3D Multi-Sensor Scanner Precisely Positioned

Linear axis enables exact measurement of large parts in a matter of seconds

The 3D multi-sensor system ZScan from senswork scans high-resolution, seamless and three-dimensional components and compares the result with the CAD model in order to determine the manufacturing quality - in a process time not previously achieved. Jenaer Antriebstechnik (JAT) supplied the precision axis for this.

With ZScan, senswork, an expert in industrial image processing, offers an ultra-fast 3D multi-sensor scanner that measures large components with a volume of 1.5 by 0.7 by 0.5 meters inline in a few seconds. Thanks to several triangulation sensors with free spatial arrangement, the system enables almost shadow-free detection of the test objects.

The new technology consists of a high-precision linear axis and a multi-sensor head with up to eight profile scanners. Due to the special inclination of the sensors and the flipping of the sensors towards each other, areas that are difficult to access, such as undercuts or shadow areas, can also be detected.

Strong partner

In the search for a suitable partner for drive technology, Rainer Obergrußberger, managing director of senswork, came across Jenaer Antriebstechnik (JAT) through internet research. The company, based in Jena, develops high-precision drive systems for lasers, lenses and sensors that are moved in a highly dynamic manner in the sub-micrometer range. senswork and JAT have been working together since July 2020.

“The big challenge was the high precision requirements for the running precision of the axis,” explains Marco Schwarz, sales engineer at JAT. In order to master this demanding task, JAT designed a linear axis that is guided overhead.

The axis, which is built on a granite stone, is operated by an ironless linear motor with a two-meter stroke. In connection with a high-resolution functional safety measuring system, it offers optimal and safe synchronization. This structure enables a running accuracy of ± 5 µm over the entire stroke, as well as a tilt error of a few µrad. "We asked numerous providers, and at JAT we had the best feeling that they could meet our high requirements there," says Rainer Obergrußberger.

The 3D data is processed in VisionCommander. The powerful software from senswork offers flexible 3D functions, for example the comparison with CAD, various alignment methods (RPS, BestFit, 3-2-1), volume determination, position recognition or the detection of deformations or defects.

New type of 3D inline measurement

With ZScan, complex, tactile measurements become much easier. The new type of 3D inline measurement enables a multitude of new applications that were previously only possible in the measuring room.

In the production of busbars, ZScan determines the form deviation of automatically manufactured busbars. The advantage: Thanks to quick, production-accompanying measurements and direct comparison against the CAD model, correction parameters for feed and bending angle can be determined fully automatically for each segment.

In the production of aluminum die-cast parts for the automotive industry, ZScan records RPS-aligned measuring points on the component in order to correct it using this measurement data. Expensive fee-check lessons will no longer be necessary in the future. In addition, the components no longer have to be sprayed for the measurement - as was previously the case. ZScan has been in use at one of the world's largest manufacturers of aluminum die-cast parts since the beginning of August - a great benefit for the customer thanks to the high-precision drive technology.

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