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Dr. Siegmar Lampe,
Head of Research and Development at SIKORA AG
Magazine for wire and cable
SIKORA EXTRA
Issue #01/April 2011
www.sikora.net
Measuring technology for energy cables
Quality Management system for customer satisfaction
Dr. Siegmar Lampe is new Head of R&D at SIKORA
Product of the quarter: PREHEATER 6000
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2 SIKORA EXTRA ·FOREWORD
Full wind speed ahead.

Dear customers, partners and businesses of SIKORA,
Welcome to the first issue of the EXTRA in 2011. This time we deal
with efficient measuring and control devices, which are proven to
be needed in the production of energy cables. There is an increased
growth of offshore wind power plants, where energy cables
are used for power transmission from the sea to the mainland.
We also present to you our quality management system according
to ISO 9001 and explain how we continuously further improve our
processes to increase customer satisfaction.
Only recently, we opened up our new employee restaurant “Roofgarden”.
The restaurant on the 4th floor of our Technology Center
spoils our employees and guests daily with fresh and organic raw
food.
Life in the SIKORA world remains manifold. Therefore, we introduce
to you our new head of the R&D department Dr. Siegmar Lampe.
Since January 2011 he has been the successor of Harald Sikora.
Read about his ideas and visions.
The header “Knowledge” explains the LASER measuring principle
of the SIKORA diameter gauges and shows their added value for
production lines.
Enjoy reading.
Kind regards,
Harry Prunk, chairman of SIKORA AG
WWW.SIKORA.NET
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SIKORA EXTRA · TITLE
Non-contact
Temperature sensor
Preheating system
(1) (2)
Offshore windparks are the future:
Quality assurance during the production of energy cables
There were more wind power plants built in European seas in
2010 than ever before. More than 300 plants with a total power of
more than 880 megawatt were added.
Great Britain was the precursor in the matter of wind power. More
than half of the new plants were established around the British Isles.
There are now 51 percent more wind power plants at sea than
in 2009. The total power of all installed wind power plants at sea
in Europe counts 2,950 megawatt. The German share amounts to
92 megawatt (3 %). According to the European Wind Energy Association
(EWEA), there will be strong investments in the future on
the construction of new wind turbines at sea in Germany. 1
Power transmission from offshore wind parks to the mainland is
currently being funnelled by undersea cables. These cables have to
provide different requirements as well as environment conditions.
Thus, the cable design complies with national and international
standards. In order to fulfil these requirements cable manufacturers
use innovative measuring and control technology in their production
lines. This controls all cable specifications during the production.
SIKORA offers a band width of measuring technology for the
use in CV-, VCV- or MDCV-lines.
(3)
Sagging measurement
CSS 2 assures the cleanliness of the melt (1)
In a CV-line, for example, a CSS 2 (Cleanliness Scanning System)
is installed for real time monitoring and detection of impurities of
the polymer melt. The flow channel between main extruder and the
cross head is equipped with sight glasses and an optical CCDcamera
system, which transilluminates the insulation material. Thus,
the system assures that only pure PE material is used for the cable
production. As a result, a higher electric strength of the cable can
be achieved.
ULTRATEMP 6000 assures an optimum melt temperature (2)
SIKORA’s product range for energy cables also includes the
ULTRATEMP 6000, which measures the temperature of the PE melt
during extrusion on a non-contact basis between the extruder screw
and the cross head. Besides temperature determination, the
ULTRATEMP 6000 detects inhomogeneities in the melt. Early cross
linking after screens which may lead to ambers or scorches in the
material do not occur. The device optimizes the output of a planned
production time.

X-RAY 8000 NXT assures accurate hot measuring values of the
cable parameters (3)
The X-ray measuring system X-RAY 8000 NXT is installed in the
moving part of the telescopic tube directly after the crosshead for
precise hot measurement of the wall thickness of all 3 layers (concentricity,
diameter and ovality). Measuring values for centering
and control are therefore available immediately after starting up the
line. The system is used in catenary and vertical lines.
