In the era of pursuing lean production and smart manufacturing, dimensional measurement—a critical link in product quality control—is undergoing revolutionary changes. Traditional offline sampling methods are not only inefficient and prone to human error, but also difficult to meet the real-time monitoring requirements of high-speed continuous production lines. Online digital diameter measuring instruments have emerged and, with their intelligent, automated, and high-precision characteristics, are rapidly becoming an indispensable tool in the production and testing of various types of wire materials such as cables, needle tips, optical fibers, and metal wires. Among them, POMEAS online digital diameter measuring instruments have become the industry benchmark thanks to their excellent performance.

I. Intelligent Measurement, Instant Results

1. No complicated programming required: Extremely easy to operate, completely eliminating the cumbersome setup process of traditional measuring equipment. Users simply place or pass the object to be measured (wire) through the measuring platform, and the instrument's built-in intelligent system will automatically identify, locate, and complete the measurement.

2. Instant feedback: Measurement results are displayed on the screen in real time with virtually no delay, allowing operators or control systems to immediately grasp the dimensional status of the product.

II. Seamless Integration, Space Saving

1. Lightweight and compact design: Designed specifically for industrial environments, it is small in size and lightweight, making it easy to integrate into existing production lines, automated equipment, or customized measurement stations.

2. Highly adaptable: Whether it is a high-speed wire drawing machine, extrusion production line, winding machine, or independent quality inspection station, it can be easily integrated without taking up valuable space.

III. High Precision and Repeatability

1. Non-contact measurement: Utilizing advanced optical or laser technology, this method avoids the scratches or deformations that may result from contact measurement, making it particularly suitable for precision fine wires (such as medical needle tips and micro-wires).

2. Micron-level precision: This method can consistently achieve measurement precision at the micron or even sub-micron level, ensuring the consistency of product quality.

IV. Improving Efficiency and Reducing Costs

1. 100% online full inspection: Replaces manual sampling inspection, enabling real-time monitoring of the diameter of each section of wire on the production line to prevent defective products from being released.

2. Labor savings: Significantly reduces reliance on skilled measurement personnel, lowering labor costs and the risk of human error.

3. Reduce downtime and waste: Real-time monitoring promptly identifies anomalies (such as diameter deviations or ellipticity exceeding limits), triggers alarms, or activates the control system to adjust processes, preventing batch defects, minimizing material waste, and reducing equipment idle time.

V. Data-driven, Traceable Quality

1. Data recording and output: Measurement data can be stored and output via standard interfaces (such as RS232, USB, Ethernet, 4-20mA) to PLC, MES systems, or computers for statistical analysis, process control, and quality traceability.

Practical Cases

Challenge: Specialized cable manufacturers face significant challenges when producing ultra-fine coaxial cables for high-end electronic devices. The outer diameter tolerance requirements are extremely strict (±0.01 mm), and traditional manual sampling is inefficient (only a few meters can be sampled per hour), making it impossible to cover the entire product range of high-speed extrusion production lines. Frequent instances of entire rolls being scrapped due to failure to detect minor diameter fluctuations in a timely manner have led to high customer complaints and rework costs.

Solution: The manufacturer seamlessly integrated POMEAS high-precision online laser diameter measuring instruments behind the guide rollers on its key extrusion production line. The equipment is compact in design and directly integrated into the existing guide roller bracket, with virtually no change to the original production line layout.