Bytewise designs and builds non-contact, industrial measurement systems that capture the external geometric profile of a product and analyze that data to meet measurement and/or quality control requirements. Our products are designed with the goal of providing a rapid return on investment to our customers and we attempt to accomplish this by developing systems that are easy to use, reliable to operate and effective at solving problems.
Profile360 is an on-line profile measurement system that utilizes Bytewise Profile Sensors to scan the complete outside shape of any continuously moving profile. Profile360 takes a profile scan, matches it to a design template, then displays an optical comparator screen along with key measurement parameters. Profile360 is used on extruder lines as a continuous quality checking tool to assure that key dimensions remain centered and within control limits.
The Off-Line Profilometer (Profilometer) is an instrument that measures the top and bottom profiles of tire tread and sidewall extrusions. The Profilometer is used in die shops to verify the profile and approve the die for production. The Profilometer is also used on the shop floor at the extruder as a periodic quality check for the extruded profile.
A typical Profilometer test is done by placing a short section of the extruded profile in the instrument and making an automatic scan. The instrument scans the top and bottom profiles, displays the profile superimposed on a template file, extracts key parameters, and compares them to allowable limits. Parameters include the geometric coordinates of all break points in the profile. The die maker can then adjust the die to bring the actual extruded profile into specification and then retest. Once the die is in production many users take periodic samples to verify that the process has not drifted out of specification.
The On-Line Profilometer (“OLP”) is an instrument that utilizes Bytewise Profile Sensors to measure the top and bottom profile of the moving extrusion. OLP takes a profile scan, matches it to a design template, then displays an optical comparator screen along with key measurement values. OLP is used on the extruder line either after the die or after cooling. OLP is used as a continuous quality checking tool to assure the process remains centered and within control limits.
Even when a die meets the most demanding specifications, extrusions can still go out of control due to variations in raw material properties, mixing uniformity, extruder speed and temperature, and downstream speed and cooling. The OLP display shows continuous trend graphs with green/yellow/red status indicators that alert the operator when unfavorable process changes occur. This permits the operator to correct unfavorable trends before they result in off-spec extrusions.
The OLP Software Suite is complete with data archiving and reporting tools, and can be easily networked to factory IT systems. The on-line profile measurement system can be easily networked to factory IT systems.
The Profilometer SL combines the powerful and proven Bytewise Profile Viewer software that has long been used in our Off-Line Profilometer with the Bytewise Sheet-of-Light (“SL”) sensor technology to offer a lower-cost extrusion profile measurement system. The SL sensors are fixtured above and below the measurement table so that they can digitize the top and bottom surfaces of the extruded profile sample. Once digitized, the data is displayed and analyzed in the ProfileViewer software. Easy-to-use calipers can be applied to any extusion design and these important features can then be compared to the actual extruded part to insure that dimensional tolerances are being met and maintained.
The Profilometer SL is available in measurement widths of 300mm and 450mm. The system uses no moving parts, making it extremely reliable in the field. Data acquisition time is instantaneous wth the SL sensors and measurement results are displayed immediately.
The Profilometer-SL is designed for tire manufacturers who want faster, lower-cost and more reliable profile measurements to support die design and die management and quality control management programs in their extrusion operations.
The Circumferential Tread Wear Imaging System (“CTWIST”) is a complete measurement system for characterizing tread wear in passenger and truck tires. CTWIST is used in tire development centers and test tracks to support new tire development programs.
A typical CTWIST test begins with a scan of a new tire, after a short warm-up period, to establish the base-line for tread wear. The tire is then driven on a roadway or test track for a distance (2,500 km for example) then re-scanned. The driving and scanning is repeated for a total of 10,000 or more km. The CTWIST analysis software processes all scans and produces a series of standard reports that characterize tread loss, irregular wear, heel-toe wear, tread-life projections, and other wear parameters.
This tread wear measurement information is used by compound development chemists, tread designers, and tire engineers to develop tire designs with better wear behavior.
The Bytewise Blade360 offers a non-contact, high-speed measurement solution for airfoil section and platform measurements. The accuracies required for airfoil measurement are challenging for any technology. Blade360 achieves these accuracies by functioning as a comparator. The system is “mastered”, or calibrated, to a part of known dimension. The variation from the known part is then determined for subsequent parts. With cycle times as fast as 3 seconds per section, Blade360 is 5 to 10 times faster than a traditional CMM.
