BEND­CHECK Straight­ness Meas­ur­ing Sys­tem

Why BEND­CHECK?

The Zumbach BENDCHECK solution provides a complete inline inspection system that automatically separates OK and NOT OK bars based on diameter, ovality, and straightness—a key factor for customers who require perfectly straight bars for their processes. Unlike other solutions, BENDCHECK performs 100% inspection without stopping production and measures bars without rotation, ensuring faster and more efficient quality control. Powered by the BENDCORE processor, the system can integrate with existing PLCs or be delivered as a full solution with USYS®. Available in 3 or 5 laser station configurations, the system can also inspect bar ends (“hooks”) to ensure full-length quality.

• Reliable straightness control: Detects precise deviations (e.g. 380 µm/m) and flags any bar exceeding the threshold for reinspection, ensuring defective products are removed before reaching the end customer.
• 100% inline inspection: Monitors every bar in production, unlike off-line sampling methods (e.g., 1 in 100), ensuring consistent quality and eliminating the risk of missed defects.
• Continuous, non-stop measurement: Inspects bar straightness inline without stopping or rotating the bar, eliminating downtime and speeding up production.
• Seamless USYS® integration: Easily integrates with existing Zumbach systems (e.g., ODAC® TRIO) to deliver a unified quality control solution on a single USYS® platform.

Proven per­form­ance world­wide

Zumbach BENDCHECK systems are deployed in bar and tube production lines worldwide, supporting a wide range of materials and applications where straightness is a critical quality parameter. Proven in continuous, high-speed production environments, they deliver reliable, real-time measurement without interrupting the process, ensuring consistent product quality and reducing the risk of defective material reaching the end customer. With decades of expertise in non-contact laser measurement, Zumbach supports both specialized manufacturers and high-volume producers, helping to improve yield, minimize rework, and increase overall process efficiency.
BENDCHECK integrates seamlessly with Zumbach’s USYS® monitoring and control platform, making it an ideal fit for operations already using Zumbach measurement technology.

Fre­quently asked ques­tions

Where should BENDCHECK be positioned on the line?
The system should be positioned carefully within the production line to avoid areas where the bar may be unstable, such as immediately after aggressive processing stages. A stable bar path is critical for precise measurement.

How does vibration affect measurement accuracy?
Vibrations from nearby equipment or the production line can interfere with the system’s ability to detect small bending values. To maintain accuracy, BENDCHECK should be installed in a mechanically stable position with minimal vibration.

Can bar movement or “jumping” affect results?
Yes. Bar movement, especially at the head and tail (end of the bar), can create apparent bending values that are not representative of the actual product. Managing these movements or accounting for them in the setup is important for reliable measurements.

Does BENDCHECK require special mechanical support?
Yes. A rigid, stable mounting structure helps minimize external disturbances and ensures the system delivers consistent, high-precision measurements.

How much space is required to install BENDCHECK on my production line?
BENDCHECK requires a minimum of 1 metre of available space within the line. Adequate space is important to ensure proper positioning and stable measurement conditions, especially in high-speed production environments.

Are there any special requirements for rollers or surrounding equipment?
Yes. To guarantee accurate measurements, BENDCHECK should operate independently of motor and roller vibrations. Additionally, only hard steel rollers are recommended. Plastic or resin rollers are not suitable, as they can introduce instability and affect measurement precision.