RAYEX® D Dynamic X-Ray Measuring System
X-ray measuring device for measuring wall thickness, eccentricity, diameter and ovality of low, medium and high voltage cables
Real-time measurement and continuous monitoring of cable insulation and geometry during production
Why RAYEX® D?
The Zumbach RAYEX® D X-ray measurement system is a next-generation, non-contact solution designed for continuous low, medium, and high voltage cable production. Installed directly after the extrusion crosshead in processes such as Catenary, Horizontal and Vertical Continuous Vulcanization, XLPE, EPR, and silane lines, it uses dual-axis X-ray scanning to measure wall thickness, eccentricity, diameter, and ovality in real time, ensuring precise monitoring of cable geometry and insulation quality.
Featuring dynamically moving X-ray tubes driven by a motorized spindle, RAYEX® D is specifically engineered for larger cable diameters and slower line speeds, making it ideal for CV processes, silane systems, and heavy-duty submarine cables (up to 140 mm diameter). By delivering continuous measurement data, it enables immediate process correction and closed-loop control, optimizing material usage, minimizing scrap, improving concentricity, and ensuring consistent, high-quality cable production with full traceability.
- Comprehensive X-ray measurement: Simultaneous measurement of wall thickness, eccentricity, diameter, and ovality using dual-axis (X & Y) scanning for complete cable geometry control.
- High-precision performance: Advanced micro-beam X-ray technology delivers exceptional accuracy with repeatability better than ±0.03 mm across a wide range of cable sizes.
- Optimized for power cable production: Designed for low, medium, and high-voltage cables, ideal for CCV, VCV, MDCV, and silane production lines.
- Smart integration & process control: Built-in OPC UA, PROFINET, EtherNet TCP/IP and EtherNet/IP connectivity with continuous monitoring, data logging, and seamless PLC/SCADA integration for closed-loop control.
Properties
- Advanced X-ray measurement of wall thickness, eccentricity, diameter, and ovality
- Dual-axis dynamic scanning (X & Y) for simultaneous, real-time measurement
- High-precision micro-beam X-ray technology with repeatability better than ±0.03 mm
- Wide measurement range: 15–140 mm product diameter, 0.3–40 mm wall thickness
- Suitable for single and multilayer cable constructions (up to 3 layers)
- Integrated high-voltage X-ray source for exceptional long-term stability
- Built-in web server for system setup, diagnostics, and operation
- Industrial connectivity: EtherNet TCP/IP, PROFINET, and EtherNet/IP
Benefits
- Ensures precise wall thickness and concentricity control for superior cable quality
- Reduces insulation material consumption and lowers production costs
- Minimizes scrap and start-up waste, improving overall efficiency
- Detects process deviations early for immediate corrective action
- Enables closed-loop process control for consistent production performance
- Easy product recipe creation without additional cost, simplifying setup and reducing changeover time
- Reduces operator intervention through automated monitoring and control
- Enables full production traceability with integrated data logging
Number of measuring axes
Min. object diameter (mm)
Max. object diameter (mm)
Scan rate (scans/s)
Technical data
For accessories and detailed product information, refer to the respective brochures
RAYEX® 160D
- Measuring axes
- 2
- Object diameter
- 90 / 3,54″
- Min. wall thickness
- 0.3 mm / 0.012″
- Scan rate
- 1 … 3/s
- Brochure
- RAYEX 160D (PDF, 3.69 MB)
RAYEX® 220D
- Measuring axes
- 2
- Object diameter
- 140 / 5.5″
- Min. wall thickness
- 0.3 mm / 0.012″
- Scan rate
- 1 … 3/s
- Brochure
- RAYEX 220D (PDF, 3.69 MB)
VISU-Touch
- Number of sensors (ODAC®, CAPAC® etc.)
- 1
- Number of controllers
- Up to 5
- Display, int.
- 7 Inch
- Brochure
- VISU-Touch (PDF, 740.58 KB)
Proven performance worldwide
For more than 20 years, many hundreds of RAYEX® D X-ray measurement systems have been successfully deployed worldwide across leading cable manufacturing facilities. Trusted by producers of low, medium, and high voltage cables, and built on Zumbach’s proven X-ray measurement technology, RAYEX® D delivers reliable, high-precision performance in demanding production environments where accuracy and consistency are critical. Manufacturers rely on RAYEX® D to improve insulation quality, optimize material usage, reduce scrap, and ensure compliance with stringent industry standards. Backed by Zumbach’s global service and support network, the system provides long-term operational reliability and continuous process optimization for modern cable production.
Areas of application
Medium & High Voltage Cable Production:
Engineered for low, medium, and high voltage power cables, including XLPE, EPR, and specialty insulated cables where precise wall thickness and concentricity control are critical.
CV & Silane Extrusion Lines:
Ideal for demanding cable manufacturing processes such as CCV, VCV, MDCV, steam CV, and silane systems, where continuous, high-accuracy measurement ensures consistent insulation quality.
Subsea & Heavy-Duty Power Cables:
Optimized for large-diameter and high-value products such as offshore and submarine cables, where reliability, material optimization, and defect detection are essential.
Large Diameter & Slow-Speed Production:
Specifically designed for larger cable diameters (up to 140 mm) and slower line speeds, making it the preferred solution for heavy-duty cable applications requiring deep, precise X-ray measurement.
Frequently asked questions
What is the difference between the RAYEX® D and RAYEX® S, and which one is right for my application?
The RAYEX® D, uses 2 dynamic scanning axes that continuously scan the product, based around a pressure tube / window mounting assembly for fitting within the vulcanizing tube directly, making it ideal for medium and high-voltage power cables, larger diameters (15–140 mm), and thicker insulation walls up to 40 mm. In contrast, the RAYEX® S uses 2 static measuring axes with high-speed measurements up to 10–20 measurements per second, is designed specifically for open trough cooling type extrusion lines, making it ideal for cables, tubes, hoses, pipes, and medical tubing up to 100 mm diameter.
What types of cables can be measured with the RAYEX® D?
The RAYEX® D is suitable for low-, medium-, and high-voltage power cables, including XLPE and EPR insulated cables. It is ideal for energy cable production, particularly in applications requiring accurate measurement of thick insulation layers and large diameters.
Can the RAYEX® D be installed on existing cable production lines?
Yes, the RAYEX® D is designed for integration into existing extrusion lines. It is supplied with customized measuring tube segments, allowing seamless installation without major modifications and ensuring compatibility with various production setups.
Does the RAYEX® D support closed-loop control in extrusion processes?
Yes, the RAYEX® D enables real-time closed-loop control by providing continuous measurement data. This allows automatic adjustment of extrusion parameters, helping to reduce material consumption, minimize scrap, improve concentricity, and ensure consistent cable quality.
Is the RAYEX® D compatible with PLC and SCADA systems?
Yes, the RAYEX® D supports PLC and SCADA integration via OPC UA, PROFINET, EtherNet/IP, and TCP/IP. This enables real-time data exchange and process control, making it easy to incorporate into modern automated cable manufacturing systems.
Is the RAYEX® D X-ray system safe to operate?
Yes, the RAYEX® D is fully safe for industrial use. Radiation levels are far below international safety limits, and the system includes multiple safety interlocks, ensuring safe operation for personnel in cable production environments.
