3D laser scanner measurement

What is meant by “3D laser scanner measurement”?

3D laser scanner measurement is an advanced method for precise three-dimensional measurement of objects using laser line triangulation sensors, also known as laser scanners. This technology enables the accurate determination and comparison of measured values such as length, width, height, angle, radius, flatness, parallelism, diameter, defect sizes and more. Unlike traditional 2D image processing with cameras, 3D laser scanner measurement enables a three-dimensional representation of an object.

In which processes and in which industries and sectors is 3D laser scanner surveying used?

3D laser scanner measurement is widely used in various industries, especially for visual monitoring of production processes. It enables the automatic inspection of individual parts and steps during the production of products. Especially in inline quality control, 3D laser scanner surveying has its benefits, as it can check 100% of the produced parts in real time.

Typical industries and sectors where 3D laser scanner measurement is used include:

• Metalworking
• Mechanical Engineering
• Welding technology
• Automotive
• Battery manufacturing
• Aerospace
• Smartphone manufacture
• Power Engineering
• Mining
• Metrology

Why is 3D laser scanner measurement so important for plant engineering and manufacturing companies?

3D laser scanner measurement plays a critical role in improving production quality, especially in demanding environments. Compared to 3D camera systems, it has proven to be extremely robust against interfering ambient light. This makes it a reliable choice for plant engineering and manufacturing companies that must maintain the highest quality standards. 3D laser scanner surveying enables precise and reliable measurements even under difficult conditions.

The use of a 3D laser scanner measurement in quality assurance offers numerous advantages. It reduces scrap in production, minimizes customer complaints and avoids costly rework due to faulty production parts. These lead to a significant increase in productivity and cost efficiency. Especially in the production of high-quality products in large quantities, the use of 3D laser scanner surveys results in considerable economies of scale, which can lead to significant savings in production costs.

Overall, the implementation of 3D laser scanner surveys in quality assurance is an important step towards optimizing production processes and increasing a company’s competitiveness in demanding markets.

3D laser scanner measurement aluminum block

Basics and methods of 3D laser scanner measurement

In the 3D laser scanner measurement with laser triangulation, two different lasers are used:

Point laser
Linear lasers.

➜ Point laser triangulation:

One technology in 3D laser scanner measurement is triangulation. In triangulation, a laser beam is directed perpendicularly at an object and the diffuse reflection of this beam is measured at a known angle (e.g. 40°). Since the angle is known, and also the distance between the laser source and the light receiver (camera module), the height of an object can be calculated exactly. These methods were initially only realized as point-based methods.

➜ Point laser time-of-flight measurement:

One technology used with point source lasers is time-of-flight measurement. The time between emission and reception of the laser beam is measured. Since the speed of the light is known, distances can be measured.

However, minimum distances of several meters to the measurement object must be maintained, since due to the extremely high speed of light, measurement electronics require a minimum time for processing.

Such point-shaped time-of-flight methods are used in so-called trackers, which are used, for example, to measure buildings or rooms in buildings. A laser with a receiver sits on a tripod and uses motorized rotary axes to scan various points on the object one after the other. The acquisition of objects with trackers can take many minutes to hours, since for each new measuring point, the rotary axes must move. Furthermore, the resolution and accuracy of such trackers are often significantly worse than the values achievable with laser triangulation.

➜ Point laser phase comparison measurement:

Another point-based laser measurement technology is that of phase comparison, which measures the phase shift of the light wave. However, this method has similar limitations as the point-based time-of-flight measurement.

➜ Line laser triangulation:

With the progress of digital cameras, special camera chips were developed that are capable of capturing a laser line. This allows not only the measurement of the height of a single laser point, but also the simultaneous measurement of an entire laser line, which today can include up to 8000 measurement points. In this way, both the width (X) and the height (Z) of a laser line located on an object can be precisely determined.

Now, when many such laser lines are captured at close distances from each other by a measurement object, a comprehensive 3-dimensional point cloud is created.

➜ Precise 3D laser scanner survey with XYZ point cloud:

Thanks to 3D laser line triangulation, measuring ranges from just 5 to 1500 mm can be measured extremely precisely with impressive accuracy in the range of 1 to 3 µm. At the same time, considerable measuring speeds of 200,000 profiles per second are achievable. This opens up a wide range of possible applications in various industries and applications where highly precise 3D measurements are essential.

Quelltech 3D Laser Scanner Measurement: Reliable and Robust Technology

The 3D laser scanner measurement from QuellTech is based on the proven laser line triangulation, as already described. Here, the diffuse laser line reflected from the object to be measured is projected through special receiving optics onto a sophisticated image sensor and analyzed in lightning speed by extremely fast evaluation electronics.

Our technology uses various selectable evaluation algorithms that take into account the specific optical behavior of the object to be measured. By using monochromatic laser light, the spectral detection range of the sensor is severely limited. This means that QuellTech 3D laser scanners are extremely resistant to extraneous light and the different color variations of the objects being measured – a problem that often poses major challenges for conventional 2D camera systems.

QuellTech 3D laser scanners are characterized by precision and robustness. Thanks to a design without moving parts and comprehensive factory calibration, our scanners can output calibrated 3D data in millimeters as long as an object is within the sensor’s detection range.

Unlike conventional 2D camera systems, changes such as adjusting the camera distance, changing the illumination angle or even sudden changes in ambient lighting do not pose a challenge to QuellTech 3D laser scanners. This extraordinary robustness against external influences is clearly demonstrated by the fields of application of our scanners. One example is weld seam tracking, where QuellTech 3D laser scanners are a standard application.

