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Ein 2D-/3D-Profilsensor vermisst ein Aluminiumprofil.

2D/3D Profile Sensors – Precision and Accuracy in 2D and 3D

With the 2D/3D profile sensors, almost any measurement application can be carried out precisely – from standard applications such as 360-degree gap-free object measurement, precise position control of robots and micrometer-accurate inspection to demanding welding applications and use in intensive washdown areas. The wide wenglor portfolio offers model variants with different measuring ranges, laser classes and intelligent functions.

Model Variants at a Glance

MLSL Series

Precise resolution in a compact housing

MLWL Series

High-end performance with the highest profile quality

MLZL Series

Robust format for guiding welding robots

Stainless Steel Series

Stainless steel housing for highest durability in hygienically critical areas

MLSLxxxS50

Plug-and-play variant for immediate initial startup on brake presses

Gap-Free Measuring Ranges

Maximized application freedom: The portfolio of 2D/3D profile sensors fully covers a wide range of measuring ranges.
Highest precision: Thanks to the different measuring ranges, the sensor with the optimal resolution and maximum data quality can be selected for each task.
Efficient integration: There is no oversizing or undersizing in the sensor selection, minimizing space requirements, costs and integration effort.
Faster project planning: The structured portfolio makes it easy for users to select the right sensor solution.

Fünf Profilsensoren sind nebeneinander angeordnet und zeigen die Vielfalt der Profilsensoren.

What Does Oversizing and Undersizing Mean for Measuring Ranges?

Oversizing

Oversizing is selecting a sensor with a measuring range that is too large for the application. The object is fully captured, but the resolution drops because the available pixels are spread out over an area that is too large. This leads to inaccurate measurement results, especially for small or finely structured objects. The sensor used is not optimal for this application, as it is usually too expensive and too large and therefore more difficult to integrate.

Undersizing

With undersizing, it’s exactly the opposite. The selected sensor has too small a measuring range so that the target object cannot be fully detected. As a result, data is missing or several sensors must be combined. This leads to additional costs, complexity and sources of error.

Visual Field Graphics of the MLSL and MLWL Series

MLSL1

MLSL2

MLWL1

MLWL2

Applications with Small and Large Measuring Ranges

Applications with Small Measuring Ranges

Small measuring ranges enable high resolution and accuracy of detail. This is ideal for inspecting delicate components where even the smallest deviations need to be detected immediately.

Examples:

Quality assurance for electronic components
Measurement of fine plastic parts
Checking sealing lips or seals

Applications with Large Measuring Ranges

Large measuring ranges fully capture extensive and complex geometries. Large objects can be inspected quickly and reliably without the need to combine multiple sensors.

Examples:

Measurement of vehicle bodies
Inspection of large metal profiles or pipes
3D form measurement of very large components

Immediately Ready for Use Thanks to Factory Linearization

All 2D/3D profile sensors from wenglor are linearised at the factory and deliver immediately usable measurement results in real millimeters. The measured profile data is converted by the sensor precisely and reliably into the actual measuring range. On-site calibration is no longer necessary. This ensures consistent accuracy and the highest measurement quality over the entire service life.

Flexible Laser Classes for Every Application

The 2D/3D profile sensors are available in laser classes 2, 3R and 3B and can be optimally adapted to various measurement tasks. Users benefit from constant measurement quality and maximum process reliability in both standard applications and highly dynamic processes.

Laser class 2 is ideal for many applications and enables safe operation without additional protective measures. It impresses with its easy integration.
Laser class 3R offers higher laser power for more demanding measurement tasks. Shorter exposure times, higher measuring rates and reliable results can also be achieved on dark or difficult to detect surfaces.
Laser class 3B is the optimal choice for demanding, highly dynamic applications. Thanks to the high laser power, extremely fast measurements and stable profile acquisition are possible even at very high speeds, difficult surfaces or large measurement distances.

2D/3D Profile Sensors with Safe Laser Shutdown

Die 2D-/3D-Profilsensoren der S40-Serie besitzen einen dritten Anschluss, der der sicherne Laserabschaltung dient.

