High speed, high accuracy 2D laser line profile sensor
is easy to set up, configure and adapt.
A non-contact laser line profile measurement system has
been developed that enables end user manufacturers,
systems integrators and machine builders to detect beads
(ie. bulges or bumps) of glue or weld seams, and to inspect
grooves, channels, gaps and edges in a variety of applications.
The system has standalone plug-and-play capability, and is easy to
set up, configure and adapt for different measurement applications.
Engineers require no special software programming skills to change
measurement parameters and to get the system up and running quickly.
The scanCONTROL 2810, Micro-Epsilon's latest version of its
scanCONTROL range of sensor systems, was unveiled at last year's
Hanover Fair in Germany and officially launched in Autumn 2005.
The system builds on the success of the company's scanCONTROL
2800 2D/3D laser line sensor, but goes even further and is capable
of measuring up to 256,000 points per second up to 4kHz. It also
easier to integrate, set up and configure for individual applications.
The scanCONTROL 2810 uses the same laser line triangulation
measurement principle as the scanCONTROL 2800. The sensor
has an integrated, highly-sensitive CMOS array, which enables
measurements of almost any shiny, reflective or transparent surface,
independent of the reflection from the target. This means excellent
accuracy, resolution and reliability are achieved, even at high
A line optical system projects a laser line onto the surface of the object
being measured. The back scattered light from the laser line is
registered on a CMOS matrix by a high quality optical system. Along
with distance information (z-axis), the controller calculates the true
position along the laser line (x-axis) from the camera image and
outputs both values in the sensor's 2D coordinate system. A moving
target or traversing sensor generates a 3D representation of the
object being measured.
scanCONTROL 2810 is capable of measuring up to 256,000 points
per second and so is ideal for real time quality inspection or online
process guidance. Depending on the resolution and size of the
measurement range, a profile frequency of up to 4,000 profiles per
second can be attained.
Customers are using the sensor for detecting
weld seams, beads of adhesive, edges, angles
and for detecting grooves, channels and gaps.
In the automotive industry, VW and BMW are
using the system to check the height, width
and integrity of glue beads. In the drinks industry,
Syscona is using the system to verify the position
of barrel cups on its production lines. Qion is
using the system to check the position of a welding seam on its pipelines,
and in the aircraft sector, DLR is checking the angle of helicopter rotor
blades for calibration in an engine test cell.
The system itself comprises a sensor and integrated controller, which
calculates the dimensions of the bead or groove. The system works
in two ways: either in a stationary mode, with the sensor fixed and
looking at moving targets, or in a scanning mode, where the sensor
works in combination with a motion control device or robot. The sensor
uses an innovative CMOS array with a real time, high speed electronic
shutter (rather than conventional rolling shutters), which captures the
entire profile and processes the information instantaneously.
The controller evaluates the measurement data and provides control
signals via analogue or digital outputs. The system can be easily
configured using the parameter software included within the sensor
package. Parameters that can be configured include area, height and
width of the bead. The user simply connects a laptop or PC to the
controller and configures the sensor via easy-to-use software. Triggers
and alarms can also be set up using the software, so that when limits
or tolerances are exceeded, users are alerted.
Chris Jones, Managing Director at Micro-Epsilon UK, commented:
"We are selling the system to machine builders, systems integrators
and direct to end users, because it is so easy to adapt the system
to different applications. It is also easy to set up and configure for
different measuring fields and no special software programming skills
are required to do this. The system also offers very high speeds and
accuracies, enabling end users to inspect their products in-process
in real time."
Typical applications for the sensor system include: welding seam
inspection; glue bead inspection; door edge detection; angle
measurement; step and height measurement; planarity and surface
control on PCBs; robot guidance and positioning; and groove width
and depth measurement.