The point cloud captured by our 3D laser scanners is then measured and analysed in 3D image processing software. The results can be conveniently displayed on the screen and/or forwarded to control PLC systems or robots.

This seamless integration into various applications and the combination of precision and robustness make QuellTech 3D laser scanners a top choice for demanding tasks in a wide range of industries.

Advantages of 3D laser scanner surveying from QuellTech

QuellTech’s 3D laser scanner surveying offers an extremely flexible measurement method that can be scaled from tiny measurement objects of a few millimetres in width to several meters.

Often, the movement of the measurement objects can be used for measurement with the help of existing conveyors, axis gantries or robots. The high measuring speed of inline measurements usually enables such a short measuring cycle that no additional cycle times are required.

QuellTech’s 3D laser scanner measurement is extremely robust against extraneous light, temperature fluctuations, weld spatter, vibration, electromagnetic influences and moisture.

The calibration of the QuellTech 3D laser scanners is fixed in the sensor and remains constant over the entire lifetime. Since the sensors do not contain any moving parts, there is no mechanical wear of the components to worry about.
Our 3D laser scanners from QuellTech can be precisely adapted to customer-specific requirements:

Measuring ranges from 5 mm to 1500 mm
Choice of laser wavelength (blue, red, green)
Customizable form factors (extremely small, flat, long)
High resolution of up to 0.5 µm
Applications in various environments, such as white-hot steel, underwater measurements, welding, harsh environments and normal production environments

Our software for evaluating 3D laser scanner data from QuellTech enables the creation of measurement sequences without time-consuming programming. Various 3D measurement modules are available and can be effortlessly parameterized and immediately tested, which significantly reduces development time.

The software is available in various languages and offers a flexible designer tool for creating user interfaces (GUI) for operators and result reports. In addition, third-party sensors and cameras can be easily integrated, and custom code in C++ can also be incorporated.

Wide range of applications for 3D laser scanner measurement

3D laser scanner measurement is a crucial process for improving product quality in numerous industries and fields of application:

Adhesive bead measurement in automotive manufacturing:
Precise control of adhesive joints in automotive production.
Measurement of aluminum blocks:
Accuracy testing and quality control of aluminum workpieces.
Weld seam guidance inline with robots or linear axes:
Monitoring and optimization of weld seams in real time: Weld seam guide for robot-guided welding
Weld seam inspection inline with robots or linear axes:
Inspection of weld seams for defects and irregularities.
Flatness inspection of measuring axes:
Measurement of the surface flatness of axes and workpieces: Planarity measurement on metal plates
Parallelism check of measuring axes:
Checking the parallelism of parts and components: Verification of Correct Position of Contact Pins in Electronic Assemblies
Surface defects on steel rolls and surfaces:
Identification of surface defects on steel rolls and other workpieces: Non-contact surface inspection on metal surfaces
Thickness measurement of battery foils:
Precise thickness measurements for battery foils in electronics production.
Thickness measurement of Li-Ion batteries before and after charging:
Monitoring the thickness of Li-Ion batteries before and after charging.
Sheet metal profile measurement on red-hot steel:
Measurement of sheet metal profiles in hot environments, such as red-hot steel: Measuring height and width of glowing steel castings
Defect measurement on steel pipes underwater:
Inspection and detection of defects on steel pipes underwater.
Grinding wheel measurement for radius, runout and wear:
Precise measurement of grinding wheels in production.
Pipeline inline cladding monitoring:
Continuous monitoring and optimization of cladding processes on pipelines: Automated quality control for pipeline construction in oil and gas industry
Crimp depth measurement on electric motor housings:
Measurement of crimp depth on electric motor housings.

Preventive maintenance and wear monitoring on mining machinery:
Early maintenance and wear monitoring of mining machinery to extend its service life.
Wear inspection on screw jack rotors:
Inspection and monitoring of wear on screw jack rotors.
Particle Layer Thickness Measurement of Solar Thermal Power Plants:
Precise measurement of particle layer thickness in solar thermal power plants to increase efficiency.

QuellTech products for 3D laser scanner measurement

Q4 Laser Scanner Family:
Small form factor, low weight, many housing variants, high laser powers in blue, red and green, very high robustness against environmental influences.

Quelltech Q4 Laser Scanner

Q5 Laser Scanner Family:
Medium form factor, high resolution, very high speed, laser measurement widths up to 800 mm.

Quelltech Q5 Laser Scanner

Q6 Laser Scanner Family:
Medium form factor, very high resolution, very high speed, many housing options, measuring widths up to 1500 mm.

QuellTech Laser Scanner Q4-80s with small form factor (86 x 44 x 25 mm) for robotic welding

QuellTech Laser Scanner Q4-60 with optional cooler and protective window system

Do you have questions about 3D laser scanner measurement, or would you like QuellTech to advise you on these topics?

If you have any questions about 3D laser scanner measurement, or would like advice from QuellTech on this topic, please do not hesitate to contact us.

We would like to help you to precisely evaluate your specific measurement task. Through an initial free test measurement of your application, we can give you an early assessment of the feasibility.

There is always potential for improvement, we will help you with that. Contact us for more information or to make an appointment for a consultation.

Your personal contact:

Stefan Ringwald
Tel: +49 89 124 723 75

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