Laser scanners - Import export

Particular Challenges: In the course of the production, endless cables are running at a considerable speed, and supervision has to be carried out nearly under real-time conditions. The size of the objects to be determined, i.e. of the flaws to be discovered, is in the range of only some hundredths of a mm. Another difficulty is the fact that surfaces with very different reflectivity and roughness are involved. In order to be able to check the cables all around, several laser scanners must be in place, mounted at different angles, thus covering the entire range of 360°. Quelltech Solution: The solution consists in a configuration of four Q6 laser scanners, mutually displaced by 90°, so the entire surface of the cables is in the field of view. On the basis of the 100% inline inspection, the position of defects can precisely be determined, without losing too much time.

The products get transferred in a continuous-flow process. Products go through the scanner where the mass allocation of each product is determined using X-ray technology. The products are then weighed on the integrated weighing station according to their individual track. The system features a two-stage safety guarding for its radiation source. The CPS-X 400 is specifically designed for weight-accurate slicing of speciality products like Swiss Cheese and those which vary in density, e.g. fat to lean ratio. Optional: Detection of foreign objects: as well as ensuring reliable production, detecting foreign objects also protects units located downstream. This function can be used for detecting, e. g. stainless steel > Ø = 3 mm, glass/ceramic > Ø = 8 mm (product-dependent). Advantages Up to six products in one scan cycle Weight-precise cutting of cheese with holes Density determination of products with significant density differences (fat/lean proportion)

The products to be recorded can be fed on multiple tracks into a LED camera system, which individually measures and then weighs them at a weighing station. Based on the captured data, the highest yield and minimal give-away is guaranteed during slicing of pieces/chunks and slices. Advantages Open design, simple handling High fault tolerance Excellent detection of products with extremely fluctuating color contrasts Precise measurement even in extraneous light The laser scanner is available in various sizes to fit your product.

The Z+F PROFILER® 9012 has a vertical 360° field-of-view and is the fastest profile imaging 2D laser measurement system in its class. With its scan rate of more than 1 million points per second and a maximum scanning speed of 200 profiles/sec. short distances between the profiles can be achieved even at high speeds of the carrier vehicle. Because of the high point density, even small objects are registered and processed by the software. Because the laser measurement system corresponds to laser class 1, the scanner can be used in urban environments without any restriction. A hardware-assisted pixel-by-pixel synchronization makes it possible to process signals form external devices. As a result, the position and orientation of the scan data can be determined.

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The new QuellTech Q5 Laser Scanner Series combines the advantages of small form factors with both high resolution and scan rate. The sensor disposes of different set-up possibilities with respect to the analysis algorithm. Measurement results are delivered via Ethernet, calibrated in the X / Z plane. Special adjustable algorithms can be selected, extremely useful particularly also for optically most demanding surfaces. Time-consuming calibration tasks for the user are no more required, as the calibration routine runs on board. High Scan Rate with up to 14,000 Profiles per Second Due to an appropriate limitation of the image range (AOI) in X and Z direction, the scan rate could considerably be increased. High resolution and detection frequency with up to 14.000 profiles and 28 Mio. points per second •X measuring range from 10 to 1022 mm •Z measuring range (height) from 5 to 878 mm •Laser wave length blue 405/450nm, red 650nm

Plastic Mold Part (AC Controller) Inspection At this point the manufacturer is looking for scratches and chips and dimension specifications manually. In this respect manual inspection is not a repeatable or trustworthy method to guarantee steady quality of goods. It will be demanding for a human worker to detect this for a long period. QuellTech Solution Plastic Mold Parts are easily measurable materials for QuellTech scanners. Using the QuellTech Q4-120 Laser Line Scanner it is possible to obtain very precise reflection free 3D point clouds. A Software making necessary detections in 3D point clouds can effortlessly check dimensions and find scratches or any other defect which allows the manufacturer to automatically parse outparts that do not pass the tolerance levels.

The Z+F PROFILER® 9012 M has a vertical 360° field-of-view and is the fastest profile imaging 2D laser measurement system in its class. With its scan rate of more than 1 million points per second and a maximum scanning speed of 200 profiles/sec. short distances between the profiles can be achieved even at high speeds of the carrier vehicle. Because of the high point density, even small objects are registered and processed by the software. Because the laser measurement system corresponds to laser class 1, the scanner can be used in urban environments without any restriction.A hardware-assisted pixel-by-pixel synchronization makes it possible to process signals form external devices. As a result, the position and orientation of the scan data can be determined.

