Micro-Epsilon Introduces 4K Laser Scanners Powered by Green Laser Technology
Micro-Epsilon announced the expansion of its scanControl LLT product portfolio, launching a new generation of ultra compact LLT8x00 4K laser line profile sensor. This series adopts green laser technology, which is superior to traditional red and blue laser schemes in terms of measurement performance, setting a new performance standard for high-precision 3D measurement.
The new product combines an ultra-high resolution 4K sensor matrix, built-in 3D data processing capabilities in the sensor head, and an industrial Ethernet communication interface, which not only improves measurement accuracy and stability, but also further optimizes system integration efficiency, meeting the demand for high-speed and high-precision 3D measurement in applications such as industrial automation and quality inspection.
4K resolution and micron-level precision
The new 4K sensor matrix enhances inline measurement with up to 4,224 points per profile. Line point resolution is down to 6µm, and a z-axis linearity of <0.8µm allows structures to be captured with clarity, while maintaining high-speed performance across varying surfaces and lighting conditions.
The scanControl LLT8500 provides the highest measuring rate in its class with a 10kHz profile frequency and 25 million points per second.
Green Laser Technology
The green laser operates close to the peak quantum efficiency of the receiver and delivers:
Stable signals with minimal noise
Superior performance on challenging surfaces such as shiny metals, PCBs, and organic/translucent materials
Shorter exposure times for faster measurement cycles
Increased repeatability and process reliability
The result is a consistently accurate measurement in applications where conventional laser technologies struggle, expanding the range of viable inspection tasks.
Integrated 3D intelligence
Full 3D data processing is performed inside the sensor head, eliminating the need for external processing units of PCs during production and reducing system complexity, costs, cabling, and integration time.
Processed measurement values can also be transmitted to PLCs via Industrial Ethernet, or users can output calibrated 3D point clouds for further analysis, making the LLT8x00 series suitable for machine building and automation tasks.
Flexible data output
The LLT8x00 series can operate as a standalone Smart 3D sensor with onboard evaluation, or as a high-speed 3D data source for external processing.
For onboard Smart 3D evaluation, Micro-Epsilon’s 3DInspect software tool enables users to configure measurement programs, analyse point clouds, and extract features within the sensor environment. Calibrated point cloud data can also be exported for processing using the customer’s image processing software or existing vision processing tools
Precise real-time 3D scans
3D laser scanners from Micro-Epsilon capture surfaces, geometries and height differences with high precision, even during rapid movements. They can outperform conventional image processing technologies and ensure maximum process reliability in challenging industrial applications.
Typical applications include:
Pin inspection on connectors: In the production of cable harnesses and connectors, precise pin positioning and completeness are critical. The scanControl sensors scan the connector surface and generate an accurate height or profile image of the pin row. The number, position, and flatness of the pins are checked quickly, consistently, and with high resolution. Inspection is integrated into the production process without interrupting the flow of materials.
Presence detection and flatness inspection on PCBs: To ensure reliable assembly and subsequent processing, it is essential to verify component presence and flatness, as height deviations can cause soldering defects, contact issues, or mechanical stress. Their high z-resolution enables scanControl sensors to detect even the smallest height differences. This allows precise measurement of presence, height profiles, and coplanarity. The measuring structures are stored on the scanner and transmitted to the PLC.
Precise 3D geometric inspection of cylindrical battery cells: In cylindrical cell production, precise positioning and alignment of cells are vital to quality and safety. Cells installed at an angle, or positioned too low or too high, carry the risk of short circuits, poor electrical contact, or mechanical damage. The scanControl LLT8x00 sensors capture cell geometry at high resolution and verify both correct alignment and the exact installation height of each cell, ensuring all cell tops fall within production tolerances.
Inspection of stent mesh structures: Even the smallest defects can compromise the implant’s function and safety. The scanControl 8×00 sensors enable high-resolution, inline inspection within the manufacturing process. They detect the mesh structure, defects, geometrical deviations, deformations, and surface irregularities. Defective stents are detected early and removed before they enter downstream processes.
Inline inspection of adhesive beads: In modern manufacturing processes, adhesive application is a critical quality factor. The scanControl 8×00 laser scanners are utilised for precise monitoring of the adhesive application. The compact scanners are mounted in a fixed position or on the robot and measure the height, width, and position of the bead, enabling immediate quality control and enhancing process reliability.
Inline inspection of adhesive beads: In modern manufacturing processes, adhesive application is a critical quality factor. The scanControl 8×00 laser scanners are utilised for precise monitoring of the adhesive application. The compact scanners are mounted in a fixed position or on the robot and measure the height, width, and position of the bead, enabling immediate quality control and enhancing process reliability.
Cooling for high ambient temperatures
All scanControl 8×00 models can be equipped with additional heat sinks, including passive heat sinks, active heat sinks with fans, or connections to the customer’s cooling solutions. This enables the sensors to be used reliably even in challenging production environments, such as steel manufacturing or welding.
Automatic weld seam inspection
The scanControl scanners are used in the welding process to monitor the weld seam in real time. The sensor can detect the seam geometry and generate a height or cross-sectional profile. The results are fed back to the process control system immediately, enabling corrections during the process or early detection of defective welds.
source: engineerlive
