DJH Wolf WFM1 Online Wet Film Thickness Measurement System
| Brand | DJH Designs |
|---|---|
| Origin | Canada |
| Manufacturer Type | Authorized Distributor |
| Origin Category | Imported |
| Model | WFM1 |
| Pricing | Available Upon Request |
Overview
The DJH Wolf WFM1 Online Wet Film Thickness Measurement System is an industrial-grade, non-contact optical sensor engineered for real-time, in-line monitoring of wet paint film thickness on continuous coil coating (color-coating) production lines. Utilizing precision laser triangulation and high-speed CMOS imaging, the WFM1 captures cross-sectional profile data across the full strip width—enabling continuous, millisecond-resolution measurement of uncured organic coatings immediately after application and before curing. Designed specifically for demanding coil coating environments—including high line speeds (up to 200 m/min), elevated ambient temperatures, and aggressive solvent-based or waterborne chemistries—the system delivers stable, drift-free performance under factory conditions. Its robust mechanical housing (IP65-rated) and thermally compensated optics ensure long-term repeatability without manual recalibration, making it suitable for integration into automated process control loops compliant with ISO 9001 and IATF 16949 quality management frameworks.
Key Features
- Real-time wet film thickness acquisition at up to 100 Hz sampling rate, synchronized with line encoder signals
- Measurement range: 5–150 µm (wet), with ±0.3 µm repeatability under controlled calibration conditions
- Full-width scanning capability (standard 1,200 mm field-of-view; customizable up to 2,000 mm)
- Integrated thermal stabilization module to maintain optical path integrity across ambient temperatures from 10°C to 50°C
- Self-diagnostic firmware with automatic lens contamination detection and signal-to-noise ratio monitoring
- Modbus TCP and EtherNet/IP communication protocols for seamless PLC integration (Siemens S7, Rockwell ControlLogix, Beckhoff TwinCAT)
- Passive cooling design—no compressed air or external chillers required
Sample Compatibility & Compliance
The WFM1 is validated for use with standard coil coating formulations including polyester, polyvinylidene fluoride (PVDF), silicone-modified polyester (SMP), and plastisol-based systems. It accommodates both solvent-borne and high-solids aqueous dispersions, with minimal sensitivity to pigment loading variations (tested per ASTM D1210 and ISO 2808 Annex B). The system meets CE marking requirements (EMC Directive 2014/30/EU and Low Voltage Directive 2014/35/EU) and complies with machinery safety standards EN ISO 13857. All firmware and configuration logs support audit-ready timestamping and user-access controls aligned with FDA 21 CFR Part 11 principles for electronic records and signatures—enabling traceability in regulated manufacturing environments.
Software & Data Management
The WFM1 operates with WolfView™ v4.2 software suite, a Windows-based platform providing live thickness mapping, statistical process control (SPC) charting (X̄-R, Cpk, Ppk), and automated report generation in PDF/CSV formats. Historical data is stored in an embedded SQLite database with configurable retention policies (default: 90 days, extendable via network-attached storage). Trend analysis tools include moving average filters, edge deviation profiling, and zone-specific thickness deviation alerts (configurable per strip position: center, ¼-width, edge). Software supports role-based access control (Operator, Technician, Administrator), change history logging, and export of raw pixel intensity arrays for third-party spectral analysis. Optional OPC UA server module enables bidirectional data exchange with MES platforms such as Siemens Opcenter Execution or Rockwell FactoryTalk.
Applications
- Continuous monitoring of wet film uniformity on pre-painted steel and aluminum coil lines
- Feedback control input for automatic viscosity adjustment in roll coater systems
- Root cause analysis of streaking, orange peel, or edge build-up defects during commissioning and troubleshooting
- Process validation for new coating formulations prior to oven cure optimization
- Quality gate verification prior to rewinding or slitting operations
- Supporting Six Sigma initiatives through quantitative thickness capability studies (Cp/Cpk) across shifts and batches
FAQ
What substrates are compatible with the WFM1?
The system is optimized for metallic substrates (cold-rolled steel, galvanized steel, aluminum alloys) with surface roughness Ra ≤ 1.6 µm and reflectivity ≥ 20% in the 650–850 nm band.
Does the WFM1 require periodic calibration using physical standards?
Yes—initial factory calibration is traceable to NIST SRM 2134; field verification is recommended every 6 months using certified step-height reference wafers (supplied by DJH Wolf Calibration Services).
Can the WFM1 operate in high-humidity environments typical of waterborne coating lines?
Yes—housing ingress protection is rated IP65, and optical windows feature hydrophobic anti-fog coatings tested per ASTM D1748 for 95% RH exposure over 72 hours.
Is remote diagnostics supported?
Yes—WolfView™ includes secure remote access via TLS 1.2 encrypted tunnel; diagnostic logs and live sensor health metrics can be exported for DJH Wolf technical support review.
How is measurement data time-stamped and synchronized with production events?
All measurements are tagged with microsecond-precision timestamps aligned to the line encoder’s zero-reference pulse; synchronization accuracy is ±10 µs relative to PLC scan cycle boundaries.
