Magazine for wire and cable - Sikora

Harry Prunk, Harald Sikora and Bernadette Sikora -
New perspectives for 2011
Magazine for wire and cable
SIKORA EXTRA
Issue #03/December 2010
www.sikora.net
Measuring technology for automotive,
communication and installation cables
Diameter gauge heads with guarantee
China: Strong growth despite crisis
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2 SIKORA EXTRA FOREWORD
New perspectives for 2011.

Dear customers, partners and businesses of SIKORA,
2010 comes to an end and we look back to a year full of surprises.
Who would have thought that the economy recovers that quickly
and that the difficult times offer enormous potentials for growth? In
particular, the second half of the year was characterized by order
increases and concrete project discussions. In fact, China was our
growth engine in the last year. In 2011 we expect order growth
and thus look confident into the New Year.
The EXTRA focuses this time on the manufacturing of automotive,
communication and installation cables. Therefore, the theme deals
with the CENTERVIEW 8000, which was specifically developed
for quality control of such cables.
Our company plans for the future. From January 1st 2011 Harry
Prunk takes the chairmanship of the company. Harald Sikora, present
chairman of the AG, will manage together with his wife Bernadette
Sikora the newly developed SIKORA Holding GmbH & Co.
KG. Read more about the new company structure on page 6.
In the next year as well we support the SOS Children’s Village Bhuj
in India. Furthermore, we decided to adopt 13 girls of the village.
In doing so, we want to make our contribution to offer the children
a better future.
Our title header “Knowledge“ answers the question, what FFT-
Analysis means.
At this point, we thank you very much for your loyalty and confidence
in our company. For the upcoming year we wish you all the
best filled with health, luck and success.
Enjoy reading,
Harald Sikora
Harry Prunk
WWW.SIKORA.NET
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SIKORA EXTRA · TITLE
Always in the middle
Safe quality control of automotive, communication
and installation cables
The CENTERVIEW 8000 helps the operator of an extrusion line
to center the conductor in the insulation, to monitor the concentricity
and moreover to provide measuring results that allow for a control
of the outer diameter or wall thickness to the nominal size.
Start-up losses are avoided, the quality of the cable permanently
improved and simultaneously the productivity of the line increased,
without increasing the expenditures for operation, calibration and
maintenance. The measuring system is suitable for single conductors
with massive or multi-wire conductor with outer diameters from
0.1 to 25 mm. These conductors are especially used as automotive,
communication or installation cables. Furthermore, the device
releases the operator and convinces with regard to freedom from
maintenance, reliability and long-life precision, which ensures maximum
material savings.
Reliable measurement of cable parameters
The CENTERVIEW 8000 calculates eccentricity and insulation
wall thickness by means of a highly precise inductive and optical
measuring principle in four planes.
The inductive measuring system measures the exact position of the
conductor in the gauge head, while the optical system measures at
8 points the outer position of the insulation in the measuring field.
The cable passes through a ring core transformer. The ring core
transformer feeds an alternating current into the conductor. This alternating
current creates an electro-magnetic field around the conductor.
Inside the CENTERVIEW 8000 gauge head there are inductive
sensors, arranged in a circle around the conductor. With
the help of these sensors the precise position of the conductor is
calculated from the distribution of the intensity of the magnetic
field.
The optical part of the system is based on the principle of the shadow
projection with the help of the diffraction analysis, combined
with pulse driven laser diodes, whose light beam projects a shadow
of the cable onto the particular CCD line sensor. The optical
systems measure at 4 axes the width and the position of the shadows.
That means, they measure the outer diameter of the cable
and calculate the position of the cable surface inside the gauge
head and define the ovality each with 8 points of the periphery.
From the position of the shadow in relation to the position of the
conductor signal processors calculate precisely the exact value of
the eccentricity at 8 points. If the conductor and the insulation layer
have the same center there is concentricity. There is an eccentricity
if both centers differ from each other.
The inductive measuring system additionally positions the measuring
head automatically relative to the position of the conductor so
#02
#01

#01 Das CENTERVIEW 8000 zum Einsatz in Produktionslinien von
Kommunikationskabel,. Automobil- und Installationsleitungen
#02 Visualisierung der Messwerte mittels der Punktwolke
#01 The CENTERVIEW 8000 integrated into a line
#02 The Cloud Diagram shows the single values of the distribution of the eccentricity
(circle and ring type distribution (from left))
#03 Standard representation of eccentricity at the ECOCONTROL 2000
that the cable is always the middle of the measuring field. At this
position the accuracy is the highest. As a result of the automatic
positioning of the measuring head there is no need for an extensive,
manual adjustment of the measuring head or a mechanical
guide of the cable before or after the CENTERVIEW 8000. In
consequence, a maximum accuracy is achieved.