The Z+F PROFILER® 9012 A has a vertical 360° field-of-view and is the fastest profile imaging 2D laser measurement system in its class. With its scan rate of more than 1 million points per second and a maximum scanning speed of 200 profiles/sec. short distances between the profiles can be achieved even at high speeds of the carrier vehicle. Because of the high point density, even small objects are registered and processed by the software. Because the laser measurement system corresponds to laser class 1, the scanner can be used in urban environments without any restriction. A hardware-assisted pixel-by-pixel synchronization makes it possible to process signals form external devices. As a result, the position and orientation of the scan data can be determined.

The Z+F PROFILER® 9020 and 9020-2 is a highly efficient 2D laser scanner for mobile mapping applications. The rotation speed of the Z+F PROFILER® 9020 is 267 Hz or 16,020 rpm max.. It measures up to 182 m and has a very high data quality. For data capturing in close range, it is equipped with special optics. Compared to previous models, it has an internal reference plate, a very low power consumption, very fast startup time and over 50% reduced weight and size. A new, very powerful laser technology and further developed algorithms ensures highly accurate measurement results on rails, roads, street signs and other traffic control systems such as traffic lights. Technical highlights: 267 profiles/sec. P9020: 1.094 million points/sec. P9020-2: 2.188 million points/sec. 0.2 mm accuracy 182 m range 360° field of view The Z+F PROFILER® 9020 and 9020-2 can be flexibly integrated into different MMS

The Z+F PROFILER® 9020C is the world's first mobile 2D laser scanner with integrated cameras. Generate colored point clouds without external cameras The P9020C has four integrated cameras, each with 5 MPx, which cover the entire 360° scanning area as of a distance of 40 cm. The recordings have high color fidelity and a high dynamic range. Significant differences in light conditions are compensated in such a way that the processing of the images afterwards takes short time or is completely eliminated. Shaded or overexposed areas can hardly be seen in the colored 3D representations. Less cabling and connection effort - only one USB 3 cable required The P9020C's built-in cameras allow for quick installation. Only a USB 3 cable is required for the transmission and control of the system components. Fewer cables also mean less susceptibility to errors and, conversely, more security when collecting data.

Based on the high quality laser scanner Z+F IMAGER®, Zoller + Fröhlich GmbH and DMT GmbH & Co. KG have developed an explosion proof 3D laser scanner. The Z+F IMAGER® 5006EX pioneers surveying in underground mining and industries where explosive atmospheres occur. The Z+F IMAGER® 5006EX is the world´s first ATEX approved 3D laser scanner for use in mining and industrial applications under explosive conditions.The Z+F IMAGER® 5006EX is class I and class II approved according to ATEX directive 94 / 9 / EG. The ATEX directive 94 /9 / EG "Equipment and protective systems intended for use in potentially explosive atmospheres" is a European standard. The ATEX approval for this equipment is widely accepted outside the European community as well.

The terrestrial 3D laser scanner Z+F IMAGER® 5016A combines compact and lightweight design with state-of-the-art 3D laser scanning surveyor technology - allowing the user to reach new levels. It's equipped with an integrated HDR camera, internal lighting and positioning system. All components of the terrestrial 3D laser scanner have been further developed and adjusted to the new design, resulting in even better scanning results and a more efficient workflow. With feature A, which stands for Advanced, the 5016 receives twice as high scan rate of up to 2.187 million pixels/second and more options for leveling the scanner. If the dynamic compensator is deactivated or the tilt is outside the defined range, the tilt is detected by the IMU of the Z+F IMAGER® 5016A.

Particular Challenge: For the assessment of rotating parts, numerous parameters have to be taken into consideration: Concentricity, radial run-out and axial run-out (i.e. wobble); furthermore thickness, diameter, planarity and the absence of surface defects had to be examined. The solution developed by QuellTech consists in a configuration of three Q6 Laser Laser Scanners.Each of the lateral surfaces is assigned to its own scanner. In order to enable the thickness precisely to be determined, both laser lines are mutually oriented in opposite direction. The third scanner inspects the outer circumference of the wheel, this way measuring diameter and radial run-out. All of these scanners are subject to encoder signals supplied by the rotary axis and synchronously triggered, so possible defects on the wheel can precisely be localized. The measurement takes place at a resolution of ca. 30 µm, and a cloud comprising several millions of points are obtained.