X-RAY 8700 NXT assures precise cold values (4)
While the X-RAY 8000 NXT provides information for a fast centering
and direct control, the X-RAY 8700 NXT supplies precise quality
data about the final product. The X-RAY 8700 NXT measures
the diameter, wall thickness and eccentricity and is suitable for all
cable types with solid, stranded or Milliken conductor and with
single, double or triple layer insulation. With the use of the X-RAY
8000 NXT at the beginning of the line for collection of the hot
measuring values and the X-RAY 8700 NXT at the end of the line
for measuring the cold values, 3 shrinking values are analyzed for
every insulation layer of the cable. Consequently, an optimum process
is assured.
(4) (5)
CV-line (Catenary line)
WWW.SIKORA.NET
LENGTH 6000 assures the precise cable length (5)
For example, at the end of the line the length measuring system
LENGTH 6000 is installed for accurate measurement of the produced
cable length. With the system manufacturers avoid short or
over lengths, which may lead to profit cuts. SIKORA’s mature
measuring and control technology is characterized by an exceedingly
high precision and reliability. The devices support manufacturers
of energy cables to fulfill all quality demands.
SIKORA’s mature measuring and control technology is characterized
by precision and reliability. The devices support manufacturers
of energy cables to comply with quality demands and to run
their production more economical.
1 The European offshore wind industry key trends and statistics 2010. A report by the European Wind Energy
Association. January 2011.
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SIKORA EXTRA · CORPORATE NEWS
#01
SIKORA opens up new
employee restaurant “Roofgarden“
New cuisine for increased satisfaction
At the beginning of February 2011 SIKORA opened up their new
employee restaurant “Roofgarden“ on the 4th floor of the newly
built Technology Center. The restaurant provides SIKORA employees
and guests with healthy and diversified food in a stylish atmosphere.
It provides a breathtaking panoramic view about Bremen
which makes eating there a food experience.
For SIKORA, healthy food is part of a lively company culture. “We
would like to create a “time out zone” for our employees in pleasant
atmosphere”, explains Bernadette Sikora, Managing Partner
of the SIKORA Holding GmbH & Co. KG. “Our employees should
enjoy coming into the restaurant, feel comfortable and return to
their work relaxed and satisfied. This is an enormous added value
for the employee and for our company”, explains Bernadette Sikora
further.
#02
“The new company restaurant “Roofgarden”
The meals are daily prepared in the newly created SIKORA company
canteen. A balanced and seasonal food range is in the focus.
The concept of the restaurant was developed and realized in
cooperation with the agency for healthy life “Essenszeit”.

“You have to think outside the box”
Dr. Siegmar Lampe, Head of Research &
Development (R&D) at SIKORA, in an interview
Since January 1st 2011 Mr. Dr. Siegmar Lampe is head of the
R&D department at SIKORA. We asked him about his new job, his
plans and visions.
Mr. Dr. Lampe, for 3 months you have been responsible for the
R&D department at SIKORA. What has changed for you since
then?
Since the take-over of my new position, the organization and coordination
of the R&D activities determine my daily function. The work
is diversified because I get all development topics on my desk from
which new ideas and suggestions for new projects result. Of
course, I know about my new responsibility and take it very seriously.
What Mr. Sikora has built up with regard to innovations in the
last over 30 years raises the bar. Nevertheless, I will meet the
challenge and I am pleased to continue his vision. By the way, I
am proud to have a motivated team behind me who daily live the
thought of innovation with me.
How would you like to push forward the innovation activities of
the company in the future? Do you have concrete ideas?
Customer conversation is important for me. With communication
only I know what the customer needs. Simultaneously, I have to
recognize which technologies could be helpful to further optimize
or support the production process. In this regard, I have the function
of an adviser. In my opinion, a great potential in the future offers
the X-ray technology. I am sure that this know-how will be of decisive
importance for the cable, hose and tube industry as well as for
other markets.
What characterizes SIKORA measuring technology in contrast to
alternative technologies?
Our aim is to provide optimum technology which fulfills and possibly
exceeds all customer demands. This maxim is also reflected in
our claim “Technology to Perfection”. The drive to perfection is part
of our company philosophy. Thus, we have established for example
a wide network of offices and representatives worldwide in order
to comprehensively support our customers every time and everywhere.
