Non-Destructive, Radiation-Free Measurement of Nonwoven Fabric Weight on Production Lines: Hakko Automation Launches "EM SENSE RF-M801" Sensor Utilizing Automotive Millimeter-Wave Radar Technology on July 1st.

Millimeter-Wave Sensor EM SENSE RF-M801

Hakko Automation Co., Ltd. (Headquarters: Kasuya-cho, Kasuya-gun, Fukuoka Prefecture; hereinafter referred to as "the Company") has launched a new product, the "Millimeter-Wave Sensor EM SENSE RF-M801," which enables non-contact, non-destructive, and 100% inspection of the "weight per unit area" (basis weight, grams per square meter: g/m2) that influences the quality of nonwoven fabrics, felt, and glass wool (glass fibers) directly on the manufacturing line.

This product applies the technology of millimeter-wave radar for automotive collision avoidance. By leveraging the characteristic of radio waves to penetrate the interior of objects, it completely eliminates the use of radiation (equivalent safety to automotive radar / technical standards conformity acquired), thus requiring no qualified personnel or controlled areas, and can be retrofitted to existing lines. It achieves "visualization of basis weight during production," which was previously difficult, contributing to the suppression of quality variations, improvement of yield, and reduction of material waste.

Background of Development: Basis Weight Directly Affects "Performance," But It's Not Managed "During Production"

The "basis weight (g/m2)," which indicates the weight per square meter, is an index that directly influences the performance of nonwoven fabrics and glass wool. For example, in filters, the basis weight determines the filtration performance itself, such as collection efficiency and airflow resistance. In insulation materials, it affects insulation performance. Particularly for high-value-added materials, even slight variations in basis weight can lead to performance degradation or defects, directly resulting in high disposal costs.

However, in many manufacturing sites, the basis weight is currently managed by measuring the weight after it has been rolled. This is only a post-production check, and an overall average, meaning variations occurring during production cannot be grasped in real-time. When defects are noticed, long lengths have already been produced, often leading to situations where they must be discarded in large batches. On the other hand, inspection equipment using radiation such as X-rays requires qualified personnel like radiation handling supervisors, usage permits, and the establishment of controlled areas, posing a significant burden, especially for retrofitting to existing lines.

The importance of these challenges has been further amplified by social factors. Nonwoven fabrics are expanding their applications into high-functionality and high-value-added fields, including various filters. For such materials, variations in basis weight significantly impact performance, yield, and cost. Furthermore, there is a growing demand for automated 100% inspection (to address labor shortages in the manufacturing industry).

Comparison with Conventional Methods

Solution Provided by Millimeter-Wave Sensor: "Visualization" of Production Variations Without Radiation

The millimeter-wave sensor utilizes the characteristic of millimeter waves to penetrate the interior of substances, enabling continuous measurement of "basis weight" from the manufacturing line in a non-contact and non-destructive manner. By feeding the measurement results back to the manufacturing equipment, it achieves stable production with suppressed variations and early detection of defects.

From post-production weight management to 100% inspection during production: Continuous inline measurement detects variations on the spot, preventing the production of long defective lengths.

Radiation-free: Equivalent safety to automotive radar for collision avoidance, eliminating the need for qualified personnel, usage permits, and controlled areas.

Retrofit to existing lines: Compact design of 100x81x91mm. Compatible with retrofitting to existing lines where large X-ray inspection equipment would be difficult.

Improved yield and reduced costly waste: Stabilizing basis weight, which directly affects performance, suppresses defects and material loss. Contributes to resource conservation and cost reduction.

Introduction support as an engineering company: We handle modifications to machinery and PLC integration. Free test measurements with customer materials are conducted before introduction.

Replacement of Radiation Inspection Equipment

Measurement Principle (Reference)

Millimeter waves are radio waves with wavelengths in the millimeter range. They have strong directivity and excellent environmental resistance to weather, which is why they are used in automotive radar and 5G smartphones.

Millimeter waves propagating inside a substance change their apparent wavelength according to density. The higher the basis weight, the slower the arrival time for reflection and return. The millimeter-wave sensor converts this difference in arrival time into basis weight and outputs it.

Principle

Main Specifications

Item

Details

Measurement Method

Non-contact, non-destructive measurement using millimeter waves (continuous inline measurement)

Object Shape to be Measured

Sheet shape

Material of Object to be Measured

Nonwoven fabric, felt, glass wool (glass fiber), artificial leather *Conductive materials are not supported.

Applicable Object Thickness

1 to 50 mm (upper limit depends on material)

Linearity

±3% F.S. (with 2-point correction, temperature range ±5°C)

Sampling Speed

100 msec

Spot Diameter

φ100mm *Depends on the size of the corner reflector

Millimeter-wave Output Level

Equivalent to automotive radar for collision avoidance, no impact on humans

Number of Connectable Sensors

Maximum 2 heads per controller

Power Supply

DC24V (±10%) 28.5W

Operating Temperature Range

0 to 50°C (non-condensing)

Size/Weight

Controller: 103x81x36mm Sensor Head: 100x81x91mm

*Specifications are subject to change without notice for improvement purposes.

Main Intended Applications and Target Industries

Various Filters: For functional filter applications where basis weight directly influences collection efficiency and airflow resistance (filtration performance).

Artificial Leather: High-grade artificial leather using nonwoven fabric as a base material. High-value-added applications such as automotive and aircraft interiors and furnishings, where basis weight (density) influences texture and strength.

High-Performance Insulation Blankets: Advanced insulation materials like aerogel. Industrial applications such as oil refining and power plants, where basis weight (density) directly influences insulation performance.

Building Materials/Insulation: Density (basis weight) management of insulation materials such as glass wool. Stabilization of insulation performance corresponding to higher insulation performance.

Medical/Sanitary Materials: Inline management of basis weight for sheet-like materials.

Pricing and Availability

Release Date: July 1, 2026 / Price: Open price

For consideration of introduction, we offer "free test measurements" using your materials. Please feel free to contact us first.

Company Profile

Company Name

Hakko Automation Co., Ltd.

Head Office/Factory

2753-5 Oaza Nakabaru, Kasuya-cho, Kasuya-gun, Fukuoka Prefecture, 811-2304

Business Activities

Development, design, manufacturing, and sales of industrial automation, millimeter-wave sensing, control systems, and appearance inspection equipment (engineering company)

Representative

Kazuo Ono

Established

June 1968

URL

https://www.hacmat.co.jp/

Hakko Automation Co., Ltd.

Hakko Automation (Co., Ltd.) is an engineering company that handles everything from the development of inspection and measurement equipment to the control of factory production equipment and air conditioning/heat source equipment, and the design, production, and on-site adjustment of industrial automatic control devices. We support the resolution of challenges faced by manufacturing industry customers, such as improving production efficiency and product accuracy, through the development of custom control systems and inspection/measurement equipment. We back up the stable operation of production lines with control tailored to the specific needs of each site.

<Product Inquiries (General)>

Hakko Automation Co., Ltd.

Sales Department

2753-5 Oaza Nakabaru, Kasuya-cho, Kasuya-gun, Fukuoka Prefecture, 811-2304

TEL: 092-611-5751

FAX: 092-611-5747

E-MAIL: [email protected]