Laser Scanner Solution: This task is a typical application of the high-resolution QuellTech 2D/3D Q5-880 Blue Laser Scanners. Two of these units are placed at the left and at the right of the measuring objects, at a defined inclination angle. Blue laser light in this case is a prerequisite, as the cast parts are red-hot, hence emitting in the red spectral range. Additionally, the client was in need of a software solution for the project, so a 3D point cloud processing application was implemented, performing inline and evaluating width, height and angle results. QuellTech customer is able to inspect continuously the product quality, simultaneously avoiding scrap. He uses the same system for more than 10 different types of castings. Errors caused by manual inspection are considerably reduced, and safety for personnel is enhanced.

Wear is a damage consisting in gradual removal or deformation of material on solid surfaces, caused by mechanical (e.g. erosion) or chemical (e.g. corrosion) influences. In machine elements, wear may give rise to material failure or loss of functionality. For the application in question, our client has to measure wear on the surface of rollers in cement mills. Up from a certain depth, reactions are required, generated by a warning system to be developed In this project, we used several robust QuellTech Q6 scanners to cover fully the roller width. Due to the high rotational speed of the rollers, we preferred our fastest scanners for this application. We furthermore developed a software solution and implemented a warning system, based on the critical depth of the wears on the surface. By means of this system, the customer can determine the correct time for exchange of the rollers.

The QS View software package is intended for dimensional control in 2D or 3D QS-View 2D / 3D software for all measuring tasks 3D representation of an irregular body for determination of volume and weight. With the 2D / 3D software a wide variety of parameters can be processed and displayed, e.g. length, width, angle height, gap, presence, volume (resp. weight), seam geometry (height, width), gap dimensions. Due to the modular structure of the software, customized specialties can be added any time. Each module delivers the results to an individual output module. The universal SPC interface allows simple connection to S7 controllers via Ethernet. 2D / 3D software developer kits are available for integrators with corresponding knowhow.

Laser sensor Q4 – with a small form factor – Q4 for standard 2D / 3D measuring applications: Low sensitivity against influences of secondary light Measuring ranges from 5 mm to 1000 mm Laser wave lengths starting from UV via blue, red and green through to IR Average measuring speed up to 350 Hz frame The Q4 laser sensor has been designed to meet the requirements of standard measuring applications. Thanks to its increased flexibility, it can be used for several tasks also in complex projects. The dimensions of the ultra-compact version amount to only 86x40x25, at a weight of 140 g. Protective panes and cooling modules are available as an option. The Q4 laser sensor model enables users to obtain stable measuring results also on difficult surfaces, whether mirroring or transparent. The QS-View Standard Software comprises a comprehensive selection of application modules, to be invoked at once without previous programming steps. Customized adaptations are possible any time.

The QuellTech laser sensor family Q4 or Q5 used for these tasks is generally mounted on an arm of a rotational axis, to scan along the complete 360° angle of the internal surface in a sequence of strips. The Q4 sensors can also be used to control the weld seam tracking itself for rapid setup and ease of use. Even during a project, the range and scope of the Q Series sensor demonstrates the advantages of a modular system to quickly adapt to project needs, where the smallest system has provided fast analysis of pipes as small as 105mm. The low power, with standard communication protocols, enable battery powered systems to transmit wireless data to other systems for review and cloud back up.

Many materials cannot be measured tactilely, therefore non-contact thickness measurements become necessary. Especially e.g. with glowing materials, or wet processes, a continuous tactile measurement is nearly impossible. Furthermore, web speeds in plant engineering and production have increased, requiring a corresponding fast sampling rate of the measuring systems. In addition, high measuring widths are often required. Why is contact free measurement technology so perfect for this application? Can be used in any web width, Scalable measurement thicknesses from a few millimetres to several meters, Thickness and coating thickness can be measured for different materials, Vibrations of the web materials, can be compensated, Turnkey solution for mechanical engineering, Non-contact and non-destructive measurement method, Large distances to the measured object are possible, Measurement of free forms,

QuellTech Solution: The performance of a manual inspection cannot be compared with the speed and the repeatability of a contactless QuellTech Q4-1000 laser scanner. It is even possible to install several instruments in parallel to cover the whole width of the ingot with one single scan. These instruments are mounted on an existing portal and correctly synchronized, so that interaction of the laser light originating from the other scanners is excluded. The QuellTech laser line scanners produce 3D point cloud of the raw ingot surface, and the software calculates the coordinates of the highest and deepest levels of this surface. After scalping the flat surface can be scanned again for any defects. Benefits for the Client: Thanks to QuellTech’s wide area laser line scanners, the cycle times for ingot scalping could considerably be reduced, and excessive material scrap due to a too low scalping level is prevented.

