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3D sensor for the inspection of shiny surfaces
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In many areas, ever-increasing requirements are being placed on the quality and appearance of surfaces. Particularly with shiny and reflecting surfaces, faultless, high quality production is expected. The parts are often subjected to manual inspection, which can lead to defects being missed due to tiredness of the inspectors.
reflectCONTROL is designed specifically to meet the high quality requirements that ensure high quality for shiny surfaces. The system based on deflectometry projects a striped pattern onto the measurement object. Defects on the surface cause deviations from the striped pattern which are recorded by cameras and evaluated by software.
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Deflectometry sensor for 3D measurements of shiny surfaces
The reflectCONTROL RC130 is intended for shape measurements of shiny objects. This sensor displays a striped pattern which is mirrored by the surface of the measuring object into the sensor cameras. The sensor provides a 3D image of the surface which allows for the topology of the components (e.g. flatness, deflection, curvature) to be determined. The RCS130 model is specially optimized for measurement and inspection tasks, e.g., in production lines. Moreover, the sensor has a GigE Vision interface that offers GenICam compliant data.
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Surface inspection of shiny components
The reflectCONTROL RCS110-245 with integrated controller is designed for stationary measurements or integration into machines. This compact sensor detects anomalies on shiny surfaces which are processed and displayed as reflectivity and curvature image by software. GigE Vision enables the transfer of surface images to a wide range of image processing software packages for further analyzes.
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Convenient user interface
The 3D-View software offers a convenient user interface for reflectCONTROL sensors. This user-friendly software enables quick commissioning and evaluation of the sensor. It offers among other things set up and optimization of parameters and ensures the correct positioning of the measuring object and sensor. Creation and management of parameter sets for different measurement tasks are also possible. The software can also be used to start data acquisition. The images obtained are visualized and can be saved for further processing. The 3D-View software is particularly helpful for system integrators as it provides important information:
They can access all GenICam parameters, which considerably simplifies the integration of the software. For inline applications, the display of the measurement duration allows conclusions to be drawn about the cycle time.
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Software integration via Micro-Epsilon’s 3D-SDK
reflectCONTROL is equipped with an easy-to-integrate SDK (Software Development Kit). The SDK is based on the GigE Vision and GenICam industry standards including the following function blocks:
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 Network configuration and sensor connection
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Comprehensive sensor control
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Control of image transfer
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Management of user-defined parameter sets
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C++ example programs and documentation
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Precise 3D sensor for the inspection of large surfaces
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The surfaceCONTROL 2500 series is designed for the inspection of diffuse surfaces such as metallic surfaces (uncoated, electroplated, EPD), plastic surfaces and ceramics. The sensor uses the fringe projection principle and scans the surface. Therefore a sequence of structured light pattern is projected on the measuring object. The calibrated cameras use this pattern for searching corresponding points, from which the 3D data is calculated. Sensors with different measurement areas and resolutions are available.
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Application examples:
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Injection molded components such as car fender, fuel doors or covers on the doors and sliding roofs
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Composite parts (SMC) such as tailgates or spoilers
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Inspection of the dashboard
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Homogeneity of a furniture front
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Technical data:
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Large measuring field up to 575 x 435 x 300 mm³
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Resolution from 0.25 mm (lateral)
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Interfaces: Gigabit Ethernet (image data output), USB 2.0 (sensor control)
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surfaceCONTROL DefMap3D software for individual surface analysis
surfaceCONTROL DefMap3D is the most comprehensive software solution for the detection and analysis of surface defects. It includes all components and processes required for set up, configuration and evaluation of inspection tasks.
The wide range of features equally supports the analysis of individual parts, the measurement of small series as well as the robot-supported inspection of several measuring fields. Sensor control, calculation of the 3D point cloud and defect detection can be automated using macro commands.
