How is the Data Handled?

Many 3D machine vision engineers are specialized in identifying and measuring defects from a completed 3D height map. However, they don’t want to deal with the complexity of triggering and combining data accurately from multiple sensors into one 3D point cloud/height map.

A 3D smart sensor takes care of this by extracting the data from multiple sensors and automatically aligning, merging, and resampling it into an aggregate 3D height map. The scan results are combined within a single world coordinate system, which allows the engineer to extract high-precision measurements on the combined 3D profile data.

As a result, engineers no longer have to carry out Software Development Kit (SDK) programming to combine the raw data. Everything is done natively onboard the sensor using built-in multi-sensor networking capabilities.

Application Examples

A. Z-rotation angle correction is critical for data correlation of small electronic parts

• Electronics, machining tools, and medical supplies inspection requires correlating results to CMM measurements
• Correlation is done by comparing height data at specific XY locations
• Slight Z-rotation misalignment results in skewed data, which affects correlation results
• 6 DoF alignment allows engineers to correct for this skew

B. High accuracy scanning of large automotive components

• Six Gocator® line profilers are networked to cover the full part
• The sensors automatically combine profile data and generate a single 3D height map for measurement and inspection
• Gocator delivers the necessary coverage, resolution, and speed for 100% inline inspection

Conclusion

6 degrees of freedom in sensor alignment allows the user to choose the axes on which offsets and rotations are calculated. This functionality provides important options to improve scan results and measurement accuracy in specific application scenarios.

Here is a quick recap of the benefits for today’s busy vision engineer:

• Choose the axes on which offsets and rotations are calculated

• Align multi-sensor systems with built-in 6 DoF software

• Stagger multi-sensor systems using Y offset (e.g., for small FOV sensors)

• Automatically correct for inaccurate mounting or purposeful rotation using X rotation (e.g., in specular mounting) and Z rotation (e.g., angling the sensor to reduce edge noise)

Gocator 3D smart sensors are used for inline inspection in a wide variety of industrial applications. You can get more of the story in our inline inspection brochure.