Enhancing Diamond Saw Blade Inspection with Advanced Laser Scanning and Vision Technology

Dual 3D camera system detects dimensional deviations on saw blades during the running process

Background

The cutting quality and lifespan of diamond saw blades are critical factors in their performance across various industrial applications. Ensuring these blades meet stringent dimensional criteria is essential for maintaining high standards of precision and efficiency. Traditional inspection methods often fall short in capturing the comprehensive data needed for optimal quality control.

Challenge

A manufacturer sought to improve the accuracy and efficiency of the inspection process of diamond saw blades. The primary goal was to capture detailed dimensional data on saw blades, including gear geometries, blade width, cutting width, angularity, and diameter, during the manufacturing run. The existing methods were inadequate in providing the necessary precision and real-time data required for immediate quality assessment and adjustments.

Solution

To address these challenges, the manufacturer partnered with senswork, together with Plattner, to develop an advanced inspection system. The solution involved equipping a measuring station with a double-head laser scanner system. This system was designed to measure and record all critical dimensional data of the saw blades in real-time as they moved through the production line.

Key components of the solution included:

• Double-Head Laser Scanner System: The dual laser heads provided comprehensive coverage of the blade's geometry, ensuring accurate measurements of complex features.
• VisionCommander® Image Processing Software: This powerful software handled the real-time evaluation of the scanned data, analyzing multiple parameters such as gear geometries, blade width, cutting width, angularity, and diameter.

Implementation

The implementation process involved several stages:

1. System Design and Calibration: The double-head laser scanner system was designed to accommodate the specific dimensions and geometries of the diamond saw blades. Initial calibration ensured that the system could capture high-precision data consistently.

2. Integration with Production Line: The measuring station was seamlessly integrated into the existing production line, allowing for continuous monitoring of saw blades during manufacturing.

3. Software Configuration: VisionCommander® was configured to process the data from the laser scanners, providing real-time feedback on the blade dimensions. This enabled immediate detection of any deviations from the specified tolerances.

4. Testing and Optimization: The system underwent rigorous testing to ensure reliability and accuracy. Any issues identified during the testing phase were addressed, and the system was optimized for peak performance.

Benefits

• Can be adjusted to different saw blade diameters
• Resolution of the 3D profile scanner: 5 µm
• Measuring sequence: 20 seconds

Results

The integration of the double-head laser scanner system and VisionCommander® software yielded significant improvements in the inspection process for the diamond saw blade manufacturer:

• Enhanced Accuracy: The laser scanners provided highly precise measurements of all critical dimensions, reducing the margin of error.
• Real-Time Data: Immediate evaluation of the scanned data allowed for swift adjustments during the manufacturing process, ensuring consistent quality.
• Increased Efficiency: Automated data capture and analysis streamlined the inspection process, reducing the time and labor required for manual inspections.
• Improved Quality Control: The comprehensive data collected enabled more informed decisions, enhancing overall product quality and lifespan.