Visualization of the measuring values
The cloud diagram* is an additional way of presenting the measured
values of the ongoing measurement at the ECOCONTROL. The
cloud diagram provides information on the distribution of short term
variation of eccentricity in graphical form. Each dot corresponds to
a single measured value of eccentricity in relation to the amount
and angle. The extension of the cloud diagram is an indicator of
the standard deviation of eccentricity.
A circle type distribution of the single values of the eccentricity indicates
their fluctuation range. This display is helpful to optimize the
process in terms of minimizing standard deviation.
A ring type cloud diagram indicates that there is a permanently
rotating eccentricity value. This could be a result of the conductor
rotating/oscillating before it enters the extruder crosshead.
The standard way of representing eccentricity using a cross-section
of the cable is very helpful for the operator when centering the
crosshead. But only the display of single values in the form of a
cloud diagram gives the operator the necessary information to take
suitable measures to minimize eccentricity.
*Patent pending
WWW.SIKORA.NET
#03
#03
#02
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SIKORA EXTRA · CORPORATE NEWS
#01
New company structure
SIKORA plans for the future
The supervisory board and management board of SIKORA have
decided the restructuring of the company. From January 1st 2011
Harald Sikora, present chairman and head of the R&D department
at SIKORA, withdrawals from the operational business in order to
pave the way for the next generation. He changes to the newly
founded SIKORA Holding GmbH & Co. KG.
Mrs. Bernadette Sikora is also appointed to the Holding and is
responsible for the business areas Finances and Controlling. Harald
Sikora will support the company as consultant. Successor of
Sikora is Harry Prunk, present member of the board of the SIKORA
AG. As chairman Prunk takes over the management of the company
with the business areas Production, Service, Purchasing, Sales,
Marketing and Research and Development.
Dr. Siegmar Lampe is appointed director of the R & D department.
Until now he was the deputy director of development under Harald
Sikora. The SIKORA AG is a division of the SIKORA Holding
GmbH & Co. KG and has at present ten offices worldwide.
#02
SIKORA continues its partnership
with the SOS Children’s Village Bhuj
Better educational perspectives for 13 SIKORA
godchildren
Nearly one year has passed since SIKORA has started a partnership
with the SOS Children’s Village Bhuj in India under the motto
“Education is my road to the future“. Instead of sending Christmas
presents SIKORA provided the necessary financial means for the
school attendance of 50 children in the village.
In the next year as well SIKORA supports the educational opportunities
of the children in Bhuj. Furthermore, the company takes god
parenthood for 13 girls of the village. “Despite huge advancements
children, and in particular, girls in India are still excluded
from education. Therefore, we decided for this partnership”, explains
Katja Giersch, Head of Marketing at SIKORA. “Wars, natural
catastrophes and famine hit predominantly the least of society, namely
the children”, continues Giersch. “Precisely because our own
children and those of our customers are doing well, we do not
want to forget all the kids who have to grow up under the most
difficult life conditions, such as the children in Bhuj.“

#01 Mr. Premjeet Saggu, Manager SIKORA INDIA, vsited the SOS Children‘s Village Bhuj
in September this year.
#02 Muskan Sinha, 7 years old, has found a permanent home in the SOS- Cildren’s Village Bhuj.
Her mother has died; her father alone was not able to care for Muskan.
Muskan is one of the 13 SIKORA children.
#03 The Diversity-award „The colorful key - Create Diversity!“ goes to SIKORA
SIKORA AG is a “TOP company”
Munich Strategy Group and „Die Welt“ publish
ranking on the German medium-sized
businesses 2010
The SIKORA AG takes the 21st place of the TOP 100 mediumsized
companies in Germany. This is the result of a study, published
in “Die Welt” on October 18 2010, in cooperation with the Munich
Strategy Group. More than 1000 medium-sized companies in
Germany have been examined in the course of this study.
In Bremen SIKORA is the only company, which belongs to the TOP
100. The ranking is based on two criteria, which are equally
weighted, namely the average growth in sales as well as the average
rate of return in the years 2005 to 2009.
Bremer Diversity-Award
goes to SIKORA
Corporate success through diversity
SIKORA wins the first Diversity-award namely “The colorful key –
Create Diversity!“ for small and medium sized companies. The
price was awarded on December 2nd 2010 in the course of the
final conference of the ESF-Projects (European Social Fund)
BremenForum:Diversity in the upper city hall.
