PFG4030-i4
Profile Flaw Gauge
Advanced laser triangulation gauge for flat, figure-8, sector-shaped and other complex-profile cable extrusions. Full 360° surface inspection and dimensional measurement — inline, non-contact, in real time.
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Profile & Flaw Gauge for Complex Cable Extrusions
The InteliSENS PFG4030-i4 uses four laser profile gauges positioned at 90° intervals, alternating 405 nm and 450 nm wavelengths to minimise 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 of non-round cable cross-sections.
Standard round-wire gauges cannot handle the measurement demands of flat, sector, figure-8, or multi-lobe extrusion profiles. The PFG4030-i4 was engineered specifically to close that gap — delivering inline dimensional measurement and surface inspection in a single instrument.
- Real-time display of profile dimensions, concentricity, and out-of-roundness data
- Four 3D laser triangulation devices ensure complete 360° surface coverage with minimal optical interference
- Fast scanning at up to 19,000 scans/s overcomes limitations of traditional lump and neck detection
- Detects lumps, neckdowns, and surface defects across the full extrusion surface
- Multiple communication protocols for easy integration with existing line controls
- All measured parameters logged for storage, SPC analysis, and production reporting
- User-friendly interface with profile teach-in for fast changeover between product runs
How It Works
Multi-plane laser projection
Four laser triangulation sensors project laser lines onto the object's surface at 90° intervals, using alternating wavelengths (405 nm and 450 nm) to minimise cross-sensor interference and ensure clean measurement data.
High-speed image capture at 19,000 scans/s
High-speed cameras capture the reflected laser patterns. Surface topography deforms the projected lines; the PFG analyses these deformations to calculate precise distance to each surface point, generating a cross-section coordinate data set.
3D surface reconstruction and flaw detection
As the cable moves, the PFG continuously stacks cross-sectional profiles. An integrated SL gauge or external speed sensor provides velocity data for accurate 3D surface representation, flaw detection, and dimensional measurement.
Supported Profile Geometries
Purpose-built for the full range of non-round extrusion geometries in power, data, automotive, and specialist cable manufacturing.
Technical Specifications
| Parameter | PFG4030-i4 |
|---|---|
| Maximum size | 30 mm (1.20 in) |
| Minimum size | 0.3 mm (0.012 in) |
| Measurement accuracy | ±30 µm |
| Flaw height accuracy | 3% |
| Scan speed | Up to 19,000 scans/s |
| Surface coverage | 360° |
| Measurement method | Laser triangulation (non-contact) |
| Laser wavelengths | 405 nm / 450 nm (alternating) |
| Number of sensors | 4 × 3D laser triangulation, at 90° intervals |
Inputs & Outputs
Electrical & Environmental
Size & Weight
One instrument. Complete profile measurement.
360° surface inspection
Four sensors at 90° intervals provide complete coverage with no blind spots — lumps, neckdowns, and surface defects detected across the full extrusion surface.
Real-time process control
Live data output at up to 19,000 scans/s feeds directly to your extrusion line controls — correct deviations before scrap accumulates on the drum.
Built for complex profiles
Unlike standard round-wire gauges, the PFG4030-i4 handles flat, figure-8, sector, elliptical and custom geometries that traditional instruments simply cannot measure.
Full SPC integration
Statistical process data, trend analysis, configurable alarms, and production reporting — all built into the instrument software, with standard industry interfaces.
Inline, non-contact measurement
No line stoppages, no contact with the cable surface. The PFG4030-i4 measures continuously at production speed with IP 65 environmental protection.
Multiple connectivity options
RS232/422/485, Ethernet, Wi-Fi, and iBUS — plus relay outputs and analog options — ensure the PFG4030-i4 integrates into any existing line control architecture.
Industries & Applications
If your line runs non-round cable profiles and dimensional accuracy matters, the PFG4030-i4 was built for your application.