High speed, high accuracy 2D laser line profile sensor is easy to set up, configure and adapt

Citation

(2006), "High speed, high accuracy 2D laser line profile sensor is easy to set up, configure and adapt", Sensor Review, Vol. 26 No. 4. https://doi.org/10.1108/sr.2006.08726dad.003

High speed, high accuracy 2D laser line profile sensor is easy to set up, configure and adapt

High speed, high accuracy 2D laser line profile sensor is easy to set up, configure and adapt

Keywords: Lasers, Sensors

A non-contact laser line profile measurement system has been developed that enables end-user manufacturers, systems integrators and machine builders to detect beads (i.e. 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. 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 (Plate 3).

Plate 3 The scanCONTROL 2810™, is the latest addition to the range of sensor systems from Micro-Epsilon

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 measurement speeds.

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.

Web site: www.micro-epsilon.co.uk