Category: 3D

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AT Sensors – XCS 3D Sensor Laser Profiler

Ideal for industrial applications requiring precision, reliability, high speed, and high resolution, AT Sensors (previously known as Automation Technology) XCS 3D sensor laser profiler 3070 WARP achieves speeds up to 200 kHZ with the dual head model. Even the single head can achieve 140 kHz. The key innovations in the XCS series are in the laser-line projection technology.

XCS 3D sensor laser profiler – Courtesy AT Sensors

Aren’t all 3D sensor laser profilers similar?

Many indeed share underlying similarities. Often they use triangulation to make their measurement. And the output is a 3D profile (or point cloud) of a target, built up by rapid laser pulsed stepwise “slices” of the X dimension as the target (or sensor) moves in the Y dimension. Triangulation determines variances in the Z dimension based on how the laser angle reflects from the target surface coordinate onto the sensor. For a brief refresher on the concepts, see our overview article and illustrations.

What’s special about AT Sensors XCS Series?

Key attributes are shown in the video and called out in the following text.

30 second overview of XCS series

Homogeneous thickness laser line

Using special optics, the XCS series projects a laser line of homogeneous thickness across the target surface. AT Sensors uses Field Curvature Correction (FCC) to create the uniform projection, overcoming the so-called line “bow” effect. This enables precise scanning of even small structures – regardless of whether such features are in the middle or edge of the laser line. What’s the benefit for the customer? It enables applications with high repeatability and accuracy – such as for ball grid arrays (BGAs), pin grid arrays (PGAs), and surface mount devices (SMDs).

Clean Beam Technology

The XCS Series utilizes AT Sensors own Clean Beam function to insure a precisely focused laser beam, effectively suppressing side lobe noise interference.. Clean Beam also assures a uniform intensity distribution, which also contributes to the reliably consistent results.

Scanning a pin-grid array (PGA) – Courtesy AT Sensors

Optional Dual Head to avoid occlusion

X FOV 53mm +/-

X Resolution 13mm +/-

Z Range to 20mm

Z Resolution to 0.4 µm

GigE Vision interface, GenICam compliant

For plug and play configuration with networking cables and adapter cards familiar to many, the GigE Vision interface is one of the most popular machine vision standards. And GenICam compliance means you can use AT – Automation Technology’s software or diverse 3rd party SDKs.

Additional features

Automatic RegionTracking, Automatic RegionSearch, Multiple Regions, MultiPart, AutoStart, History Buffer, Multi-Slope, MultiPeak

contact us

Is the XCS 3D sensor laser profiler best for your application?

AT Sensors is confident there are demanding users for whom the XCS 3D laser profiler delivers just the right value proposition. Is that what your application requires? But AT also provides 3 other product families of laser profilers, including the CS Series, the MCS Series, and the ECS Series. It all comes down to speed and resolution requirements, field of view (FOV), and cost.

1st Vision’s sales engineers have over 100 years of combined experience to assist in your camera and components selection.  With a large portfolio of cameras, lenses, cables, NIC cards and industrial computers, we can provide a full vision solution!

About you: We want to hear from you!  We’ve built our brand on our know-how and like to educate the marketplace on imaging technology topics…  What would you like to hear about?… Drop a line to info@1stvision.com with what topics you’d like to know more about. 

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AT Sensors’ Solution Package

AT Sensors, previously known as Automation Technology, is a leading manufacturer of 3D laser profilers, and also infrared smart cameras. As customary among leading camera suppliers, AT Sensors provides a comprehensive software development kit (SDK), making it easy for customers to deploy their cameras. The Solution Package is available for both Windows and Linux. Read on to find out what’s included!

Graphic courtesy of AT Sensors.

Let’s unpack each of the capabilities highlighted in the above graphic. You can get the overview by video, and/or by our written highlights.

Video overview

Courtesy AT Sensors

Overview

AT Sensors’ Solution Package is designed to make it easy to configure the camera(s), prototype initial setups and trial runs, proceed with a comprehensive integration, and achieve a sustainable solution.

cxExplorer

Configuration of a compact sensor can be easily done with the cxExplorer, a graphical user interface provided by AT Sensors. With the help of the cxExplorer a sensor can be simply adjusted to the required settings, using easy to navigate menus, stepwise “wizards”, image previews, etc.

APIs, Apps, and Tools

The cxSDK tool offers programming interfaces for C, C++, and Python. The same package work with all of Automation Technologies 3D and infrared cameras.

Product documentation

Of course there’s documentation. Everybody provides documentation. But not all documentation is both comprehensive and user-friendly. This is. It’s illustrated with screenshots, examples, and tutorials.

Metrology Package

Winner of a 2023 “inspect” award, the optional add-on Metrology Package can commission a customer’s new sensor in just 10 minutes, with no programming required. Then go on to create an initial 3D point cloud, also with little user effort required.

Screenshot of Metrology Explorer – courtesy AT Sensors

For more information about AT Sensors‘ 3D laser profilers, infrared smart cameras, or the Solution Package SDK, call us at 978-474-0044. Tell us a little about your application, and we can guide you to the optimal products for your particular needs.

1st Vision’s sales engineers have over 100 years of combined experience to assist in your camera and components selection.  With a large portfolio of lenses, cables, NIC cards and industrial computers, we can provide a full vision solution!

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Test your parts in 3D lab

Have you wondered if 3D laser profiling would work for your application? Unless you have experience in 3D imaging, for which laser profiling is one of several popular methods, you may be uncertain of the fit for your application. Yes, one can read a comprehensive Tech Briefs on 3D methods, or product specifications, but wouldn’t it be helpful to see some images of your parts taken with an actual 3D Laser Profiler?

