Smart profile sensors for simple, efficient, lower-cost inline testing and control
21 August 2020
Inline quality control systems are playing an increasingly important role in today’s manufacturing and production systems, helping to reduce downtime, minimising rejection rates and contributing to lower production costs and improved product quality.
While some systems can be complex and expensive, the continued development of key components such as sensors is helping to provide simpler, lower-cost alternatives for checking a large number of process steps quickly and easily.
A good example of this is a new ‘smart’ multi-profile sensor, the OXM200, introduced by sensing and instrumentation specialists BAUMER. It is ideally suited to inspection and measuring applications. It also provides an almost unlimited operating range, giving users ultra-efficient inline checks and multi-dimensional control of their manufacturing and processing systems.
The compact and lightweight all-in-one OX200 Sensor is designed for integration into image processing systems and thanks to an extensive set of integrated measurement functions, they are able to support inline or offline testing without the need for operators to have detailed image processing experience.
They are designed for checking and inspection applications along with checks and verification of object geometrics such as height measurement of seals, the inspection of surfaces etc. Also, there are inline quality controls of object geometries in the 1/10mm range, plus measuring operations, such as axial diameter measurements, plus edge, crack, gap and flush measurements. They can also be used for control and regulation tasks, including position control of feed parts, vision-guided robotics (control of robot positioning), pick and place (control of robot grabber arms) and position control of parts.
As smart multi-tools, they enable the linking of measurement tools for multi-faceted analysis, the free configuration of up to seven measured values in a web browser and position tracking of evaluation windows for checking varying positions of a measured part. They feature a compact, lightweight design with IP65 housing and simple wiring for mounting on a robot arm, no external illumination is required and thanks to Power-over-Ethernet (POE) functionality, can be used with a single cable. Set-up and handling are easy, thanks to graphic support via the intuitive Baumer web interface.
Storage of up to three sets of parameters in the sensor is possible while additional sets can be stored externally if required. Plug and play functionality, without the need for software installation or special training, helps with quick commissioning of the calibrated sensor. Also, live analysis and monitoring (seeing with the eyes of the sensor in real time) mean quick analysis through intuitive visual feedback of the algorithms.
Easy integration into automation systems is possible courtesy of a wide selection of protocols including; PROFINET, Modbus TCP, IO-Link and analog output. Direct connection to IT systems and cloud integration with OPC UA, in addition to image processing systems with an SDK (profile data via UDP streaming), is also possible.
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