The system is offered in two configurations: Small Chord (up to 25mm) and Large Chord (up to 100mm). Platform measurement capability is provided as an option.
Blade360 is a factory floor solution with limited axis of motion. It features an easy accessible, positively pressurized and temperature controlled measurement chamber.
The Feature Tracker (“FT”) is a special application of the Bytewise Profile Sensor used to sense and track geometrical features on a complex profile and continuously output the position signal to an automatic guiding system.
Tire manufacturers use FT to sense and track the position of the center die groove in a complex tread extrusion profile as it is being applied to the tire building drum. The FT signal is used as input to the user’s closed-loop control system that guides the tread onto the drum. This feature-based guiding is more precise than edge-guiding systems because edges often become distorted due to shrinkage and handling effects.
The Bead-to-Bead Profile Measurement System (“B2B”) is a special application using multiple Bytewise Sheet-of-Light Sensors to capture the complete cross-sectional profile of an inflated tire in a static measurement cycle. B2B is used in tire testing labs to check the actual inflated profile geometry against the predicted profile. B2B is also used to analyze competitors’ tires. B2B can also be set up to measure carcass growth on Tire Endurance Test Machines.
The B2B Software provides for the visualization of the measured profile, comparison to a design template, extraction of key measurement parameters such as section width and crown radius, and exporting of the profile geometry point cloud to external systems for further analysis.
The Splice Monitor is a special-purpose measurement system for monitoring the dimensions of overlapping splices on fabric calender lines used in tire component preparation operations. Many lines use automated machinery to shear the fabric, overlap the fabric strips, and splice them into continuous rolls. Small changes in the shearing and splicing machinery can result in splices that are too heavy and result in excessive radial force variation. Splices that are too small can result in splice separations when the material is applied on the tire building drum. The Splice Monitor measures 100% of all splices via right, left, and center channels to assure compliance with splice specifications, and will alarm when any splices exceed the allowable limits.
The Splice Monitor Software Suite is complete with data archiving and reporting tools. The Splice Monitor measurement system can be easily networked to factory IT systems.
The Tire Identification System utilizes Bytewise Very-High Speed (2000 Hz) Profile Sensors to rotationally scan the sidewall of a tire and identify the tire. Identification can be based on the DOT Code, a tire manufacturer’s unique mold code, molded-in bar code, or any other unique molded-in feature.
The Tire Identification System is used in tire factories to identify tires after curing for sorting into the final finish department, thus eliminating the need for human tire sorting.
The Tire ID system can also be used in auto assembly factories to match the DOT Code, including date code, to the Vehicle ID Number for purposes of recall management. The tire ID system is used in JIT Tire/Wheel Assembly facilities to verify that the correct tire is matched to the wheel for sequence management.
The Green Tire Uniformity Monitor utilizes Bytewise Very High Speed (2000 Hz) Profile Sensors to rotationally scan the green tire while it is still mounted on the tire assembly drum, and inspect the green tire for non-uniform geometry.
The Monitor is available for both portable use and for fixed mounting on the Tire Building Machine.
The portable system is a mobile, tripod-mounted instrument suitable for analyzing the green tire at any stage of assembly. The mobile unit can be positioned to monitor the placement accuracy and splice geometry for each component as it is applied to the TBM drum. This mobile instrument can be used to troubleshoot machine setups and alignments, and to verify set-up uniformity across all TBM’s.
The fixed-mounting system is can be mounted to scan any component on any TBM drum, with hard-wired connections to the drum encoder and PLC. Traditional tire building machines apply numerous components sequentially on drums in order to build up, and then shape, the final green tire carcass. In highly-automated machines, small machine changes can adversely affect the cured tire uniformity. Such defects may not be detected until several hours of green tires have been produced. 100% monitoring of the green tire geometry helps assure that no bad tires are sent to curing.
The embossing depth analysis software enables analysis of a surface profile for maximum, minimum, and average depth. Any profile can be divided into multiple segments so that multiple areas of the profile can be measured simultaneously.
Resolution is 0.001″ (0.00004mm) for the 25mm wide sensor.
Benefits for WPC and Siding Manufacturers
Use repeatable & accurate system for characterizing embossing depth
Have consistent QC method across several operators/lines/plants
Generate quantifiable data to prove embossing is in spec
Reduce and/or eliminate customer complaints and returns