Image courtesy Teledyne DALSA.

While prototyping at your facility is of course one option, if your target objects can be shipped, Teledyne DALSA has a Z-Trak Application Lab, whose services we may be able to arrange at no cost to you. Just describe your application requirements to us, and if 3D laser profiling sounds promising, the service works as follows:

  1. Send in representative samples (e.g. good part, bad part)
  2. We’ll configure Z-Trak Application Lab relative to sample size, shape, and applications goals, and run the samples to obtain images and data
  3. We’ll send you data, images, and reports
  4. Together we’ll interpret the results and you can decide if laser profiling is something you want to pursue

Really, just send samples in? Anything goes? Well not anything. It can’t be 50 meters long. Maybe a 15 centimeter subset would be good enough for proof of concept? And if the sample is a foodstuff, it can’t suffer overnight spoilage before it arrives.

A phone conversation that discusses the objects to be inspected, their dimensions, and the applications goal(s) is all we need to qualify accepting your samples for a test. Image courtesy of Teledyne DALSA.

Case study

In this segment, we feature outtakes from a recent use of the Z-Trak Application Lab, for a customer who needs to do weld seam inspections. The objective is to image a metal part with two weld seams using a Z-Trak 3D Laser Profiler and produce 3D images for evaluation of application feasibility. The images and texts shown here are taken from an actual report prepared for a prospective customer, to give you an understanding of the service.

Equipment:

  • Z-Trak LP1-1040-B2
  • Movable X,Y stage
    X-Resolution: ~25 um
    Y-Resolution: 40 um
    WD: ~50 mm

Image courtesy Teledyne DALSA

Conditions:
The metal part was laid flat on the X,Y stage under the Z-Trak. The stage was moved
to scan the part.

To the right, see the image generated from a perpendicular scan of the metal part. Image courtesy Teledyne DALSA.

The composite image below requires some explanation. The graphs on the middle column, from top to bottom, show Left-Weld-Length, Right-Weld-Length, and Weld-Midpoint-Width (between the left and right welds), respectively. The green markup arrows help you correlate the measurements to the image on the left. The rightmost column includes summary measurements such as Min, Max, and Mean values.

Image courtesy Teledyne DALSA

Now have a look at a similar screenshot, for Sample #2, which includes a “bad weld”:

Image courtesy Teledyne DALSA

With reference to the image above, the customer report included the following passage:

The top-right image is the left weld seam profile. In the Reporter window the measurement of this seam is 1694.79 mm long. However, a defect can be noted at the bottom of the left weld. In addition to the defect it can be seen from the profile that the weld is not straight in the Z-direction. The weld is closer to the surface at the top and further from the surface at the bottom

Translation: The automated inspection reveals the defective weld! Naturally one would have to dig in further regarding definitions of “good weld”, “bad weld”, tolerances, where to set thresholds to balance yields and quality standards vs. too many false positives, etc.

Conclusion

The report provided to the customer concluded that “This application is feasible using a Z-Trak 3D Laser Profiler.” While it’s likely that outcome will be achieved if we qualify your samples and application to use the Z-Trak Application Lab service, it’s not a foregone conclusion. We at 1stVision and our partner Teledyne DALSA are in the business of helping customers succeed, so we’re not going to raise false hopes of application success.

Recap

To summarize, the segments above are representative outtakes from an actual report prepared by the Z-Trak Application Lab. The full report contains more images, data, and analysis. Our goal here is to give you a taste for the complimentary service, to help you consider whether it might be helpful for your own application planning process.

Next steps?

To learn more, see a recent blog “Which Z-Trak 3D camera is best for my application?“. Or have a look at the Z-Trak product overview.

If you’d like to send in your parts, please use this “Contact Us” link or the one below. In the ‘Tell us about your project’ field, just write something like “I’d like to have parts sent to the Z-trak lab.” If you want to write additional details, that’s cool – but not required. We’ll call to discuss details at your convenience.

1st Vision’s sales engineers have over 100 years of combined experience to assist in your camera and components selection.  With a large portfolio of lenses, cables, NIC card and industrial computers, we can provide a full vision solution!

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3D Scanning Applications with AT Sensors

Previously we’ve introduced AT Sensors‘ 3D scanners, which use triangulation – together with precision optics and embedded algorithms – to build a point cloud representation of 3D objects.

MCS – 1280 3D scanner
– courtesy AT Sensors

While there are interesting scanning applications in diverse industries, including automotive, food processing, battery production, display inspection, and more, in this piece we focus on the automotive industry. Below we offer a collection of short videos that help to tell the story. Each application utilizes AT Sensors 3D laser profilers.

CONTACT US to discuss your application! We have longstanding returning customers who know we like to help you choose the right cameras and components. It’s what we do.

Inspection of brake discs, for surface defects, duration 1 minute 24 seconds:

Inspection of stamped metal parts, duration 37 seconds:

Inspecting asymmetrical objects, duration 50 seconds:

You don’t have to be in the automotive industry to take advantage of AT Sensors – previously known as Automation Technology – 3D laser scanning! Food processing, display inspection, battery production – indeed all sorts of 3D applications are enabled or enhanced by laser triangulation approaches to building 3D point clouds for a scanned object, and comparing the scan to the idealized perfect object. The difference calculation determines if the test object is within the defined tolerances.

3D point cloud
From real space to 3D point cloud model – Image courtesy of AT Sensors

We have videos for other industries and applications available, and sales engineers who can help guide you to a solution for your particular needs. Call us at 978-474-0044.

1st Vision’s sales engineers have over 100 years of combined experience to assist in your camera and components selection.  With a large portfolio of lenses, cables, NIC card and industrial computers, we can provide a full vision solution!