UMAC® Ultrasonic Measuring System
Non-contact ultrasonic measurement of wall thickness, concentricity, and eccentricity for tubes, pipes, hoses, & cables
Real-time inline control reduces scrap, saves material, and ensures consistent quality
Why UMAC®?
The Zumbach UMAC® WALLMASTER is a complete ultrasonic measurement and control system for inline wall thickness, concentricity, and eccentricity measurement during the extrusion of tubes, pipes, hoses, and cables. Using the proven ultrasonic time-of-flight principle, a piezoelectric transducer emits a sound pulse through the product. The system measures the echo travel time from the outer to the inner surface and calculates wall thickness with high precision, without any contact with the product. With 4, 6, or 8 measuring points arranged around the product, wall thickness is measured simultaneously at multiple positions, enabling full concentricity and eccentricity control. The latest UMAC® CI processor adds an integrated webserver, modern connectivity, and a compact OEM-ready design, making 100% inline quality control possible where previously offline measurement was the only option.
- Non-contact ultrasonic wall thickness measurement from 0.05 mm to 99.95 mm: inline, in real time, with up to 1,000 measurements per second per channel.
- Simultaneous multi-layer measurement of up to 5 layers covering single and multi-layer cables, pipes, and hoses in a single system.
- Wide product range coverage: product outside diameter from 0.2 mm to 400 mm with larger custom solutions available on request, offering a comprehensive range of interchangeable transducer holders (UMAC® A, RZ, Z, and R series) for tubes, hoses, cables, and large pipes.
- Full process integration: USYS® IPCe WALLMASTER processor with 19″ touchscreen HMI, closed-loop linespeed/extruder control, SPC/statistics, and connectivity via PROFINET IO, EtherNet TCP/IP, EtherNet/IP, OPC UA, and RS interfaces.
Properties
- High-precision ultrasonic wall thickness measurement down to 0.05 mm
- Wide measurement range for cables, wires, and pipes (0.2 mm to 400 mm diameter)
- Multi-layer measurement system (up to 5 layers simultaneously) for complex cable and pipe constructions
- Extensive multi-point measurement (up to 8 sensors) for full eccentricity measurement
- Suitable for round and flat extruded products
- High-speed inline measurement of up to 1,000 Hz per channel
- Integrated webserver for remote monitoring and process visualization
- Full connectivity via industrial interfaces (EtherNet, PROFINET, EtherNet/IP, OPC UA)
Benefits
- Real-time inline wall thickness control that compensates for dimensional variations during extrusion
- Accurate eccentricity measurement ensuring uniform wall thickness can be achieved through manual or automated correction for improved product quality
- Faster extrusion start-ups reaching target dimensions quickly, reducing scrap
- Significant raw material savings: optimized extrusion control reduces overuse of material
- Inline measurement offering continuous quality control for cables, wires, and pipes
- Automatic extrusion control that adjusts line speed or extruder output for consistent optimized production
- Easy integration into existing extrusion lines and cooling troughs
- Reliable, low-maintenance system offering long service life and reduced downtime
Measurement points
Wall thickness (mm)
Object diameter (mm)
Scan rate (scans/s)
Technical data
For accessories and detailed product information, refer to the respective brochures
UMAC® A8
- Diameter measurement range
- 0.2 … 8 mm
- Measurement points
- 4 or 8
- Ultrasound transducer frequency
- 10/20 MHz
- Ultrasound transducer focal distance
- 19 mm
- Brochure
- UMAC® A8 (PDF, 4.09 MB)
UMAC® A11
- Diameter measurement range
- 0.2 … 11 mm
- Measurement points
- 4 or 8
- Ultrasound transducer frequency
- 10/20 MHz
- Ultrasound transducer focal distance
- 19 mm
- Brochure
- UMAC® A11 (PDF, 4.09 MB)
UMAC® A21
- Diameter measurement range
- 0.2 … 21 mm
- Measurement points
- 4 or 8
- Ultrasound transducer frequency
- 10/20 MHz
- Ultrasound transducer focal distance
- 25.4 mm
- Brochure
- UMAC® A21 (PDF, 4.09 MB)
UMAC® A28
- Diameter measurement range
- 3.5 … 28 mm
- Measurement points
- 4 or 8
- Ultrasound transducer frequency
- 10/20 MHz
- Ultrasound transducer focal distance
- 25.4 mm
- Brochure
- UMAC® A28 (PDF, 4.09 MB)
UMAC® R
- Max. object diameter
- Customizable 2 … 400 mm
- Measurement points
- 4 / 6 / 8
- Scan rate
- Standard: 60 Hz
Super High Rate: 15 KHz - Brochure
