KW Lump & Neck­down De­tect­or

Why KW?

The Zumbach KW TRIO is a high‑reliability dimensional flaw detection system engineered for continuous production of wire, cable, and other extruded products as well as products checked or packaged on a rewind line. Unlike conventional single‑ or dual‑axis systems with inherent blind zones, the KW TRIO’s three‑axis optical design provides superior circumferential coverage and significantly higher detection certainty. Using three light beams arranged at 60° intervals, KW TRIO detects even short faults at high line speeds with exceptional accuracy. Built on decades of Zumbach expertise, it combines advanced optical technology with full digital signal processing for intelligent fault analysis, classification, and logging.
By delivering faster and more reliable fault detection, KW TRIO ensures product quality, and enhances overall production efficiency. For the most demanding applications, dual systems can be combined to a 6‑axis measurement for maximum coverage.

• 3‑axis optical detection system: three light beams at 60° intervals minimize blind zones, delivering up to 3× higher detection certainty; optional 6‑axis configuration for maximum coverage.
• Micrometer‑level sensitivity: detects faults as small as 0.01 mm (KW 13TRIO) / 0.025 mm (KW 33TRIO) and lengths down to 0.25 mm, with just 4 µs recovery time between faults.
• Resistant to ambient light interference: advanced optics and digital signal processing ensure reliable detection even under intense ambient or stray lighting conditions, with integrated air purging to keep measuring windows clean, and even provides fault detection on reflective and opaque products.
• Integrated fault database & flexible connectivity: stores the last 100 faults with full parameters, with support for multiple industrial Fieldbus interfaces. Connection to Zumbach USYS® processors or optional VISU-Touch utilizing the built-in webserver for standalone or remote operation.

Proven per­form­ance world­wide

Zumbach KW TRIO lump and neckdown detectors are used in wire, cable, fibre, monofilament and tube production lines worldwide as a standard tool for continuous quality control. Building on nearly 60 years of Zumbach expertise in optical fault detection, the KW TRIO represents the latest evolution of this proven technology, combining advanced digital signal processing with a unique 3‑axis detection concept to deliver maximum reliability.
Proven in high‑speed extrusion environments, the KW TRIO ensures that even the smallest faults are detected before they reach the customer. It is an essential component in modern production lines, alongside diameter gauges and spark testers, helping manufacturers consistently improve product quality and reduce scrap.
The system integrates seamlessly with Zumbach’s USYS® monitoring, process control and data acquisition platform and supports all major industrial communication protocols, making it easy to incorporate into both new and existing production lines.

Fre­quently asked ques­tions

What is the difference between a lump detector and a diameter gauge?
A diameter gauge (e.g. ODAC®) measures the continuous outer diameter, while a lump and neckdown detector (e.g. KW TRIO) identifies fast, short‑duration dimensional faults. Used together, they ensure complete inline quality control.

Why is a 3‑axis system better than a 1‑ or 2‑axis system?
A 3‑axis lump and neckdown detection system significantly reduces blind zones compared to 1‑ or 2‑axis designs, delivering up to 3× higher detection certainty. For maximum coverage, two systems can be combined for full 6‑axis detection.

Which model do I need – KW 13TRIO or KW 33TRIO?
The model number indicates the measuring field diameter: KW 13TRIO provides a 13 mm measuring field, KW 33TRIO provides a 33 mm measuring field. Choose the model where your largest expected product diameter (including any lumps) and product movement fits within the measuring field. The KW 13TRIO offers higher sensitivity (0.01 mm smallest fault) and is preferred for fine wire and optical fibre applications.

Can the KW TRIO detect very short faults at high line speeds?
Yes. The narrow beam and the 4 µs recovery time means two consecutive faults separated by as little as 4 microseconds are registered as separate events. At 3,000 m/min line speed, this corresponds to a fault separation of just 0.2 mm. Even very short faults, minimum length 0.25 mm (KW 13TRIO), are reliably detected at maximum line speed.

Does the KW TRIO work in bright or dusty environments?
Yes. The unique optical concept combined with digital signal processing provides immunity to stray and intense ambient light. Integrated air purging keeps the measuring windows clean automatically, preventing false alarms from dust or contamination. The housing is rated IP 65 for protection against dust and water jets.

Can the KW TRIO be used as a standalone unit without a USYS® processor?
Yes. The KW TRIO is available with the optional VISU-Touch 7″ touchscreen display, which provides full local operation and configuration directly at the detector. The display can also be mounted remotely as a networked display. For integration into larger line monitoring systems, the KW TRIO connects to Zumbach USYS® processors or directly to PLCs and host computers via RS, PROFIBUS DP, EtherNet TCP/IP, PROFINET, or EtherNet/IP.

How can I configure my KW TRIO?
In addition to the Fieldbus connection, KW TRIO provides a dedicated EtherNet TCP/IP port for the connection to a PC, Network, Webclient, USYS® Touch or similar. The KW TRIO has a built in Webserver with graphical user interface to access a full range of configuration and maintenance menus. The Webserver also provides the pages needed to act as a local display and provides access to the fault log.

How can I verify the calibration of my KW TRIO?
The calibration of the KW TRIO can be verified by placing a pin with a known diameter into the measuring field of the KW TRIO fault detector. One has to ensure the precision of the pin meets the detection accuracy of the KW 32TRIO. Zumbach provides kits with pins and holders to support the pin. For advanced verification of the calibration, Zumbach provides kits with pins that have a step with two different diameters simulating a dimensional flaw. The pins can be certified and made traceable to local and national standards.