Blow molding is used to manufacture various hollow objects, such as barrels, liners for hydrogen pressure vessels, IBC containers or canisters. All of these applications can be measured using radar technology. A prerequisite for measurement is a wall thickness of more than 2 mm and the ability to position the radar sensor perpendicular to the surface of the component.

Measurement using radar technology can be performed on the finished component or directly on the extruded melted tube. Thanks to the automated measurement data, the component quality can be continuously evaluated, potential changes identified and ultimately the process can be controlled based on real measurement values. The wall thickness information from the sensor is used to adjust the wall thickness profile (WDS) as well as for partial wall thickness control (PWDS^®). Even without controlling the process, precise quality data is crucial to monitor quality-critical products and document the quality.

The WARP GAUGE sensor provides a flexible, automated solution for blow molding. With the WARP portable, measurement data can be easily and non-destructively taken manually. Both solutions replace destructive or cumbersome testing methods and save valuable time in quality assurance.

Rotational molding is a manufacturing process for plastic parts. In this process, the mold is filled with raw material, heated, rotated, cooled and the end product is removed. The wall thickness of the plastic is built up layer by layer through the rotating movements, enabling the production of seamless hollow objects without pinchlines. Rotomolding is predominantly used to manufacture smaller and more complex end products with particularly large volumes, such as fuel tanks, containers and special industrial applications.

Comparatively long cycle times make efficient, non-destructive quality assurance essential to achieve increased productivity. It is necessary to measure the end product promptly after production and to measure it nearly completely. iNOEX's radar-based measurement technology enables this for wall thicknesses of 2 mm or more. Thus, even slight production deviations within the wall thickness can be identified and corrected directly in the subsequent component.

With WARP GAUGE, automatic and continuous measurement of the end product is made possible. The WARP portable is used for precise manual measurements. The measurement memory holds 500 measurements and can be exported for further documentation.

In the extrusion of plastic pipes, a wide range of products (such as gas and pressure pipes, hot water pipes, sewage pipes, etc.) are covered, as well as various materials (such as PP, PE, PVC, PA, PVDF, etc.) are used. Withstanding enormous pressure loads, maintaining the prescribed wall thicknesses and ensuring flawless processing are just some of the crucial requirements. iNOEX uses radar technology, among other things, to meet these challenges. In addition to increasing product quality and providing comprehensive documentation, material savings are a key focus for customers. For this purpose, inline measuring systems are used in the extrusion area, which cover the pipe up to 100 % in the circumferential and longitudinal directions, as well as the WARP portable. The handheld measuring device is used for measurements in the medium and large pipe range to enable further optimization steps through very early measurements. All radar measuring systems play a decisive role in automation and process control.

Years of experience in the field of pipe extrusion have made it possible for iNOEX to use this comprehensive knowledge now also in the field of Industrial Packaging and make it accessible for further manufacturing processes in the field of plastics technology. The underlying goals (such as process transparency, material savings, process control) are comparable. Synergies have arisen between the two areas through continuous further development in radar technology, such as the measurement of ever thinner wall thicknesses.

Hydrogen is becoming increasingly important as a versatile energy carrier, especially with regard to climate protection. Fiber composite containers (Type IV pressure vessels) offer an attractive alternative to steel cylinders, especially for mobile applications such as in the automotive sector or as mobile storage modules. They are up to 70 % lighter and can withstand very high loads. The liner forms the actual pressure vessel in which the hydrogen is stored. As a necessary hydrogen barrier, it is responsible for the tightness of the container under high pressure (up to 700 bar operating pressure). The component, usually made by blow molding, rotational molding or joining, is subject to strict quality requirements and is responsible for the safety and durability of the Type IV pressure vessel.

iNOEX radar technology can make a decisive contribution to ensuring liner quality. In the cylindrical area, the wall thickness (from 2 mm), the diameter and the eccentricity can be checked non-destructively, contactless and automated. In the dome area, the contour as well as the wall thickness and deviations from the target geometry can be determined using suitable kinematics. In this way, critical thin areas can be identified as well as areas with excess material can be optimized.

iNOEX radar measuring systems can be flexibly used for a variety of liner sizes. From manual spot measurement with the WARP portable to fully automatic measurement of all produced liners using kinematics and the WARP GAUGE sensor.
 

Open head drum, closed barrels and lid barrels are used for the transportation and storage of various liquids and goods. Compliance with standardized dimensions, high precision and stacking strength are just some of the criteria that must be met. Their usability is very versatile, depending on the industry and certification. Highly precise manufacturing and quality control are particularly important in quality-sensitive areas such as the semiconductor, electronics, pharmaceutical, cosmetic and hygiene industries to ensure that any risks are excluded.

Producing these standardized and certified end products requires an experienced operator and the adjustment of various parameters. Low-temperature drop tests and checking the crack resistance are used for error detection. Individual critical points require very precise quality checks to comply with safety standards.

iNOEX provides radar-based measurement technology to maintain and improve the precision of the barrels (such as distortion and wall thickness), enabling quality control in accordance with applicable standards. With the WARP portable, wall thickness measurements of the barrels can be carried out manually at various points. The WARP GAUGE offers an automated measurement solution that can measure 100 % of the produced components.

Axial and radial measurement of the barrels enables the optimization of thin and thick areas on the surface of the barrels, achieving up to 5 % material savings while enabling quality control.

