Precision sensor manufacturer Micro-Epsilon has extended its range of 2D/3D measurement systems with the 3D Profile Unit (3DPU), a powerful computer platform that enables the calculation and profile stitching of up to eight individual profiles from the scanCONTROL 30xx series of laser profile sensors into a common coordinate system. This allows a composite 2D profile or a composite 3D point cloud to be generated.
Why stitch lines together?
scanCONTROL sensors are available with a range of line widths from 25 mm to 788 mm, however the number of measuring points is fixed across the line. Therefore the wider the line the greater the spacing in the x direction between points. Having the ability to arrange multiple sensors in a row and stitching those lines together allows for improved point spacing and/or improved coverage of complex geometries, for example 360° coverage of extrusions.
With the 3DPU, a wide variety of geometries can be recorded, measuring ranges extended and thickness measurements implemented. Precise assignment of the position of each sensor to a common coordinate system is carried out by registration. After the sensors have been set up, the position of each individual scanCONTROL sensor is determined in a common overall coordinate system – referred to as multi-sensor registration. Registration brings the individual sensor readings into a common coordinate system during the set-up process. Micro-Epsilon offers an individual registration target for each measuring range of the scanCONTROL sensors and for each measuring arrangement. A special registration target can be designed for individual configurations and measurement setups. The sensors can also be registered without a registration target. In this case, registration is done manually via a Golden Sample.
Smart 3D evaluation and output of stitched 2D/3D profile data
Two versions of the 3DPU are available. The 3DPU-X system calculates the profile data of several scanCONTROL sensors into a common coordinate system and makes it available as 2D profiles / 3D point clouds via GigE Vision. This enables direct integration with machine vision and 3D software, as well as communication with any GigE Vision client.
The 3DPU-X/IE system compares the profile data of several scanCONTROL sensors into a common coordinate system, evaluates the 2D profiles or 3D point clouds and makes the measured values available via integrated fieldbus interfaces (Gigabit Ethernet, Ethernet/IP, Profinet, EtherCAT, Modbus TCP) for example, as a good or bad result. The smart 3DPU Controller in the 3DPU-X/IE version offers integrated 3D evaluation and results output in conjunction with the Industrial Ethernet connection, enabling the application to be controlled and measured values to be output to a PLC.
Flexible, industrial-grade hardware with passive cooling allows easy, space-saving installation of the 3DPU. The unit can be installed in a control cabinet or mounted directly in a machine. An external PC can easily be connected to configure the system.
Typical applications for the 3DPU include thickness measurement (using two opposing profile sensors) of battery film, smartphone carrier plates and cold rolled steel strip. Using a linear arrangement of profile sensors, applications include checking the completeness of assembled PCBs, web edge monitoring, inspecting the dimensions of extruded square profiles, inspection of pins on automotive connectors, and the recording of road profiles.
Data evaluation and parameter setup
Evaluation of data and parameterisation of the system is carried out using the 3DInspect software from Micro-Epsilon. This unified, easy-to-use software tool enables parameterisation of the 3DPU and the recording of measurement data directly from the software. Powerful tools allow the alignment and filtering of the point cloud, intuitive recognition and selection of relevant areas, as well as the combination of programs. 3D point clouds can be processed as desired and measured values can be output to the controller.
For more information on the 3D Profile Unit, please visit www.micro-epsilon.co.uk
