensors, the DLN 10 performs up to 750,000 diameter measurements per second across three independent axes. Its exceptional 1µs exposure time ensures accurate data acquisition, even under vibration and high-speed conditions. This data density allows detailed detection and characterization of defects such as lumps, neck-downs, and geometric variations all in real-time. The DLN 10 measures diameters from 0.3to 10.0 mm with ±0.005 mm accuracy and ±0.001 mm repeatability(3σ), offering stability and reliability without the need for averaging.

The system also monitors non-circularity, peak-to-peak diameter, and the max/min per axis, providing a complete overview of wire or tube shape consistency. Defects as small as 0.04 mm in length and 0.005 mm in height can be detected, making the DLN 10 a critical tool for manufacturers focused on tight tolerances and high-performance outputs.

‍

‍Designed for Seamless Integration and Versatile Application

‍

Compact and lightweight, the DLN 10 is easy to integrate directly into production lines. Its robust design includes a maintenance-free light source, IP54 protection, and no moving parts, ensuring long-term stability. For enhanced integration, the DLN 10 supports USB, Ethernet, and digital I/O, with,with optional industrial fieldbus protocols like Modbus-TCP, Ethernet/IP, or Profinet, and BNC analog outputs for process control.

‍

‍

Applicable across various sectors including automotive, telecom, aerospace, and medical device manufacturing the DLN 10 is suitable for insulated or jacketed wires, stranded conductors, optical fibers, metallic wires, and medical tubing. This makes it a versatile tool for manufacturers requiring stringent quality assurance and compliance with industry standards.

To help customers experience the benefits of this device, our sales engineers offer on-site demonstrations, allowing you to evaluate its performance directly in your production environment.

If your goal is to enhance quality control, reduce raw material waste, and meet increasing market demands for traceability and precision, the DLN 10 is the measurement solution to consider.

‍

Want more about DLN10 ?

‍

How does it work ? click here !

Inline demo click here !

Product page click here !

‍

‍