The award is intended to companies and institutions that have developed
and implemented measurements and strategies for the
conscious and positive use of diversity in their organization. “Diversity
Management means to SIKORA „Corporate success though
diversity“. This motto is not only part of the company philosophy,
but is lived by all participants“, explains Dr. Margrit Kaufmann, Institute
for culture research at the University Bremen. “The management
does not only consider classical Diversity categories, but responds
to individual needs. Through the concrete use of particular
capabilities of the employees and consideration of specific life situations
the SIKORA AG is considered to be a model of the medium
sized companies in Bremen”, says Kaufmann.
Entrepreneur of the year 2010:
SIKORA is finalist
Economy prize dignifies innovation
and personal commitment
WWW.SIKORA.NET
SIKORA has reached the final round of the competition „Entrepreneur
of the year“. The finalists are characterized by high innovation
thanks to the commitment of qualified employees. With efficient
organizational structures and short decision making processes they
are able to flexibly react to market conditions.
In total 68 companies are in the final round of the competition. The
consulting company Ernst & Young awarded the title for the 14th
time. “Due to its ambitious criteria the price has gained high reputation
in the last years“, says Wolfgang Glauner, project manager
of the competition. “The performance of the candidates is not only
checked with the help of key data of the companies, but also in a
personal interview.“
#03
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SIKORA EXTRA PRODUCT NEWS
2 years guarantee, for sure
The LASER Series 6000: Reliable with the highest accuracy
Measuring precision combined with outstanding functionality and
perfect design – these are the features of the new gauge heads of
the LASER Series 6000. This model range is more than a facelift of
the successful 2000-series and achieves an even higher productivity.
The applicable design of the LASER-devices, with small dimension
and optional swivelling gauge head, includes a measuring value
display directly at the gauge head for a further improvement.
Moreover, there are no external plugs. A universal interface module
is directly integrated into the gauge head. As a result the plugs as
well as the cables are protected from any environmental influences.
In addition, the gauge head opening of the LASER Series 6000 is
twice as big as the measuring range. This wide opening as well as
the big sight field allows for an easy cable feeding.
Regarding electronics the SIKORA-engineers once again raised the
bar: The devices have a measuring rate of 2,500 measurements
per second with high single value precision independent from the
position of the product within the measuring field and thus ensure
an optimum line control and reliable statistical data.
The new gauge heads of the LASER Series 6000
The gauge heads do not include moving parts and maintain their
accuracy during the entire operation time. Calibration procedures
or maintenance are not necessary. The measuring devices cover
diameter ranges from 0.25 to 80 mm. In addition, SIKORA offers
further 2-axis diameter gauge heads for products from 0.05 to 500
mm as well as 3-axis measuring devices for product diameters from
0.2 to 100 mm.
Novelty: From now on customers get a 2-year warranty for a
gauge head of the LASER Series 6000 .

We assume liability
Optimum conductor preheating for
wire and cable extrusion lines
PREHEATER 6000
The PREHEATER 6000 is specifically developed for the use in
production lines for communication cables. A reliable conductor
preheating is required for this application field in particular in order
to achieve a better adhesion of the insulation on the copper wire.
Simultaneously, humidity and lubricants (flux and cooling materials
from the drawing die) vaporize and thus ensure an optimum cable
quality, which is important in the high frequency range.
The device is used before the extruder and heats the wire through
inductive heating. A control module regulates the power of the
PREHEATER 6000 in dependency on line speed and product diameter.
Thus, the temperature remains stable and ensures optimum
adhesion of the insulation on the conductor.
The PREHEATER 6000 is controlled via the processor system
ECOCONTROL 600. The ECOCONTROL 600 includes a product
library, where product recipes can easily be stored for diverse
cable types. Alternatively, the control is via Profibus-DP.
Successful without break downs
Reliable spark tester
WWW.SIKORA.NET
SPARK 2030 UL
Designed for diverse cable types, SIKORA offers high frequency,
DC and AC testers for reliable fault and bare wire detection.
All Spark testers include powerful signal processors.
SPARK 2000 UL, a high frequency high voltage spark tester
with a robust bead chain electrode precisely detects defects in
the insulation during the production. It is typically used for building
wires, automotive wires and signal cables. The test voltage
is continuously adjustable.
SPARK 2000 DC is a DC spark tester, especially developed for
the testing of telephone wires, data cables and mini-coax
cables with foam insulation. The solid electrode and the electronic
box of the Spark Testers form one integral unit. Optionally,
the display and control device REMOTE 2000 can be fully integrated.
The successful spark tester range also includes models for specific
applications such as the SPARK 6000 BS, a high voltage
AC test device for cables with bigger diameters up to 200 mm.