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As part of the surface analysis, the software provides several methods of detecting and objectively evaluating shape errors within the surface data. The targeted use of different filter types can reduce the effects of surface structures (e.g. graining). A report containing the inspection results is generated. surfaceCONTROL DefMap3D is available in different versions whose scope of performance is oriented towards different measurement tasks. |
Mobile inspection system – surfaceCONTROL Mobile
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TIM thermal imaging cameras are designed for non-contact measurement of surface temperatures from -20 °C to 2450 °C. They enable efficient monitoring and control of temperature-critical processes both with low temperatures (e.g. in cooling chains) and with very high temperatures (e.g. in glass and metal processing). Their high thermal sensitivity makes these infrared cameras ideally suitable for precise and dynamic tasks. Different performance classes enable a suitable model to be selected for every application. The camera is connected via a USB interface, which also supplies the power. |
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Inspection of large components – surfaceCONTROL Robotic
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For the inspection of the surface of components in different places, surfaceCONTROL Mobile is the ideal solution. The portable system, which consists of a laptop and a sensor, can be safely transported in a carry case. It can be mounted on a tripod. The standard measuring area is about 410 mm x 300 mm. |
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Inspection of small test pieces – surfaceCONTROL Compact
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When mounting the sensor to a robot, the system can be quickly and easily adapted to different measurement tasks. Six degrees of freedom of the robot are available. According to the requirements, a robot with a certain dimension can be chosen. If the component is positioned on a rotary table as seventh axis, it can be turned towards the sensor reducing the required outreach of the robot. Due to surfaceCONTROL Robotic large components can undergo a complete inspection with only one sensor. |
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The new generation of high precision inline 3D measurements
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The high precision surfaceCONTROL 3D 3500 is a 3D fringe light sensor which is ideally suited to automated inline geometry, shape and surface inspections on diffuse reflecting surfaces. The surfaceCONTROL 3D 3500 stands out due to its compact design and high measurement accuracy combined with high data processing speed. Two models cover different measuring fields.
In addition to the fast data output via Gigabit Ethernet, the sensor offers an additional digital I/O interface. The 2D/3D Gateway II supports EtherNet/IP, PROFINET and EtherCAT connections. Powerful software tools enable precise 3D measurements and surface inspections. GigE Vision compatibility also allows easy integration into third-party image processing software. The comprehensive SDK for customer software integration rounds off the software package.
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Application examples:
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3D geometry inspection and shape detection
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Inspection of electronic components
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Defect detection
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3D text recognition and detection of finest structures
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Special features:
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Complete 3D images in 0.2 s
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Micrometer-accurate snapshots with large measuring fields
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Highest precision up to < 0.4 μm
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Up to 2.2 million 3D points / second
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Digital interfaces (integrated): GigE Vision / GenICam
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Digital interfaces (via 2D/3D Gateway): PROFINET / EtherCAT / EtherNet/IP
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Digital in-/outputs: 4 digital I/Os for which parameters can be set (for external trigger, sensor control, output of sensor states)
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Evaluations from 3DInspect can be transmitted to a PLC via these fieldbuses. Sensor settings can be loaded by a controller via 3DInspect using parameter set mapping. |
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3D Inspect software for 3D measurement tasks and inspection
The 3DInspect software is a powerful tool for sensor parameter set up and industrial measurement tasks. This software transmits the measurement data from the sensor via Ethernet and provides the data in three-dimensional form. This 3D data is further processed, evaluated and assessed with 3DInspect measuring programs on the PC and, if necessary, logged and transmitted via Ethernet to a control unit. If required, these 3D data can be saved with the software. Furthermore, the set up and configuration of the sensor is possible via the software.
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3D-View software for 3D visualization
The 3D-View software offers a convenient user interface for surfaceCONTROL sensors. This user-friendly software enables quick commissioning and evaluation of the sensor. It offers set up and optimization of parameters and ensures the correct positioning of the measuring object and sensor. The software can also be used to start data acquisition. It visualizes the 3D data obtained and exports it in different file formats (ASCII, CSV, STL, PLY) for further processing.
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The 3D-View software is particularly helpful for system integrators as it provides important information. They can access all GenICam parameters, which considerably simplifies the integration of the software. For inline applications, the display of the measurement duration allows conclusions to be drawn about the cycle time. |
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