The 2D/3D profile sensors of the MLSLxxxS40 series enable fast and robust profile detection thanks to their high laser power in classes 3R and 3B. The sensors have an additional third connection for safe laser shutoff and thus offer maximum safety and efficiency in the application. The certified plug allows the S40 product group laser to be switched on and off safely in accordance with EN ISO 13849–1:2016 without the need to switch off the sensor or include a mechanical laser shutdown. The operating personnel are protected from laser radiation by the switch-off function, so that there is no longer any need for a laser protection officer to be present. This increases operational safety and productivity while minimizing downtime and risk.

The Right Wavelength for Every Surface

wenglor’s 2D/3D profile sensors are available in various laser colors. This allows the sensor to be optimally adapted to the relevant material and its reflection behavior. Precise results are achieved even on challenging surfaces.

Red Laser

Sensors with red laser can be used universally for matt to medium-gloss surfaces.

Blue Laser

Due to the lower penetration depth compared to red laser, the blue laser provides stable measurement results on dark, rubbery or highly absorbent materials. This makes it ideal for applications in the food industry, as the detection is limited to the surface and deeper layers of material are not affected.

UV Laser

Sensors with UV lasers are used to detect transparent, UV-reflecting materials such as films, glasses or adhesives.

Combinable Wavelengths

2D/3D profile sensors with different laser colors can be used in parallel and without interference in a system. This allows simultaneous measurements from different viewing angles or at multiple stations without signal interference or quality loss.

The combination of multiple sensors is particularly advantageous in complex or space-critical applications, as there is no need to compromise on cycle time, data stability or system flexibility. If the sensors are triggered in a targeted way, even sensors with identical laser colors can be used in parallel.

Versatile Application Options Thanks to Complementary Accessories

The 2D/3D profile sensors are complemented by a wide range of accessories, including protective screens, cooling units, welding housings and a large selection of cables. The right accessories reliably protect the sensors against external influences and ensure durability in demanding ambient conditions.

Heat Sinks

Support thermal management by protecting sensors from overheating and ensuring reliable operation.

To the products

Protective Screens

Protect the sensor from contamination, scratches or damage at the viewing windows of the laser output and optics.

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Protective Housing for Welding Applications

Specially designed for harsh environments to protect sensors from sparks, heat and dust in welding applications.

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Sensor Mounting

Die Befestigungsschelle für MLWL und MLBS ermöglicht eine einfache und schnelle Montage von Sensoren.

Offers flexible mounting options and guarantees the right holder for every application.

To the products

Suitable Cables

Available in different lengths and designs, including drag chain and robotic versions, for maximum flexibility and reliability.

To the products

Calibration Certificate

The calibration certificate confirms the metrological accuracy of the sensor, makes it easier to prove quality to customers and meets the requirements of industry standards.

2D-/3D-Profilsensoren sind in verschiedenen Bauformen und Laserklassen verfügbar, wodurch sie in einer Vielzahl von Anwendungen eingesetzt werden können.

Flexibility from Profiling to Evaluation

wenglor’s 2D/3D profile sensors can be precisely adapted to the requirements of the application and offer maximum flexibility – both at the hardware and software level.

Profile Capture

The 2D/3D profile sensors capture detailed 2D height profiles of the object. The sensors feature high-quality optics, different laser classes and colors, and linearized measuring ranges in several sizes.

Mode of Operation

Depending on the application, two operating modes can be selected for the 2D/3D profile sensors.

In “Smart Profile Sensor” mode, the profile is captured and evaluated on the sensor.

In “Profile Generator” mode, the sensor only captures the profiles while the evaluation takes place on an external machine vision controller.

Evaluation

Whether directly in the sensor or on an external PC – wenglor’s uniVision software or an external software solution from third-party providers can be used for evaluation of the profile data.

uniVision offers an intuitive user interface, modular functions and numerous pre-built tools for typical measurement and inspection tasks.

Alternatively, the sensor can also be easily integrated into existing software and system environments thanks to standardized interfaces.

Evaluation with the uniVision Software

wenglor’s uniVision image processing software is used to configure and evaluate machine vision products for a wide range of tasks in industrial image processing. Thanks to the modular design, evaluations can be individually adapted to different applications via the graphical user interface. In addition to simple parameterization, uniVision offers the option of programming your own solutions. For example, HALCON scripts from the HDevelop software from MVTec can be integrated directly.

