USYS® Data Pro­cessor and Con­trol­ler

Why USYS®?

The Zumbach USYS® is the centralized intelligence of modern production lines, combining multi-sensor data acquisition, processing, visualization, and control into a single, scalable platform. Designed for demanding industrial environments, USYS® seamlessly integrates measurement data from multiple instruments to provide a complete real-time view of product quality and process performance.
By unifying measurement, control, and analytics, USYS® enables immediate process optimization, reduces material waste, ensures consistent product quality, and delivers full traceability for data-driven manufacturing.

• Multi-sensor integration: one USYS® processor connects and processes data from ODAC® laser gauges, UMAC® ultrasonic systems, CAPAC® capacitance sensors, spark testers, and more, centralizing all quality parameters in a single platform.
• Self-optimizing process control: SIGMA EXPERT automatically adjusts process parameters in real time to maintain tight tolerances, improve yield, and reduce operator intervention. With our optional CpK Pilot, target values are continuously optimized to maximize material savings while keeping production safely within specification.
• Complete statistics & traceability: built-in SPC with real-time Cp/Cpk, control charts, job reports, and comprehensive data logging options ensure full quality documentation and production transparency.
• Seamless industrial connectivity: integrated EtherNet TCP/IP and OPC UA interfaces, plus multi-user web server access, enable easy integration with PLC/SCADA systems and PC-based reporting tools for connected, Industry 4.0 environments.

Proven per­form­ance world­wide

USYS® processors are installed in production facilities worldwide across the cable, wire, plastic, rubber, and metal industries, supporting manufacturers with reliable data acquisition, process control, and quality monitoring. Used wherever Zumbach ODAC®, ODEX®, UMAC®, RAYEX® and CAPAC® systems are deployed, USYS® transforms raw measurement data into actionable insights, enabling optimized processes, reduced scrap, and fully documented production quality. From simple single-diameter gauge applications to complex multi-sensor extrusion lines, USYS® provides the performance, flexibility, and connectivity required for modern, data-driven manufacturing environments.
USYS® systems are designed for seamless in-line integration, delivering real-time monitoring, closed-loop control, and full traceability across virtually any production setup.

Fre­quently asked ques­tions

What is the difference between the USYS® models?
For single-gauge / sensor devices, the VISU-Touch is our simplest and most cost-effective display solution, while the compact USYS® 20 adds a single closed-loop control capability and limited SPC functionality. USYS® 200 / USYS®-Touch adds a customizable graphical colour screen and broader feature set including enhanced digital IO functionality, full graphical SPC, SIGMA EXPERT control, data logging, and OPC UA. USYS® IPC 1e and IPC 2e are full industrial PC systems supporting up to 2 or 6 measuring gauges, offering all the features of the USYS® 200 / USYS®-Touch plus the ability to add further devices (up to 14 in total), making it the optimal solution for complete multi-sensor production lines.

Can USYS® connect to our factory network or MES system?
Yes. All current USYS® models include EtherNet TCP/IP. An integrated web server is available in all but the USYS® 20 solutions. All USYS® models additionally support OPC UA for integration with SCADA, MES, and ERP systems. The USYS® Data Log software enables collection and export to text or Excel files from one or multiple processors.

What sensors can USYS® process, besides ODAC® gauges?
USYS® connects to UMAC® ultrasonic wall thickness systems, RAYEX® x-ray measurement systems, CAPAC® capacitance gauges, ODEX® eccentricity systems, KW lump/neckdown detectors, spark testers, speed/length encoders, and event inputs – combining all quality parameters to a single display.

What is the SIGMA EXPERT controller?
SIGMA EXPERT is a self-adapting process controller available on USYS® IPC models. It continuously monitors product dimensions and automatically adjusts process parameters – such as extruder speed or haul-off – to keep production within tight tolerances and minimize raw material usage. Unlike fixed-gain controllers, it adapts to changing line conditions.

Does USYS® support SPC and quality reporting?
Yes. USYS® 200, Touch and IPC models provide full SPC with real-time control charts, Cpk calculation, package reports, job reports, and a data log. The Report Manager stores detailed statistical data for piece, lot, and SPC periods, including graphical trend and statistics charts, enabling reproduction of historical quality reports for customer documentation and audits.

Can USYS® be used with non-Zumbach sensors?
USYS® is primarily designed for Zumbach measurement systems. Via serial and EtherNet interfaces, integration with third-party inputs is possible in many configurations, such as analogue, digital or OPC UA client inputs. Contact your Zumbach representative to discuss specific sensor and integration requirements.