We are only satisfied if our customers are satisfied.
What is your life motto?
Actually I have two. “Live the day” and “No can do is not an option
for me”. In particular, the second motto determines my work. I
am only satisfied when there is a solution – and there is always a
solution, no matter for which problem. You have only to think outside
the box.
Many thanks for the conversation.
Profile Dr. Siegmar Lampe
WWW.SIKORA.NET
Dr. Siegmar Lampe is new Head of R&D at SIKORA
1991 - 1997 Studies of Electrical Engineering with the
focus on Microelectronics/Microsystems
Technology, University Bremen
1997 - 2003 Research Assistant at the Institute for
Theoretic Electrical Engineering and
Microelectronics, graduation in the area of
Numerics, University Bremen
2003 - 2005 Development Engineer Automotive
Electronics at the IAV GmbH
2005 - 2010 Development Engineer at SIKORA AG
since 1.1. 2011 Head of R&D at SIKORA AG
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SIKORA EXTRA ·QUALITY MANAGEMENT
Quality system for your satisfaction
Since 1993 SIKORA fulfills the requirements according to ISO 9001
and evidences that the quality of their measuring and control
technology is assured and continuously improved with an effi-
cient Quality Management System (QMS).
“Quality is the precondition to fulfill the demands of the customers
for the product respectively for a service.”, says Arne Heel, Quality
Manager at SIKORA AG. In cooperation with the management
and the employees he analyzes and documents the business processes
in the company, identifies responsibilities and potential sources
of error.
SIKORA‘s QMS includes defined key data to monitor and control
processes. The so called Mean Time Between Failures (MTBF) for
example represents an internal key data, which helps to evaluate
the quality progress and to supervise the freedom from error of the
systems. The MTBF is the average time after which a device of a
series shows a repairable defect. This key data is calculated on the
Since 1993 SIKORA fulfills the requirements according to ISO 9001
basis of fault diagrams, which are also generated in the QM. They
give clear presentation of device failure and provide details about
failures of a specific device type.
A fault diagram has a horizontal (x-) and a vertical (y-) timeline. The
x-axis represents the delivery date and the y-axis the failure date.
The diagram (page 9) shows all known failures of the diameter
gauge head LASER 2010 XY. Faults are events that directly led to
a device failure and that are indirectly in responsibility of SIKORA.
That applies for example, if a group of components fails or software
faults occur. An incorrect handling or operating error by the
customer is not counted. In the diagram the delivery of one or more
devices is displayed as small black crosses. In the course of time
there develops a more or less close diagonal chain.
In the vertical level above every delivered device there can be read
its life story. If this device fails a specific symbol is shown above the
device in the vertical. The representations of device failures nor-

mally include symbols for hardware failures, software failures, failures
by reason of mechanics and other (e.g. production failures, delivery
failures, etc.).
In order to collect additional details of the device failures, there are
also fault diagrams created for specific fault types. These are differentiated
according to component groups. Among them there are for example
diagrams that only refer to device failures where at least one
hardware component contributed to the failure. All other failure types
(mechanic faults, software faults, etc.) are not shown in this diagram.
For continuous improvement of the quality there are internal and external
employee trainings at SIKORA. Moreover, SIKORA builds up cooperations
with machine manufacturers and customers to meet the
worldwide benchmark in the industry and to further perfect the processes.
“A sustainable quality management requires clear, transparent
processes and a good communication.”, explains Heel. “Feedbacks
of employees and in particular of customers are crucial for a successful
WWW.SIKORA.NET
Fault diagram LASER 2010 XY
Quality Management System”, states the quality manager
further. “With the improvement of our operational processes
according to the standards of our QMS we do not only comply
with legal requirements, but achieve at the same time an
increase of customer satisfaction”, concludes Heel.
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SIKORA EXTRA · NEWS
Fight with SIKORA against
the high oil price
Measuring and control technology saves money
For the first time since 2008 one barrel oil costs more than 100
dollars. The price for Brent-oil could in short-term even further increase,
if political pressures in Libya intensify and expand to other
states of the region. The price for copper as well has been on a
high for months due to the worldwide growing inquiry.