Das Icon stellt symbolhaft die parametrierbare Standardsoftware dar.

Easy Configuration without Programming Effort

uniVision’s graphical user interface enables quick analysis of profile data. It offers easy acccess for users with little knowledge, while experts can implement complex applications efficiently.

Versatile Toolbox for Complex Evaluations

A wide selection of freely combinable modules is available in the uniVision 3 software. These range from classic measurement methods to demanding profile applications and AI-powered models.

Central Control with the Machine Vision Controller

The combination of modular software and powerful hardware offers maximum flexibility for different inspection tasks. For example, up to 16 2D/3D profile sensors can be used in parallel.

360° Profile Analysis with the VisionApp 360

With the VisionApp 360, several 2D/3D profile sensors can be easily merged into an overall profile. This enables precise measurements of diameter, area or circumference. The results are seamlessly integrated into the uniVision software.

uniVision for Profile Analysis

Within wenglor’s uniVision software, there are specific profile modules that are optimized for pre-processing and for further analysis and processing of 2D height profiles. These modules can be used for standard applications such as measuring, monitoring and tracking 2D height profiles, as well as for complex applications. The numerous communication interfaces enable seamless further processing of the recorded data.

The uniVision software can be used either directly on the sensor or on the machine vision controller.

Smart Profile Sensor

In the “Smart Profile Sensor” mode of operation, the uniVision software is installed directly on the sensor. The captured 2D height profiles are thus processed and evaluated on the sensor. An additional machine vision controller is not required. The results, such as dimensions, position or pass/fail decisions, are output directly via the sensor’s interfaces.

2D/3D Profile Sensor with Machine Vision Controller (MVC)

If the 2D/3D profile sensor is used in the “Profile Generator” mode of operation, the recorded 2D height profiles are forwarded to an external machine vision controller for processing and evaluation. The uniVision software is installed on this. For applications with high measuring rates, the machine vision controller offers the possibility of connecting up to 16 sensors.

Smart Profile Sensor vs. Profile Generator with Machine Vision Controller

Criteria	Smart sensor	Profile generator with MVC
uniVision	On the sensor	Externally on the MVC
Computing power	Possibly limited by sensor hardware	Much more powerful thanks to external MVC
Project complexity	Suitable for simple to medium complex evaluations	Ideal for complex, computing-intensive projects with multiple tests
Number of project instances	1 project instance per sensor	Multiple project instances possible in parallel on one MVC
Flexibility of evaluation	Standardized evaluation functions directly in the sensor	Any combination of modules and sensor sources on one platform
Number of sensors	1 sensor = 1 analysis module	Several sensors with different measuring ranges, laser classes and laser colors can be combined. A combination of 2D/3D profile sensors and 2D cameras is also possible, with everything controlled centrally via the MVC.
Communication interfaces	TCP/IP, UDP, FTP, Device IO Unit	TCP/IP, UDP, FTP, Device IO Unit, Device Industrial Ethernet*, Device Robot Weld Seam Tracking

* Industrial Ethernet is a generic term for all Ethernet standards for real-time data transmission between the control and sensor. Industrial Ethernet protocols include, for example, EtherCAT, Ethernet/IP or PROFINET.

uniVision
On the sensor	Externally on the MVC
Computing power
Possibly limited by sensor hardware	Much more powerful thanks to external MVC
Project complexity
Suitable for simple to medium complex evaluations	Ideal for complex, computing-intensive projects with multiple tests
Number of project instances
1 project instance per sensor	Multiple project instances possible in parallel on one MVC
Flexibility of evaluation
Standardized evaluation functions directly in the sensor	Any combination of modules and sensor sources on one platform
Number of sensors
1 sensor = 1 analysis module	Several sensors with different measuring ranges, laser classes and laser colors can be combined. A combination of 2D/3D profile sensors and 2D cameras is also possible, with everything controlled centrally via the MVC.
Communication interfaces
TCP/IP, UDP, FTP, Device IO Unit	TCP/IP, UDP, FTP, Device IO Unit, Device Industrial Ethernet*, Device Robot Weld Seam Tracking

Combine and Analyze Height Profiles with the VisionApp 360

In the VisionApp 360, several individual profiles of different sensors can be merged into a common, complete height profile. This combined height profile can then be further processed and evaluated in the uniVision image processing software. This enables precise position, height or volume detection even for multi-sided or large objects.

