Wire and Cable Inspection Sensors

The key characteristics of wire inspection sensors mostly depend on the type of wire being manufactured. Regardless of the type, wire inspection sensors must feature high accuracy to detect even the smallest inconsistencies in wire or insulation diameter.

Durability is also a crucial factor, as many of these sensors are exposed to heat, dust, and mechanical vibrations—especially those mounted near the insulation extrusion machines that are used to apply insulation coating to the copper conductor.

KEYENCE’s LS-9000 high-speed optical micrometer meets both requirements. These units have built-in air purge filters and an IP67 rating, making them perfectly suited for harsher environments. They can also measure wires as small as ø10 µm since their optical design enables the measurement of ultrafine gaps and diameters.

The LS-9000 can also measure/inspect flat wires. Its rapid sampling speed allows the thrubeam optical micrometer to monitor the width of a flat wire with high precision and detect even the smallest of edge breaks.

When it comes to cladding flat wires, the CL-3000 confocal laser displacement sensor acts as a wire inspection sensor that performs non-contact thickness measurements. It enables 100% wire bond inspection without impacting cycle time while simultaneously enabling high-accuracy measurement of rough or hairline surfaces.

When it comes to multi-strand flat cables, 2D/3D laser profilers (such as the LJ-X8000) are used to inspect the width and shape of flat cables. They can also check for conductor position and the color of individual conductor strands within the cable. These measurement sensors can also be used to profile the outer diameter of a coated cable during extrusion.

Using wire inspection sensors brings significant benefits to the entire manufacturing process, primarily by enhancing the overall quality of the product through early defect detection. This prevents defective products from reaching the end consumers to maintain product quality and brand reputation.

Additionally, wire bond inspection sensors increase the overall manufacturing process efficiency by allowing for real-time monitoring and adjustments, which subsequently reduce downtime and material waste. This contributes to sizable reduction costs over time, mostly due to minimized need for post-production corrections and rework.

Wire and cable production involves several different production processes, like drawing the wire to a desired diameter and coating it with an insulated material. Some wires have additional shielding, which is applied over their initial insulation coating and before another insulation layer is applied.

The process is only more complex if a cable contains several conductor strands, some of which might require additional shielding with braided copper sheaths and perhaps even steel bands to provide the cable with additional mechanical strength.

Wire inspection sensors are used at each step of the production process to ensure that all products are adequately dimensioned and that the insulating coats are adequately applied. This is mostly done by checking various dimensional measurements to ensure the quality of the product.

KEYENCE is the world’s leading expert in precision technologies and a reliable partner to many wire and cable manufacturers. If you’re looking for highly precise and accurate wire inspection sensors, don’t hesitate to contact KEYENCE and inquire about integrating our products with your production line.