It is all the more important that measuring technology is used in
production lines, which reduces material consumption drastically. It
assures that only the amount of plastics material is used that is necessary
to fulfill the cable specifications. Moreover, the measuring
equipment permanently detects non-conformities in the material
and assures cable concentricity.
Check your individual specific material savings associated with investment
in an X-RAY 6000 (for measurement of eccentricity, wall
thickness, ovality and diameter) using our online ROI calculator
at:
http://www.sikora.net/media/roi-calculator.php
ROI calculator
Product of the quarter
The new conductor preheating system PREHEATER 6000
In insulating lines a reliable conductor preheating is important to
assure an optimum adhesion of the insulation on the conductor and
thus to proceed a proper extrusion.
For these requirements SIKORA offers their customers the wire preheating
system PREHEATER 6000. This is installed before the extruder
and heats up the wire by means of inductive heating, depending
on product type, up to 180°C. In dependency of the diameter,
the material and line speed PREHEATER 6000 automatically calculates
the necessary power and assures a stable temperature and
optimum adhesion.
Customers can easily retrofit their line with the PREHEATER 6000
– also in combination with diverse interfaces such as Profibus-DP.
Technical data PREHEATER 6000
Functional principle
Product diameter
Line speed
Frequency
Output power
Temperature
Interfaces
Technical data is subject to change
Inductive heating
0.45 to 2.8 mm for solid round
conductors
0.64 to 6 mm2 for stranded
conductors
max. 2,500 m/min
1,300 Hz
max. 15 kW
Up to 180° C
Profibus-DP, industrial field bus,
EtherNet/OPC
Monitor image PREHEATER 6000

Knowledge:
How do SIKORA LASER-gauge heads measure the diameter?
The technology of the diameter gauges of the LASER Series 2000
and 6000 is based on the principle of the diffraction analysis. On
a non-contact basis, without insertion of optics the cable is trans-
illuminated by a laser from two or three sides. In 0.2 μsec an
image of the cable is projected on the opposite CCD-line sensor.
The cable is a barrier in the optical path. Therefore, at its edges
diffraction effects occur. A powerful signal processor, which is directly
integrated in the gauge head, precisely calculates the diameter
through the analysis of the information from the diffraction
edges.
Next Events
CABLE & WIRE EXPO
7.-9. April 2011
Istanbul, Turkey
Booth 7 G102
INTERWIRE
2.–5. Mai 2011
Atlanta, GA, USA
Booth 512
Light sensor
Light source Measuring object
WIRE RUSSIA
23.-26. Mai 2011
Moscow, Russia
Booth 3 A06
Light source
Light sensor
Herausgeber/Publisher
SIKORA AG, BREMEN
WWW.SIKORA.NET
Functional principle 2-axis diameter gauge heads
The technology of the diffraction analysis as well as the elimination
of optics and moving parts allow for a very high single value accuracy
in the submicrometer range at all line speeds. Reliable measuring
values are also achieved at production related vibrations of the
measuring object. As this technology does not integrate optical
elements, neither maintenance nor local or diameter relating calibrations
are necessary to assure a high accuracy in the submicrometer
range. If a device of the LASER Series leaves the company in
Bremen, it is calibrated for its life time and provides continuously
accurate values.
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 60
giersch@sikora.net, www.sikora.net
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SIKORA AG
Bruchweide 2 · 28307 Bremen
Germany
Phone: +49 421 48900 0
www.sikora.net
sales@sikora.net
CHINA
sales@sikora-asia.com
FRANCE
sales@sikora-france.com
INDIA
sikoraindia@gmail.com
ITALY
sales@sikora-italia.com
JAPAN
sales@sikora-japan.com
KOREA
sikora@chol.com
RUSSIA
sales@sikora-russia.com
TURKEY
sales@sikora-turkey.com
UKRAINE
sales@sikora-ukraine.com
USA
sales@sikora-usa.com
kg 04/11 MD 4300