Advantages at a Glance

Up to 16 sensors can be seamlessly merged into one coordinate system.

Flexible arrangement and synchronization of the sensors, regardless of position, laser class or measuring range.

Easy calibration via an application-related calibration object without the need for programming knowledge.

The combined height profile is available directly in uniVision for further analysis.

If several sensors are used next to each other with the VisionApp 360, it is recommended to use different laser colors, for example a blue and a red laser. This prevents interference between the sensors and ensures precise, interference-free measurement.

From 2D Height Profile to 3D Point Cloud

A precise 3D point cloud is generated by moving the sensor or object to be measured along the sensor’s y-axis and continuously capturing 2D cross-sectional profiles. This point cloud represents the 3D surface structure of the object. Thanks to the encoder inputs integrated in the sensor, each recorded profile receives the exact position data. This ensures that the profiles are correctly arranged even with varying belt speeds.

Die Animation zeigt die Vermessung eines Objekts sowie die erstellte 3D-Punktewolke.

Viewing and Saving Measurement Data with the VisionApp Demo 3D

The wenglor VisionApp Demo 3D software enables the display and storage of individual profiles or entire point clouds.

Evaluation with Third-Party Software

2D/3D profile sensors can be combined with third-party software in the “Profile Generator” mode of operation. The sensor records precise height profiles and then passes them on to an external system. The evaluation is then carried out in customer-specific or third-party software. Extensive interfaces are available for transferring the blank profiles.

Operating Modes in Comparison

Operating mode/criterion	Smart profile sensor	Profile generator with MVC	Profile generator for third-party software
Profile capture and evaluation	Profile capture and evaluation directly on the sensor in the uniVision software	Profile capture by the sensor, evaluation takes place externally on the machine vision controller in the uniVision software	Profile frame by the sensor, evaluation takes place externally via the customer-specific or third-party software
Output	Measurement results directly from the sensor	Measurement results from the machine vision controller	Raw profile data for individual evaluation by external software
Interfaces	Standard Ethernet (TCP, UDP, FTP), digital I/Os	Standard Ethernet + Real-Time Ethernet (Profinet, EtherNet/IP, EtherCAT), digital I/Os	Standard Ethernet (GigE Vision, TCP/UDP), SDK for flexible integration
Performance	Suitable for simple and non-time critical applications (single sensor solution)	Higher performance for fast and complex applications (single sensor or multisensor solution)	Performance dependent on external evaluation software and hardware

Profile capture and evaluation
Profile capture and evaluation directly on the sensor in the uniVision software	Profile capture by the sensor, evaluation takes place externally on the machine vision controller in the uniVision software	Profile frame by the sensor, evaluation takes place externally via the customer-specific or third-party software
Output
Measurement results directly from the sensor	Measurement results from the machine vision controller	Raw profile data for individual evaluation by external software
Interfaces
Standard Ethernet (TCP, UDP, FTP), digital I/Os	Standard Ethernet + Real-Time Ethernet (Profinet, EtherNet/IP, EtherCAT), digital I/Os	Standard Ethernet (GigE Vision, TCP/UDP), SDK for flexible integration
Performance
Suitable for simple and non-time critical applications (single sensor solution)	Higher performance for fast and complex applications (single sensor or multisensor solution)	Performance dependent on external evaluation software and hardware

Features for Reliable Profile Capture

Surface conditions in real applications are rarely constant or ideal. Different materials, varying reflection properties, contamination or aging processes such as oxidation can significantly affect the measurement signal. Particularly glossy, matt, dark or textured surfaces influence the measurement signal and lead to incorrect profile data without targeted countermeasures. wenglor’s 2D/3D profile sensors therefore have various functions for optimizing profile quality. This enables reliable measurement results even under changing conditions.

