Door Positioning in Car Body Construction with 2D/3D Profile Sensors
In order to be able to precisely apply rubber seals for car doors, the position of the doors must be measured exactly in car body construction. For this purpose, three 2D/3D profile sensors per cell are installed on robots, which measure the doors supplied via overhead conveyor with micrometer precision. Thanks to the precise position determination, the doors can be precisely gripped and the seals positioned. Another profile sensor then checks the position of the seal.

Measurement of Coarse Wire in Steel Rolling Mills Using 2D/3D Profile Sensors
During the production of coarse wire in steelworks, billets up to 1,200°C must be rolled and then checked for geometric quality characteristics such as diameter, ovality, rolling or surface defects. There are specially developed measuring systems for this purpose that enable a 360° image of the wire in micrometer-precise resolution with four 2D/3D profile sensors each. In the profile sensors, which work ideally on red-hot steel with blue light, point clouds are initially created, which are then combined and visualized to form an overall image using 3D software.

Surface Inspection of a PHEV Battery Cell Using 2D/3D Profile Sensors in Automotive Construction
In electric car assembly lines, PHEV battery surfaces must be checked for foreign bodies such as screws with micrometer accuracy. These foreign bodies can lead to serious damage and thus to a high risk of fire. For optical surface inspection, four 2D/3D profile sensors are guided over the battery via a linear unit to measure the area. The height profiles are then combined into a 3D point cloud, which is analyzed using software. Thanks to laser class 2M, precise results are achieved and reflections are suppressed.

Volume Calculation of Potato Rösti on Conveyor Belt with 2D/3D Profile Sensor
In the production of potato rösti, the exact ratio of salt to raw potato mass must be determined. Before adding salt, the volume of the rösti mass must be calculated. A 2D/3D profile sensor in stainless steel housing (IP69K degree of protection) mounted above the conveyor belt first generates a 2D height profile via laser triangulation. Its evaluation is carried out using uniVision software, which, in combination with the belt speed, calculates the volume. This ultimately allows the calculation of the amount of salt required.

Contour Measurement of Car Seats with 2D/3D Profile Sensor
When manufacturing car seats for passenger cars, it is important to ensure that the position of the side cushions and spine cushions is identical on each seat and conforms to the specifications. For this purpose, the seats mounted on a carrier system are automatically measured on a test station from top to bottom by a 2D/3D profile sensor. Symmetries are evaluated, contours measured, the filling rate recorded or seams and the position of the seat detected. Every product can be checked and corrected before final assembly.

Weld Inspection in Cold-Rolling Plants with 2D/3D Profile Sensors
On cold rolling lines, steel strips are welded alternately by a welding machine in a fully automatic process in order to maintain processing around the clock. The quality and thickness of the weld seam must be continuously checked in order to avoid damage to subsequent processing units. For this purpose, a 2D/3D profile sensor is installed above and below the steel strip on a traversing unit, which traverses the weld seam and measures it with micrometer precision. In this way, faulty seams can be identified immediately and corrected if tolerance values are exceeded.

Automatic Welding Robot Programming with 2D/3D Profile Sensor
Automated welding of metal workpieces with batch size 1 requires micrometer-accurate information on the three-dimensional position and orientation of the objects. To avoid time-consuming programming, a 2D/3D profile sensor with a large measuring range is installed above the welding robot on a linear axis. Using laser triangulation, the sensor measures the workpiece and forwards the recorded data in the form of a point cloud to the analysis module. From this, the dimensions are calculated, which enables the welding program to be determined from a database.

Height and Angle Measurement of Ice Cream Cups via 2D/3D Profile Sensors
After ice cream is filled cups, it has to be checked that the applied cardboard lids are present and in the correct position. A 2D/3D profile sensor with IP69K degree of protection detects the entire width of the production line via laser triangulation – and thus all tracks of the conveyor technology simultaneously. Both the presence as well as the cup height and the angle of the placed lids are precisely measured – to the nearest millimeter. Web-based visualization directly on the system reports the status of the results.

Rough Edge Detection in Longitudinal Transport in Sawmills via 2D/3D Profile Sensors
Wooden boards from the edge area of the tree trunk often have sharp-edged areas, so-called rough edges, before being cut in woodworking centers. In order to keep the waste as low as possible, it is necessary to accurately detect this rough edge – before it is cut off by the saw. For this purpose, the boards are measured in longitudinal transport via a 2D/3D profile sensor from below and from above via laser triangulation. The optimal saw position is then set using the measurement results. The sensors also detect the thickness, length and width of the board.

Weld Seam Tracking in Robot Cells via 2D/3D Profile Sensors
In fully automatic robot welding cells, it is necessary to determine the exact position of joints before the welding process. For this purpose, a 2D/3D profile sensor is mounted directly in front of the welding torch on the robot. The special design created especially for the application is particularly compact in order to minimize the occurrence of interference contours on the welding torch. The sensor now detects the joint via laser triangulation. The guide point is determined via uniVision software and sent to the control system. A web correction is now carried out using this information and the weld seam is placed.

Track Bed Monitoring of Rail Networks via 2D/3D Profile Sensors
Before maintenance work, such as grinding or milling rails in track beds, can be carried out, both the position of the rails and obstacles such as stones or switches must be detected during operation. This protects the tools of the machining trains from damage. Several 2D/3D profile sensors mounted next to each other measure the profile of the track bed in a line. The height profiles are combined and analyzed using software. Cooling and heating elements make it suitable for use even in extreme climates with temperatures between –30 and +50 °C.

Profile and Diameter Testing of Used Tires with 2D/3D Profile Sensors
Used car tires on fleet vehicles are often in good condition so that they can continue to be used. To precisely determine the tread depth, diameter and radius of these tires, special test systems are used with 2D/3D profile sensors installed on the sides and overhead. During rotation, the tires and their tread are measured with micrometer accuracy by laser triangulation. If the tires still have a sufficient tread depth, they can continue to be used. If the tread has worn down too much, they are recycled. Large quantities of tires can be checked thanks to the high measuring rate.