Sensor Technology How Modern Laser Sensors Optimize Production Processes

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Modern production environments demand increasingly compact and powerful sensors. These must cope with changing environmental conditions, be versatile, and robust. Another critical factor is the connectivity of various devices at the field level. Micro-Epsilon combines all these features in its portfolio of laser triangulation sensors, which now includes a new high-performance member with the Opto NCDT 5500.

Laser triangulation sensors impress with their extremely high accuracy and precision. The sensors from Micro-Epsilon are very compact and integrate the controller within the sensor, eliminating long cable paths, improving measurement quality, and simplifying installation.

Due to the extremely small light spot they project onto the object—even over long distances—the sensors measure even the smallest measuring objects with extreme precision and accuracy. This makes the sensors ideal for numerous applications, including factory automation, electronics manufacturing, and robotics.

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With the Opto NCDT 5500, the company expands its portfolio of laser sensors with a new performance class, setting new standards in performance. Even on surfaces with weak or varying reflection, the laser sensors deliver extremely precise measurement results with a high linearity of 0.015 percent of the measuring range. Due to the excellent reproducibility of < 0.0015 percent, measurements with submicrometer precision can be performed.

Precise Measurement of the Smallest Components

Laser triangulation sensors are used for measurements with very high accuracy and resolution. They operate based on the principle of geometric triangulation: a laser diode generates a beam that hits the measurement object, while the optics direct the reflected light onto a receiving element. The distance to the object is determined by the position of the reflected light, with the intensity of the reflected beam depending on the surface of the measurement object.

Depending on the sensor design, the optical measurement principle allows measurement distances from a few millimeters to over a meter (From less than 1/4 inch to over 3 feet). Due to the small light spot at a large measuring distance, precise measurement of even the smallest parts is possible. Thanks to the large distance between the sensor and the object, measurements on very hot materials are also feasible.

Ideal for OEM And Series Applications

Due to the increased measuring rate of up to 75 kHz and the high accuracy, the laser sensors of the OptoNCDT-5500 series are ideal for displacement, distance, and position measurements in OEM and series applications. They are used, for example, in automation technology, mechanical engineering, or battery production. Other possible applications include 3D printing or measuring tracks in railway technology.

To cover the widest possible range of applications, the sensors are available in measuring ranges of 0.375, 1, 4, and 8 inches, as well as in an extended measuring range. The sensors also handle challenging environmental conditions with dust, vibrations, or high temperatures thanks to their robust design in accordance with IP67 protection rating and high temperature stability.

Convenient Installation And Easy Operation

The sensors achieve maximum flexibility through connection via highly flexible cables. To enable integration into confined spaces, the housing is designed with compact dimensions of 3.13 in × 1.25 in × 2.38 in. The patented mounting concept also allows for easy and quick installation and replacement: repeatable sensor alignment is facilitated by centering sleeves, enabling automatic sensor alignment—allowing for both simple sensor replacement and reproducible mounting of multiple sensors.

Even during operation, the sensors should be as comfortable as possible to operate and maintain. For this reason, the sensor is conveniently and easily operated via a web interface. Common presets assist with commissioning and adjustment, and users can also easily perform calibration during operation.

Innovative Interfaces for the Connected Factory

To optimally integrate the sensors of the Opto-NCDT series into factory environments—keyword: Smart Factory—they are equipped with RS422, Analog, and Ethernet interfaces. Using the optionally available IF2035 interface module, the sensors can be integrated into the field level via Profinet, Ethernet/IP, and Ethercat and networked with other sensors in the factory. With the three encoder inputs, users can optionally transmit position and speed data.

This allows users to synchronize, automate measurements, and make them efficient in dynamic environments. Drag chain-compatible extension and adapter cables ensure reliable and flexible data transmission.

Stable Measurement Results Under Changing Light Conditions

In demanding industrial environments, changing and rapidly shifting lighting conditions are common. Additionally, the surfaces to be measured often have varying reflections. To achieve stable measurement results even in such situations, Opto-NCDT-5500 sensors are equipped with an intelligent surface control—Advanced Surface Compensation (ASC)— which operates with newly developed algorithms and provides rapid exposure adjustments, ensuring stable measurement results.

