Measuring system for biaxial measurement of profile, thickness and position

The profileGAUGE is a high-precision sensor system for biaxial profile, thickness and position measurement of ultra-fine wires and round stock. It is specially developed for inline measurement tasks in industrial processes and impresses with its high accuracy, simple integration and maximum process reliability. Two optical optoCONTROL ODC2700 micrometers are pre-assembled in an X arrangement and measure the target simultaneously on two axes. As a result, exact diameter, contour and position values are reliably recorded – even at high process speeds.

Customer-side calculation and further processing of the statistical values from both axes can be carried out individually via the control system or a higher-level evaluation system. This means that the profileGAUGE can be optimally integrated into existing quality and control concepts. Connectivity is provided conveniently via Industrial Ethernet interfaces. Standard protocols such as TCP, UDP and FTP are also supported. This ensures easy integration into existing bus systems and reliable communication with control systems.

Characteristics

・Precise biaxial measurement of diameter, profile and position

・Plug & play solution: pre-assembled, aligned and wired

・Synchronous and asynchronous operation possible

・Parallel output via sensorTOOL

・Angle measurement and active inclination correction of the measuring object

・Versatile fieldbus connection for maximum flexibility: Ethernet / EtherCAT / RS422 / EtherNet/IP / PROFINET

・Ideal for inline quality control at high process speeds

Precise diameter measurement down to 30 µm

The profileGAUGE systems detect diameters as small as 30 µm – making the system ideal for the precise measurement of ultra-fine wires and very small round profiles, even with sensitive materials and high process speeds.

The active inclination correction is a decisive advantage here. The intelligent evaluation recognizes inclinations of the measured object. The internal controllers automatically adjust the measured value to the respective inclination – and therefore to the actual alignment – of the target. This effectively prevents measured value deviations due to inclination – especially in dynamic production processes. The inclination correction works over the full measuring rate of 5 kHz and is available in the measuring programs for outer diameter, wire and contour measurement.

High measurement speed for all targets

The precise measurement results can be output at a measuring rate of up to 5 kHz. The integrated, high-performance ODC2700 micrometers are also suitable for a wide range of measurement tasks, are virtually independent of surface properties and are highly insensitive to interference such as ambient light.

Intelligent contamination detection for maximum operational safety

The profileGAUGE systems feature integrated real-time data analysis that detects and compensates for soiling of the optics at an early stage. This prevents distorted measurement results and helps avoid micrometer downtime or malfunctions – for continuous production safety and reliable measurement values.

The system reports the contamination level on request, for example at scheduled maintenance intervals. The data is conveniently provided via the integrated interfaces and enables predictive maintenance. The intelligent evaluation detects even the smallest soiling, both on the glass and in the beam path. Even the tiniest dust particles or oil spray that are invisible to the human eye are reliably detected.

Three levels of soiling can be output:

・Clean: No soiling detected in the entire measuring range

・Restricted: Detected soiling is located in the ignored area

・Soiled: Soiling detected in the relevant area

Variants for extended protection

The profileGAUGE can be ordered with additional protective accessories for use in demanding industrial environments. This ensures that precision is permanently maintained even under harsh conditions. The protective glass helps prevent damage to the micrometers’ optics in harsh environmental conditions. The air purge collar is used to keep the LED beam path clean. It blows away dust, particles and other contaminants before they can settle on the optical components or influence the measurement result.