Four QuellTech Q6 3D- laser scanners are installed, mutually displaced by an angle of 90°. In this configuration, they are able to monitor the complete surface of the cable running through. It is important that the test does not lower the production speed, therefore very high sampling rates are required, supported by convenient data processing. The measured position of a defect is recorded in cable direction.

In the field of safety sensors, we offer safety light screens in various lengths and types with up to 14 mm resolution and muting function. We offer laser scanners with large protective fields for special tasks. Two-hand buttons and controls round off the range. For direct connection to the machine, we also offer versatile controls in addition to simple safety relays.

Within the frame of quality assurance, the forged pieces of this client have to be checked in an inline inspection with respect to several parameters: Inner and outer diameters, as well as the absence of surface defects have to be verified. Video of inline forgings inspection for dimensional accuracy and surface defects with QuellTech LaserScaner. Particular Challenges Manual inspection carried out until now turned out to be not reliable enough, particularly after an increase in production. The final rejection rate has seriously affected the productivity of the entire manufacturing process. A solution for a contactless inline inspection was needed. The QuellTech Solution A testing station including an index table has been designed. This configuration acts as a support for two QuellTech Q4-60 laser scanners, used for inspection of the parameters mentioned above.

Rotationally symmetrical driving gears in a line producing for automotive industry are mutually connected by electron beam welding. The camera inspection carried out until was not able to assess the quality of the weld seams at the required precision. Non-contact laser measurement system Particular Challenge: As the welding seams show a high reflectivity and are located at a position hard to access, inspection is difficult, all the more so as they dispose of a width of only 500µm. Therefore it is quite a challenge for the laser measurement system. The QuellTech solution: A QuellTech Laser Scanner Q4-5 with extremely small shape factor and high resolution proved to be perfectly suited for this application. In order to suppress reflections from elements in the surroundings, a particular algorithm has been integrated. Furthermore, this laser measurement system features a particularly adapted laser wavelength and an ultrafine laser line.

A client in automotive industry intends to improve the inline glue bead supervision performed when automatically applying glue beads inside body parts. The system to be purchased should be able to monitor position, height and width of the glue bead any time. Until now, the client makes use of a 3D laser system with very complex beam guidance, in order to compensate problems arising from narrow space available. This present configuration however involves difficulties in adjustment, often giving rise to trouble and interruptions. Therefore the client is looking for a safe and less complicate solution. The chellenge in glue bead supervision: While the glue bead is being applied, very complex geometrical patterns are followed; the nozzle for the glue meanwhile does not rotate. Therefore this nozzle must be supervised in the total angle of 360°. This glue bead supervision can only be met by a laser scanner featuring an extremely low form factor.

Particular Challenges: The seal surfaces in this case are made of very glossy metal, with the drawback of emitted reflections. This effect during an optical measurement must be eliminated. Furthermore, it is absolutely necessary to guide the laser scanner on a linear path over the surface, since fluctuations of distance may falsify the measurement result. QuellTech Solution: The Quelltech model Q5 disposes of an adequate resolution in X and Z direction and proves to be able to verify the planarity tolerances and to measure the size of defects. Meanwhile a precise rotary axle, used as guiding element, moves the scanner over the surface to be evaluated. Interfering artefacts caused by the glossy finish are suppressed by particular algorithms integrated within the software. As an encoder value is permanently supplied by the rotary axle, the position of each scanner profile within the point cloud can accurately be determined.

Defects to be examined in this application are very small, their size is often lower than 0.5 mm – hard to discover by human eye. Rework in the course of the production of the final product however, proves to be complicated and expensive. Large rolls with a diameter of 2 m and a length of 10 m are very difficult to remove and to reinstall. In order to avoid corresponding inconveniencies, it is essential to support the manufacturing process of the rolls themselves by a reliable quality control in the form of an automated final inspection.As the Quelltech Q6 laser scanner features an extremely precise resolution of 4096 Pixels/Profile at a high scan rate, this model proved to be able to meet the requirements and was mounted onto the positioning stage of the grinding machine. Furthermore, an industrial measurement computer was added, used for the analysis software of the point cloud. On the basis of this configuration, the entire roll surface could be recorded on a helical path.