For example, camera systems deployed for inline quality checks are the solution preferred by automation engineers. Less known, but just as efficient in inspection tasks are smart 2D profile sensors. This technical report presents applications with profile sensors as time and cost-saving solutions.

Whether smart 2D profile sensors are suitable for inspection tasks depends on a single criterion: the object to be inspected must provide a related feature detectable via height profile. If so, and maybe any distance information being of relevance as well, profile sensors like the Baumer OX series are a good, maybe even the better and more economical alternative to camera systems. For example edges, gaps, cable or pipe diameters and positions, or even arbitrary shapes that can be utilized for quality inspection. Typical application examples are checks of presence,completeness, shape or dimensional accuracy. 

Profile sensors to speed up processes

The use of a smart 2D profile sensor for quality inspections provides two main benefits:

1. High object speed, accelerated cycle times: Cycle times play a decisive role in productivity. This is where the OX sensors help speed up processes significantly since thanks to cycle times up to 800 Hz they identify OK/NOK parts much faster than camera systems would do. 
2. Invariance to contrast: Situations where good contrast ratios are difficult to achieve are challenging for camera-based solutions. Where inspection by height information is feasible, the smart profile sensors from the OX series perform at significantly enhanced process stability.

In short: like today's engineers deploy smart vision sensors for inspection of quality criteria in a camera image, the new sensor class of the OX series can be used to perform inspection tasks based on shapes, edges, gaps, circles, distance, etc. The OX series is even ideal if it is not feasible or difficult to extract the required information out of a gray-scale image.

Immediately ready for use

The smart profile sensors from Baumer characterize by their ease of use thanks to integrated web interface. It allows for free configuration of up to seven measuring tools with graphical support. Another benefit is live visualization of measurement tasks via web interface. This allows for cross-checking, editing and optimizing the settings straight in the sensor. The compact housing and Power-over-Ethernet ensure easy integration. Combined with their precision down to 5 micrometers, the sensors of the OX series open up new potentials for process-safe and precise solutions.

Compared to alternative solutions, this provides numerous benefits:

• The smart 2D profile sensors of the OX series are quick and easy to integrate.
• The function toolbox enables entire profile data processing straight in the sensor.
• Integrating a profile sensor eliminates the need for lighting, which is a critical aspect in camera-based approaches. The OX laser line ensures robust performance without external lighting. 
• There is no need for data post processing by the control system.

Conclusion

The smart 2D profile sensors of the OX series can be deployed wherever OK/NOK inspections are based on the evaluation of shapes or features using height information. This new sensor class provides cost-efficient solutions for inspections on shape and dimensional accuracy as well as for presence and dimension checks: 

• Dimensional accuracy of tongue-and-groove joints at floor planks 
• Securely sealed food containers 
• Simplified presence checks in lab automation