All spark testers conform to approved test standards (AS, BS,
CS, CENELEC, EN, UL, VDE) and safety regulations (as demanded
by DIN/VDE 0800, IEC 479-1).
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SIKORA EXTRA · NEWS
Strong growth in Middle Kingdom
SIKORA with powerful presence in China
In China the financial crisis was hardly to feel. It was rather the
opposite: Middle Kingdom was economically active like in the
best boom times and could push the global economy to new upswings.
In China the need for energy increased extremely in the last
years, which led to the construction of many power plants and a
higher demand for high voltage cables.
For a comprehensive power supply in China, projects such as the
extension of cable plants, are state-aided. Investments in plant and
machinery as well as reliable measuring technology, that assure
high quality standards, at simultaneously cost saving production
are highly demanded since then. This is also felt by SIKORA. The
company provides measuring and control devices for numerous
projects in China.
For 15 years SIKORA has been present with an office in China and
further extents its activities due to the strong economy in the Asian
region.
X-RAY 8000 NXT
The Middle Kingdom is booming
One hundred and eleven times
SIKORA celebrates delivery of the 111th X-RAY 8000 NXT in 2010
SIKORA has produced the 111th X-RAY 8000 NXT in this year.
The jubilee measuring device for permanent quality control in CVlines
was delivered to a customer in China. Thus, the number of
devices, which have been manufactured since 1993 increases to
730.
Online-process optimization, material saving and a permanent
quality control during the production of MV-, HV- and EHV cables*
in CCV-, VCV- and MDCV-lines** are only some advantages, that
can be achieved with the X-RAY 8000 NXT. The X-RAY 8000 NXT
measures the wall thickness, eccentricity as well as the diameter
and ovality with incomparable accuracy and repeatability. One
scan only is necessary to calculate all values. The X-RAY 8000
NXT allows the operator for a quick adjustment of the extrusion
tools as well as an optimum control of the production line in automatic
mode.
* MV (Medium Voltage), HV (High Voltage), EHV (Extra High Voltage)
** CCV (Catenary Continuous Vulcanization), VCV (Vertical Continuous Vulcanization),
MDCV (Mitsubishi Dainichi Continuous Vulcanization)

Knowledge
What is FFT-Analysis
Basically the FFT-Analysis (or Fourier-Analysis) is a mathematical
method to recognize periodically recurrent variations in signals.
Periodical variations of the diameter, eccentricity and capacitance
are a high risk for data transfer characteristics in particular during
the production of communication cables. The online FFT-Analysis
(FFT = Fast Fourier Transformation) of these measuring data is a
control tool for the identification of periodical occurring variations
during cable extrusion.
While periodical variations are generally difficult to determine from
the chronological sequence of the diameter, eccentricity or the capacitance,
with the help of the FFT-Analysis of these measuring
values variations can be graphically displayed in dependency of
their frequency.
Next Events
INTERWIRE
2.–5. May 2011
Atlanta, GA, USA
Herausgeber/Publisher
SIKORA AG BREMEN
WWW.SIKORA.NET
Monitor image FFT-Analysis
This so called frequency spectrum does not only reflect the amplitudes
of the single periodical variations, but provides helpful information
for identification of the causes of cyclic variations in the cable
production process.
A digital FFT-spectrum-analyzer is directly integrated in the gauge
head of the SIKORA measuring devices. The advantage is that
measuring values can be analyzed for periodical contents with
high precision at minimum measuring value noise. A problematic
(normally analog) transfer of single measuring values to an external
analysis-system is not required.
Impressum/Publisher
Anschrift der Redaktion/Editor’s Office
Katja Giersch
Pressesprecherin/Head of Corporate Communications,
SIKORA AG, Bruchweide 2, 28307 Bremen,
Deutschland/Germany
Tel.:/Phone: +49 421 48900 669
giersch@sikora.net, www.sikora.net
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SIKORA AG
Bruchweide 2 · 28307 Bremen
Deutschland
Tel.: +49 421 48900 0
www.sikora.net
sales@sikora.net
CHINA
sales@sikora-asia.com
FRANKREICH
sales@sikora-france.com
INDIEN
sikoraindia@gmail.com
ITALIEN
sales@sikora-italia.com
JAPAN
sales@sikora-japan.com
KOREA
sikora@chol.com
RUSSLAND
sales@sikora-russia.com
TÜRKEI
sales@sikora-turkey.com
UKRAINE
sales@sikora-ukraine.com
USA
sales@sikora-usa.com
kb 12/10 MD 4100