- UMAC® R (PDF, 4.77 MB)
UMAC® RZ35/4K/6K
- Max. object diameter
- 0 … 35 mm
- Measurement points
- 4
- Scan rate
- Standard: 60 Hz
Super High Rate: 15 KHz - Brochure
- UMAC® RZ35/4K/6K (PDF, 2.21 MB)
UMAC® RZ65/4K/6K
- Max. object diameter
- 0 … 65 mm
- Measurement points
- 4
- Scan rate
- Standard: 60 Hz
Super High Rate: 15 KHz - Brochure
- UMAC® RZ65/4K/6K (PDF, 2.21 MB)
UMAC® Z50/4K/6K
- Max. object diameter
- 5 … 50 mm
- Measurement points
- 4 / 6
- Scan rate
- Standard: 60 Hz
Super High Rate: 15 KHz - Brochure
- UMAC® Z50/4K/6K (PDF, 837.8 KB)
UMAC® Z100/4K/6K
- Max. object diameter
- 10 … 100 mm
- Measurement points
- 4 / 6
- Scan rate
- Standard: 60 Hz
Super High Rate: 15 KHz - Brochure
- UMAC® Z100/4K/6K (PDF, 837.8 KB)
UMAC® Z180/6K
- Max. object diameter
- 25 … 180 mm
- Measurement points
- 6
- Scan rate
- Standard: 60 Hz
Super High Rate: 15 KHz - Brochure
- UMAC® Z180/6K (PDF, 837.8 KB)
UMAC® CI
- Range
- 0.08 mm up to 99.95 mm, depending on product
- Sensor inputs
- 1..8 (selectable)
- Host port
- RS, Ethernet TCP/IP, Profinet IO, EtherNet/IP
- Brochure
- UMAC® CI (PDF, 3.6 MB)
SPV-1
- Supply pressure
- 0.7–7 bar (10–100 PSI)
- Output pressure
- 0.037 bar (0.54 PSI or 0–15 in. of water) / 0.074 bar (1.08 PSI or 0–30 in. of water).
Other ranges are available on request. - Capacity
- 2.04 m3/h @ 7 bar (1.2 SCFM* @ 100 PSI) supply pressure
- Repeatability
- +/- 0.20 % of F.S. at 0.06 m3/h (1.0 l/min)
- Brochure
- SPV-1 (PDF, 7.2 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
The latest UMAC® CI processor generation adds modern connectivity and OEM-ready integration, while the proven WALLMASTER system continues to perform in advanced multi-sensor configurations combining UMAC®, ODAC®, and other Zumbach measurement technologies.
Areas of application
Cable & Wire Extrusion:
Wall thickness, concentricity and eccentricity measurement of insulation and cable jackets; energy cables, control cables, automotive and aviation cables, low/medium/high voltage cables.
Tube, Hose & Pipe Extrusion:
Medical tubes and hoses, sanitary pipes, water and gas pipes, automotive and aviation tubes/hoses, cable ducting and conduits (MicroDucts).
Large-Diameter Pipe Extrusion:
Wall thickness and concentricity measurement of large pipes up to 400 mm diameter (with custom solutions realized up to 835 mm); installation directly after the die or at the cold end of the line; particularly effective for material savings in the hot zone.
Frequently asked questions
What is the difference between UMAC® CI and UMAC® WALLMASTER?
The latest generation UMAC® CI is a compact ultrasonic processor with integrated webserver, designed for standalone use or OEM integration. WALLMASTER is the complete system solution combining UMAC® CI with the USYS® IPCe processor, 19″ touchscreen HMI, and full line control software, ideal for complex multi-sensor line configurations.
How many wall thickness measurement points do I need?
4 measuring points give a good overview of concentricity for most applications. 6 points offer higher resolution for demanding tolerances. 8 points provide the most complete picture for large-diameter pipes or critical quality requirements. The transducer holder model determines the available number of points.
Can UMAC® measure multi-layer products?
Yes. The UMAC® system can measure up to 5 layers simultaneously in a single pass – covering complex cable insulation structures, multi-layer pipes, and jacketed products without any additional sensors.
Where in the line should the UMAC® be installed?
At the hot end (directly after the die): fastest response for concentricity/eccentricity correction at the crosshead – minimizes start-up scrap. At the cold end (after or in the vacuum tank or at line end): used for final quality control and documentation. All positions can be combined in one line.
What is DIACAL 8000 and do I need it?
DIACAL 8000 automatically calibrates the ultrasonic wall thickness measurement using the existing laser diameter measurement (ODAC®) before and after extrusion. This eliminates the need for manual calibration, improves accuracy, and reduces setup time. It is particularly valuable for cable jacket applications.
Can UMAC® integrate with our existing line control system?
Yes. The UMAC® CI processor supports PROFINET IO, EtherNet TCP/IP, EtherNet/IP, OPC UA, and RS-232/422/485 interfaces. The WALLMASTER system additionally supports integration with Zumbach USYS® software, enabling recipe management, full data logging, SPC reporting, and closed-loop extruder/linespeed control.