The Intermediate Bulk Container (IBC) differs from barrels and cans particularly due to its large capacity. The rectangular shape of the IBC, consisting of a plastic hollow body placed on a pallet and surrounded by a grid, makes it stackable and space-saving. This also ensures compliance with individual requirements for dynamic and static loads. IBCs are an efficient and safe solution for storing and transporting larger quantities. Due to their reusability, they are also very environmentally friendly.

Typical applications are the chemical, food and pharmaceutical industries. When there are increased quality requirements such as pressure or hazardous goods applications, it is ensured that the leakage of fillings, aroma or flavour is prevented. Special attention is paid to the plastic hollow body, whose wall thicknesses must be reliably checked for critical thin and thick spots.

iNOEX's radar-based measurement technology makes it possible to identify these critical points and provide insights into process optimization. Faulty products are detected immediately after production. The WARP portable is used for manual measurements, while the WARP GAUGE sensor performs continuous measurements. Additionally, optimized distribution of wall thickness and reduction of wall thickness to the required minimum can save raw materials.

The WARP portable is a mobile, radar-based handheld device for non-destructive, point-like wall thickness measurement. Today, several hundred systems are already in use, mainly in medium and large pipe extrusion as a quick centering aid in the start-up process, for final inspection of production or as a stock control device.

In the field of Industrial Packaging, destructive measurements are often carried out on a sampling basis. Non-destructive methods using ultrasound measurement are also used, but they are cumbersome and complicated due to the application and removal of a coupling medium (e.g. gel) and the strong dependence of the measurement on the component temperature. Other measurement methods that work by introducing a metallic ball into the containers and detecting it with a magnetic probe are also very time-consuming.

These costly and time-consuming measurement methods are being replaced by the WARP portable. The WARP portable measures wall thicknesses non-destructively and independently of the material temperature from 2 mm. The handheld device is placed on the product to be measured using a centering aid and the measurement is taken at the push of a button. The last 500 measurement values, including the measurement angle and time stamp, are stored for later data evaluation.

The WARP GAUGE sensor enables the automated and continuous measurement of plastic hollow bodies from a wall thickness of 2 mm. With the non-destructive and contactless measurement method based on radar technology, immediate product control can be carried out after the production of the hollow body, as well as further control steps to continuously improve production results. With up to 8 measurements per second, the wall thickness of the product can be accurately detected.

An OPC-UA interface enables integration into the machine and ensures live transmission of measurement data. This data can be used to detect production inaccuracies that do not meet the standards early and to adjust them immediately. Various products manufactured by blow molding or rotomolding, such as barrels, IBC containers, liners for type IV pressure vessels or other plastic hollow bodies can be measured.

The goal of measuring plastic products with radar technology is to replace the destruction of samples or the use of methods with coupling media and to establish itself as a sustainable optimization solution in Industrial Packaging. The use of innovative technology is essential not only in terms of time and material savings but also to compensate for the shortage of skilled workers, comply with increasing quality standards and obtain corresponding certifications. It is particularly important to completely exclude defective end products, especially for dangerous goods.

iNOEX's goal is to provide precise measuring systems that offer suitable measurement bases for process control in terms of data quality and quantity. Process control and automated quality monitoring are important key topics given the increasing shortage of skilled workers, increasingly complex production processes and advancing digitalization.

To implement process control for Industrial Packaging applications, it is necessary to measure the components as soon as possible after manufacture to be able to react quickly to changes. Alternatively, measurements can even be taken directly in the process (e.g. on the extruded parison in blow molding). Precise intervention in the manufacturing process can be made based on the measurement data by adjusting the appropriate controls. In blow molding, these are two direct control options. On the one hand, the wall thickness profile (WDS) can be adjusted and on the other hand, the melt can be diverted using partial wall thickness control (PWDS^®) over the circumference of the blow head. Influence can also be exerted on the process through mostly manual adjustment options on the mandrel (e.g. SFDR^® - Static Flexible Deformable Ring).

iNOEX works closely with the respective process experts of its customers who have many years of know-how to set up the control loops. The measuring task is specified together and the necessary data are defined to enable control.

For many Industrial Packaging applications, process control is only the next step. Top priority is reliable measurement data. The crucial advantage of radar technology here is that the measurement is non-destructive, precise and fast. Previously, destructive measurements or personnel- and time-intensive methods (e.g. ultrasonic measurements) were often used. This is not only expensive but also prevents close product monitoring. The step towards automated measurement and thus automated quality assurance and documentation is crucial for a wide range of applications. The reasons for this can be application-related as well as process-related. Application-related examples include the need to comply with strict regulations for transporting sensitive chemicals and goods. Process-related, production near the minimum allowable wall thickness is sought for sustainability and due to rising raw material prices.

In automatic measurement, the WARP GAUGE sensor is guided over the component by a kinematic (e.g. a robot) at a distance of about 300 mm. A network of measurement points is then obtained on the component from the combination of the sensor's movement speed and the measurement frequency. In addition to wall thickness information, the distance between the sensor and the component is also documented. This allows conclusions to be drawn about the component contour. The number of measurement points depends on the application and can be defined by the user.

iNOEX works with various partners in the field of kinematics. Of course, the kinematics can also be done by the customer. We are happy to advise you on how the position data of the kinematics can be used in combination with the measurement data of the sensors for further evaluations (contour detection, warpage).