Precision sensor manufacturer Micro-Epsilon has launched a series of high-precision 3D snapshot measurement sensors for the automatic inline measurement of object geometry, shape, and surface quality. The sensors stand out due to their extremely high resolution and repeatability, as well as their large measuring range.

The new surfaceCONTROL 3D 3500 is a 3D snapshot sensor with a compact design and extremely high resolution on the Z axis (starting from 1.0 µm). The sensor's repeatability is up to 0.4µm, setting a new benchmark for high-precision 3D measurement technology. Due to its high performance, the sensor can reliably detect even the smallest deviations in flatness, such as height differences of tiny components (e.g., IC pins) on printed circuit boards. A high data processing speed of up to 220 thousand 3D points per second enables the sensor to increase productivity in corresponding applications.

Fringe projection

The surfaceCONTROL 3D 3500 sensor operates based on the optical triangulation principle using fringe projection, allowing direct 3D measurement of components. A matrix projector projects a series of patterns onto the surface of the target object. Two cameras on either side of the projector view and record the light from the patterns. The three-dimensional surface of the target object is then generated from the recorded image sequence.

The surfaceCONTROL 3D 3500 is available in two models, each offering different measuring areas and depths of field. Both models are fully integrated industrial sensors and achieve an IP67 protection rating through passive cooling (active cooling is available for higher operating temperatures).

Wide range of applications

The sensor is suitable for a wide range of applications, including: 3D measurement of high-precision mechanical parts; measurement of rivet width, tilt angle, and position; surface defect detection; flatness inspection of circuit boards; flatness inspection of unassembled PCB substrates; detection and evaluation of cracks on clutch discs; integrity checks of electronic components on assembled PCB; 3D text recognition of embossed characters where 2D image processing fails due to lack of contrast; checking the height and thickness of adhesive beads on smartphone housings; and determining shape deviation defects on injection-molded parts.

Simple software integration

surfaceCONTROL 3D supports the latest GigE Vision and GenICam standards, enabling easy integration into third-party image processing software. A comprehensive software development kit (SDK) is also provided, allowing customers to develop their own analysis software.

The scope of supply also includes Micro-Epsilon's 3D View software, which provides a user-friendly interface for surfaceCONTROL sensors. This software allows for quick commissioning, sensor evaluation, parameter setting and optimization, and ensures correct placement of the measurement object and sensor. It can also be used to initiate data acquisition. It visualizes 3D data and exports it in various file formats (ASCII, CSV, STL, PLY) for further processing. This software is particularly useful for system integrators, as it allows them to access all GenICam parameters and simplifies software integration. For online applications, the display of measurement duration provides insights into process cycle times.

Real 3D data without data loss

Micro-Epsilon's 3DInspect software is a powerful tool for sensor parameterization and industrial measurement tasks using the SC3510 sensor model. The software included in the scope of supply transmits measurement data from the sensor via Ethernet and provides this data in three-dimensional form. This 3D data is further processed, evaluated, and assessed using the 3DInspect measurement program on the PC, and recorded and transmitted to the control unit via Ethernet if necessary. In addition to fast data output via Gigabit Ethernet, the sensor also provides additional digital I/O interfaces. Optional 2D/3D gateway modules provide EtherNet/IP, PROFINET, and EtherCAT connections for measurement value transmission.

DefMap3D for individual surface analysis

surfaceCONTROL DefMap3D is a comprehensive software solution for detecting and analyzing surface defects (not included in the standard scope of supply). It includes all components and processes required for setting up, configuring, and evaluating inspection tasks. Features range from the analysis of individual parts and measurement of small batches to robot-supported inspection of multiple measurement areas. Sensor control, 3D point cloud calculation, and defect detection can be automated using macro commands.

As part of surface analysis, the software offers several methods for detecting and objectively evaluating shape errors in surface data. Targeted use of different types of filters can reduce the influence of surface structures (e.g., granularity). Reports containing inspection results are generated. The software is available in different versions, with performance ranges tailored to different measurement tasks (e.g., Digital Shape, Digital Stone, Digital Light Hole).

Micro-Epsilon Business Development Manager Glenn Wedgbrow stated: "Previously, the method for capturing 3D images involved building a series of 2D profiles, meaning that individual profiles had to be captured before processing and constructing the 3D point cloud. The surfaceCONTROL 3D sensor captures all information in a single shot, significantly accelerating acquisition and processing times. From automotive production to electronics and mechanical engineering, the surfaceCONTROL 3D 3500 sensor will find applications in almost every industrial sector. In automated 'go/no-go' production lines, the performance of the SurfaceCONTROL 3D 3500 sensor will surpass any other 3D measurement sensor currently on the market, particularly in terms of Z axis resolution, repeatability, large measuring range, and comprehensive software development and integration tools."