InteliSENS PFG4030-i4

Profile Flaw Gauge

The InteliSENS PFG uses four laser profile gauges positioned at 90° intervals, alternating 405 nm and 450 nm wavelengths to minimize interference. Based on laser triangulation, each gauge projects a laser line whose deformation is captured by a high-speed camera. Analysis of these reflections generates precise 3D surface data, enabling accurate flaw detection and profiling.

  • Precise, high-resolution measurement
  • No moving parts for high reliability and low maintenance
  • Full integration with PLC, and gauging equipment
  • Industry 4.0 data communications
  • SMFD flaw detection
  • PID controller
  • FFT analysis; SPC; Statistics
  • Analogue output
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Performance

PFG4030-i4
Maximum Diameter 25 mm
1.00″
Minimum Diameter 0.2 mm
0.008″
Accuracy ± 1 µm + 0.008% of object
Resolution 0.01 µm
Scan Speed 15,000 scans/s (30,000 option)

†: object centered in the optical gate.

Connectivity

Maximum input voltage: 24Vdc
End user configurable function:
• Reset;
• Print Activation.

250 kHz max frequency, 30 V or 50 V max pulses, user scalable.

0 – 10 Vdc, user scalable

Isolated contact rating: Maximum 50 VDC / 30 VAC / 0.5 A User configurable function:
• Gauge OK;
• Upper tolerances exceeded.
• Lower tolerances exceeded.
• Single Measurement Flaw Detection (SMFD).

1 x RS232 / RS422 / RS485
MODBUS RTU; PROTON ASCII code or Label; USB using RS232 – USB Converter Cable; RS485 MODBUS RTU; PROTON ASCII code (not available with PROFIBUS)

1 x CANBUS Port
Proprietary CAN protocol to connect CDi4 display interface, including CS5G / via CS1000

1 x iBUS Port
Connect to a PLC using PROFIBUS, PROFINET, EtherNet/IP [all included: select one to use].
Data update rate up to 500/sec.
Flexible Data Configuration, Big Endian, Little Endian.

1 x Ethernet port
Connect to PC, Network, PLC, Cloud Service
User selectable – Modbus TCP/IP or OPC-UA for Industry 4.0 solutions.
Connect DGk gauges to your OPC UA data collection system.

Wi-Fi for gauge configuration and diagnostics.

Product Add-On Hardware

±10 Vdc output of diameters eccentricity, or errors. Updated rate: 1ms

Proportional Integral feedback controller for diameter

Optional Add-On Software

Maximum, Minimum, Mean, Standard Deviation, Cp, Cpk is collected during a selectable time or length period.

Fast Fourier Transform analysis for amplitude and frequency of periodic diameter variations

Statistical Process Control automatic set point for PI feedback controller (requires PI
feedback controller option)

Single Measurement Flaw Detection (Lump and Neck detection)

Electrical and Operating Requirements

Power Supply
100 – 240 Vac (50 – 60Hz)
Power Consumption
100 Watts
Operating Temerature
5c – 45c (41-113F)
Environmental Protection
IP 65

Size & Weight

PFG4030-i4 Height
1580 mm (62.2 in)
Width
310 mm (12.20 in)
Thickness
515 mm (20.2 in)
Weight
100 kg (220.46 lb)

Accessories

Gauge Add On Hardware
Gauge Add On Software
Display
Power
Stands & Guards
Alarm & Report
Diameter Control
Visual Software

Product Documentation