With its compact, calibrated Light section sensors "Poscon" offers Baumer a unique solution portfolio for the efficient measurement of object geometries. The sensors using the light section method close the gap between tactile sensor solutions and complex 3D measurement technology. Thanks to the combination of technical functionality, quick commissioning and easy handling, they offer new and efficient solutions for parts inspection.

Contents

• Advancing digitalization and individualized products
• Sensor concepts in the parts inspection
  • Edge measurement in material control
  • Height measurement even on dark glossy surfaces
  • Measure round objects without a reflector

Advancing digitalization and individualized products

Due to advancing digitalization and the trend towards individualized products, flexible, automated testing procedures are becoming more and more common Parts inspection increasingly important. It's about whether certain production parameters are within specified limits. The inspection can be carried out by removing the parts to be inspected from the production process (at-line/off-line) or continuously in the production process itself (in-line). In contrast to the other two methods, the in-line method enables continuous process control because results can be used immediately.

When selecting the methods, the user is faced with a wealth of instruments such as individually configured sensor solutions, tactile measuring methods, compact ones Image processing systems or 3D profile sensors as well as powerful Industrial cameras with PC based image processing programs. They all deliver high-precision measurement results, but involve different levels of effort and costs.

Sensor concepts in the parts inspection

Each of these methods has its justification. However, cost pressure in production increasingly requires simple, flexible solutions at attractive prices. The new generation of Poscon Light section sensors meet these requirements. The sensors offer complex functions such as edge or height measurement in an easy-to-use, compact sensor. The sensors work without a reflector and can be put into operation quickly thanks to the visible laser line and an optically aligned axis.

After installation, only a few parameters need to be set thanks to the predefined measurement functions – without external software. The measured values ​​are output in mm. The values ​​can be entered directly in the steering be further processed. Thanks to the intelligent evaluation, the sensors can efficiently measure molded parts as well as tools or Robot position precisely and there is a check+sort functionality based on threshold comparisons.

Edge measurement in material control

The Poscon 3D-Sensor is specialized in the measurement of object edges, widths and gaps and is suitable, among other things. for use in Material feeding or final inspection. The measurement is carried out regardless of color, surfaces and elevation. The sensors can be mounted at any angle up to ±30° relative to the standard installation.

One of the versatile possible uses is the efficient determination of Sheet thicknesses in in-line quality control during material feeding. The sensor enables automatic comparison with tolerance threshold values, even at fast transport speeds. Sheets that do not meet specifications are immediately identified and sorted out. Direct double sheet control reduces production downtimes and prevents damage to the sheet metal tools during further processing of the sheets.

Thanks to specific algorithms, the Poscon 3D also measures very precisely dark surfaces made of highly absorbent materials such as rubber – good for e.g. B. the tire industry. In the area of ​​material supply, the sensor e.g. For example, it carries out tolerance tests on black rubber bands with steel mesh without complex programming and enables rapid further processing thanks to direct evaluations.

Height measurement even on dark glossy surfaces

Also the measurement of Object heights is an important key figure in quality control. The "Poscon HM" offers intelligent height measurement of objects with five key figures without exact positioning of the measurement objects - even on very dark or shiny surfaces. In combination with its high measuring accuracy of up to 2 μm, it is suitable for a variety of applications in at-line and in-line control.

An example is the control of black people Rubber seals for side windows in the Automotive industry. The testing is carried out randomly off-line on a special test stand. The seals are mounted in special holders at a measuring station. The shape and curves of the seal can vary, but must not exceed specific limit values.

The challenge for the sensor lies in the Curves and in black, light-absorbing material. Powerful algorithms in the Poscon HM analyze up to 600 pieces of height information per measurement and determine the maximum object height regardless of the object's position. This measurement is only possible with the Poscon HM. The measurement rate is up to 1540 Hz.

For checking metallic, shiny molded parts such as Car doors (Picture above) the Poscon HM is also ideal. The sensors control e.g. B. the correct shape of the car door through measurements at numerous test points. The sensors can also be mounted close to each other without influencing each other. The measured values ​​are output in mm, which allows an immediate OK/not OK check for each test point.

Thanks to the evaluation algorithms integrated into the sensor, the sensors are a cost-effective alternative for a variety of Check+Sort-Applications. In “Delta” mode, the sensor identifies defective products due to a different shape. 

An example of this is the control of the sealing of yogurt cups. A strong bulge in the seal indicates an incorrect fermentation process. Using the Check+Sort function, defective products are sorted out directly in production. Commissioning the sensor is easy without any software or programming knowledge. After selecting the function and mode, all that remains is to parameterize the digital output and then there is the test result.

When checking Ultrasonic welding in the production of Toothpaste tubes The white material and the very weak contrasts in open folds represent a major challenge for many measuring tools - but not for the Poscon HM. Thanks to the color-independent measurement, the height information is analyzed in the sensor and the measurement result is evaluated in the form of a delta value. Open weld seams are reliably detected and defective products are sorted out.

Measure round objects without a reflector

With the Poscon CM As the third sensor in the portfolio, the center point, diameter and external positions of round objects with an external diameter of 30 to 130 mm can be easily measured. The sensor does not require a reflector or external software. Thanks to factory calibration, the measured values ​​are automatically determined in mm.

An important area of ​​application for such a sensor is: Final or acceptance inspection of steel pipes. The sensor controls the diameter of the steel pipes by determining absolute measured values. This enables early readjustment of the tools as soon as the measured values ​​lie outside a set threshold value. The measured values ​​also provide information about tool wear.

Also in the Material feeding the Poscon CM is an important control tool. Instead of a barcode, coded measuring rings are often used for round metal parts to identify the correct material for further processing. By determining external positions and the center point, it is possible to quickly check the object orientation of the round parts directly in production.

All Poscon light section sensors deliver precise measurement results for direct evaluation, without complex data clouds or expensive external evaluation software. The areas of application today are primarily in the automotive, metal and plastic processing industries as well as the packaging and pharmaceutical industries. But of course they are also suitable for all other industries.

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