Signal Selection

The “Signal Selection” function enables more precise measurements and reduces interference by eliminating unwanted reflections. First, the sensor searches for peaks in each camera column. These are signal peaks created by the reflection of the laser line. If more than one peak is detected by the sensor, the user can define which peak is used to generate the 2D height profile. Several peaks can occur when unwanted reflections are created by looking at the object. Different signal types can be selected to identify the correct signals.

Object

Camera Image

Intensity

With this setting, the most intense peak is used for the profile output.

Profile

Width

The widest peak is selected here, i.e. the laser light has penetrated deeper into the object surface.

Profile

Peak 1

The first detected peak in the column is used.

Profile

Peak 2

The second detected peak in the column is used.

Profile

Automatic Exposure Time

With this feature, the 2D/3D profile sensors automatically adjust their exposure time to varying surface brightness and deliver pin-sharp profiles, while ensuring consistently precise inspection and capturing the smallest details reliably.

Certain setting options can be defined individually depending on the application:

The function can be flexibly switched on and off.
The intensity range can be defined individually to avoid overexposure.
The X-area of the image section can be specifically defined for exposure control.

The intensity of the detected profiles varies depending on the brightness of the object surface. These differences arise due to the changing light reflections, which directly influence the signal strength registered by the sensor. While bright or highly reflective areas generate higher intensity values, darker or less reflective areas result in lower values.

Difference Between Fixed and Automatic Exposure Time

With the fixed exposure time, all profiles are captured with the same intensity, regardless of the surface brightness. The automatic exposure time reliably captures both bright and dark areas.

Ohne Autobelichtung weist das Objekt dunkle und helle Stellen auf, die zu einer ungenauen Erfassung führen können.

Intensity of Height Profiles with Fixed Exposure Time

Height Profile Intensity with Automatic Exposure Time

High Dynamic Range Imaging

With the “High Dynamic Range Imaging” (HDR) function, objects with very different surface reflections are reliably captured. In many applications, large differences in brightness occur, for example, when glossy or reflective and matt areas are in the same measurement field. Accurately capturing details in particularly bright or dark areas is challenging. While traditional measurement methods usually reach their limits here, HDR achieves very accurate measurement quality and increased data security.

Maximum Detail Depth

Even with highly contrasting objects, all contours and structures are captured precisely.

Reliable Evaluation

There is no loss of information due to over- or under-exposure.

Flexibility

Also suitable in demanding applications such as inspection of shiny metals, painted surfaces or highly reflective materials.

Product Overview

Product category	Points per profile	Measuring rate	Special feature
MLSL series	1,280	200 Hz @Full Frame 4 kHz maximum speed	Standard sensor
MLWL series	1,280	175 Hz @Full Frame 6 kHz maximum speed	Standard sensor
MLZL series	1,280	200 Hz @Full Frame 4 kHz maximum speed	Sensors for precise and reliable weld seam tracking
Stainless steel series	1,280	200 Hz @Full Frame 4 kHz maximum speed	Sensors in stainless steel housing with protection class IP69K, ideal for the food industry and all applications requiring maximum protection classes
Stainless steel series	2,048	175 Hz @Full Frame 6 kHz maximum speed
MLSL123S50	1,280	The measuring rate is reduced by internal data processing.	Smart sensor for exact angle measurements in press brakes

MLSL series
MLSL series	1,280	200 Hz @Full Frame 4 kHz maximum speed	Standard sensor
MLWL series
MLWL series	1,280	175 Hz @Full Frame 6 kHz maximum speed	Standard sensor
MLZL series
MLZL series	1,280	200 Hz @Full Frame 4 kHz maximum speed	Sensors for precise and reliable weld seam tracking
Stainless steel series
Stainless steel series				Stainless steel series	1,280	200 Hz @Full Frame 4 kHz maximum speed	Sensors in stainless steel housing with protection class IP69K, ideal for the food industry and all applications requiring maximum protection classes
2,048
175 Hz @Full Frame 6 kHz maximum speed
MLSL123S50
MLSL123S50	1,280	The measuring rate is reduced by internal data processing.	Smart sensor for exact angle measurements in press brakes

Product Comparison

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