3D Inspection for Quality Control

senswork develops high-resolution optical 3D inspection systems for quality assurance and inspection automation in industry. As a manufacturer-independent supplier, we select the best suited 3D hardware for your application at all times.

Take Advantage of 3D for Your Production 

3D automated inspection systems are texture-independent, and in many cases can add reliability and robustness to your inspection process.

Examples:

• Determination of 3D shape deviations by comparison against CAD data
• Detection of surface damage such as dents, cracks or chipping - independent of texture or material
• Evaluation of adhesive joints for completeness, width and height
• Detection of incorrectly assembled subcomponents or missing parts
• Detection of material breakage, foreign material
• 3D OCR for robust reading of embossed, cast or milled markings on parts
• and many more...

3D Technologies - Our Expertise

As a specialist in 3D laser triangulation systems, fringe light projection, time-of-flight sensors and depth-from-focus systems, we always select the most suitable scanning hardware for your application. We carefully consider the advantages and disadvantages of a 3D technology during the design and planning phase, taking into account all environmental influences and accuracy requirements.

Streak Light Projection

Fringe light projection 3D scanners provide an accurate and fast way to capture three-dimensional geometry data. Their high resolution enables detailed  representation of complex surfaces, making them particularly effective in the manufacturing and engineering industries. The versatility of these scanners spans multiple applications, including quality control, reverse engineering and prototyping.

Still, they are sensitive to ambient light changes, which can affect accuracy. Glossy surfaces present a challenge, as light reflections can interfere with structure detection.

During the scanning process, it is imperative that the part is stationary, as the 3D calculation is based on many individual images, assuming that the part has not moved.

3D Laser Scanning

3D laser scanners use the principle of triangulation. A laser line is projected onto the surface of the part and a laterally angled camera captures the path of the line in the camera image. Appropriate calibration procedures are used to create a metrically correct section through the part. By moving the scanner or the part, a complete 3D image of the surface is captured.

senswork has been committed to the principle of 3D laser scanning for many years, and with systems such as ZScan® has perfected the use of multiple scanners within one system with free spatial arrangement through sophisticated calibration procedures.

3D laser scanning is suitable for inspecting and measuring large parts, continuous material such as continuous cast profiles or strip material, and is generally more robust on different surfaces than streak light projection systems.

3D Point Cloud Processing Using Deep Learning

The use of AI and Deep Learning tools to process 3D point clouds, while still relatively new, offers significant advantages for automated 3D optical inspection of components.

Until now, the conversion of 3D point clouds into so-called range images has been a common method for processing 3D data using Deep Learning. One disadvantage, however, is that the 3D data set must be reduced to a specific perspective. With Neuralyze®, it is now possible for the first time to process complete 3D point clouds in the function modules "classification", "object recognition" and "semantic segmentation".

A real-world application example for senswork Neuralyze® 3D can be found in the inspection of laser-welded hairpins of electric motor stators in the automotive industry.

Want a free feasability study to see which technology suits your needs? Email [email protected] and describe your quality problem for a custom solution.