In addition, the sensor is extremely resistant to ambient light and can also be used in brightly lit rooms. The new algorithms compensate for ambient light up to 50,000 lux.

Improve the Quality of Electric Motors

One possible application of the sensors is so-called hairpin measurements during the production of modern electric motors for e-mobility, which ensure the quality of the motors. In this process, so-called hairpin windings—a specific type of coil winding in electric motors—are checked for their thickness. The measurement accuracy must be in the micrometer range, contactless, and conducted in a dual-channel manner, making Micro-Epsilon Opto-NCDT-5500 sensors an excellent choice. Here, the measurement range of up to 1 inch, the ease of use, and the excellent price-performance ratio of the sensors play a key role.

The surface of the hairpins can be smooth, shiny (polished), or matte, which can cause reflections in optical systems. With dynamic ASC, the sensor quickly and precisely compensates for surface irregularities, ensuring a high-quality measurement result. Since hairpins can have different shapes and thicknesses that vary from model to model, the Opto-NCDT-5500 sensors can be easily and quickly scaled to the respective measuring range.

The sensor's Ethernet output also ensures optimal connectivity, enabling fast transmission and processing of measurement data. With the optionally available Dual Processing Unit (DPU), synchronous recording and processing of two sensor values, as well as digital-to-analog signal conversion, are possible. Selectable programs allow the automatic calculation of thickness, diameter, step or slope, runout, and ovality. Data output can be digital or analog at up to 100 kHz.

Detect And Address Hazards in Rail Traffic Early

To ensure the safety of high-speed rail lines, they are regularly inspected. An innovative solution is provided by specialized grinding trains equipped with modern sensor technology. Among the key components of these trains are the laser displacement sensors of the Opto NCDT 5500 series. With their high measurement rate, the sensors measure the distance to the track, enabling precise detection of corrugations caused by wear and stress in the rail profile.

Here, the robust design of the sensors comes into play, as they are developed for extreme conditions: they can withstand high shock and vibration loads, which occur regularly when working on high-speed tracks. Additionally, the sensors provide high precision even with the varying reflective properties of the rail surface and are also resistant to ambient light. These features enable reliable rail measurements, even under challenging conditions.

Due to the high measuring rate of the Opto NCDT 5500 sensors, the grinding trains can also operate at high speeds. At the same time, the continuous detection of skid waves contributes to the safety of high-speed traffic by enabling early identification and resolution of potential hazards.

Fast Printing Processes With Maximum Detail Accuracy

In the field of additive manufacturing, sensors need to be highly powerful, compact, and highly integrable. For this reason, Opto-NCDT-5500 sensors are ideal for use in this innovative manufacturing technology. In additive manufacturing, the precise positioning of the print head plays a central role in ensuring the required accuracy in component production. The sensors from Micro-Epsilon provide the foundation for consistently high production quality through their precise measurement of the print head's position.

The compact sensor dimensions and the integrated controller allow seamless integration into modern 3D printers without affecting the mobility of the print head or the overall system setup. At the same time, their high measurement accuracy and resistance to ambient light provide the foundation for achieving fast printing processes with maximum detail accuracy.

Simple Operation of the Sensors

At the customer's request, Micro-Epsilon also provides the powerful Sensortool software, which allows users to configure and operate one or more sensors. Through the Sensortool, users can access the sensor connected to the PC, display its entire data stream, and save it to a file (in Excel-compatible CSV format). The configuration of the sensor is carried out via the sensor's web interface. All software tools, drivers, as well as the documented driver DLL (Dynamic Link Library) for easy integration of the sensors into existing or custom software, can be downloaded free of charge from the company's website.

Suitable for Numerous Applications

By utilizing modern sensors such as the laser triangulation sensors from Micro-Epsilon, companies improve product quality while simultaneously reducing waste, leading to significant production cost savings. Furthermore, the compact design and integrated controller facilitate the installation of sensors in machinery and systems, even in confined spaces. Additional interfaces enable seamless integration into the company's field level. With the unique combination of compact design, easy integration, and advanced technology, the Opto-NCDT-5500 sensors are ideal for a wide range of applications.

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