Optocomb SystemsAutomated inspection solutions to make the most of the Optocomb performance
- Checking dimensions
- Inspecting burrs and scratches
- Detecting particles
- Inspection from all angles
- Microscale resolution
- Visual inspection and GD&T
- Checking bores' dimensions
- Inspecting scratches and burrs
- Detecting particles in bores
- Optocomb sensor
- Optical camera
- High-speed inspection
- 3D scanning & fully automated inspection with high accuracy
Optocomb Sensors3 type of sensors for high-speed and high-accuracy inspection
Wide-range sensor L90
High-resolution sensor S40
Ultra-high resolution sensor M5
- XY resolution
- Ｚ resolution
- Measurement depth
- Working Distance
- Scan type
- L90Line scanS40Line scan / Area scanM5Area scan
- Measurement area
- L90Line width 90mmS40Line width 50mm /Area 40mm×40mmM5Area 5mm×5mm
- Target use
- L90 Dimensional and visual inspection of medium and large parts.
Defects: width>300µm, depth/height>20µmS40Dimensional and visual inspection.
Defects: width>180µm, depth/height>3µmM5Visual inspection of burrs etc. in localized areas.
Defects: width>90µm, depth/height>3µm
Easy 1µm-resolution 3D scanning on everyone's desktop.
High-accuracy, fast and easy 3D scanning, now available on your desktop. A standalone system by XTIA integrating both our Optocomb sensors and a motorized stage.
- A coaxial laser configuration, ideal for measuring complex shapes
- A working distance up to 127mm for a flexible use
- Large depth of focus for parts with large irregularities
Flexible 3D scanning with micro-accuracy from any angle
XTIA's Optocomb sensors integrated on a robot arm. The robot arm vibration is controlled and compensated to maintain the micro-accuracy of our sensors and ensure maximum reliability of the 3D scanning. Thanks to the degrees of freedom of the robot arm, any area of the target object can be scanned and measured, enabling multifacet synthesis of the 3D scanning data. This unique system offered by XTIA opens new and exciting opportunities for the manufacturing industry.
Dimensional inspection features:
- Geometric feature detection
- Circle to circle distance measurement
- Point-to-point/plane distance measurement
- Distortion calculation
- Flatness calculation
- Step assessment
- Data export in .csv or .stl formats.
Defect inspection can be automatically carried out by image analysis of a single scan. As a guide for visual inspection, the L90 can detect defects with widths down to 270µm, while the S40 can detect defects with widths as small as 180µm.
By introducing these systems in a wide range of areas from measurement for product design to fully automated inspection in production lines, it will soon become possible to design products with the same capability as the manufacturing process capability. As more and more advanced designs are being implemented, inspection capability is increasingly becoming a bottleneck in manufacturing. The adoption of high-precision, fully-automated inspection from the product design stage will thus ensure that quality assurance is taken into account in advanced product design.
Access the 3D profile of bores with micrometer accuracy.
Leveraging the unique coaxial configuration of Optocomb lasers, XTIA sensors can be combined with a rotating mirror. It powers our Helical Scan system, the only optical tool that can measure the inner walls of cylindrical structures with micro-accuracy. Many medium and large parts have a cylindrical shape and need to meet high quality requirements and the ever-demanding designs of modern manufacturing. Until now, the in-line inspection of such inner surfaces in 3D with micro-accuracy has remained elusive. It is especially the case for bores, as accessing visual and dimensional information deep into cylindrical structure while delivering micrometer-level accuracy is a significant challenge. Thanks to its coaxial configuration and the accuracy of the Optocomb, XTIA sensors can be leveraged to successfully address this issue.
XTIA has thus developed a helical scanner combining its high-accuracy Optocomb sensor with a rotating mirror that translates within the structure along its z-axis and probes the inner walls in three dimensions. With this system, XTIA brings a new visual and dimensional inspection solution to the table and enables the inner surface of bores and other cylindrical structures to be measured with high accuracy. This solution gives direct access to the position, diameter, cylindricity, circularity and depth of your bores with diameters ranging from 20 mm to 60 mm, thus covering a large range of manufactured parts. Moreover, it can quantitatively detect various micro-defects such as foreign particles, burrs, scratches and more.
Optimizing inspection by combining Optocomb lasers and optical cameras.
The reason why automated inspection is so difficult to implement is that there is a wide variety of defects to be inspected, and it is practically impossible to detect all of them with a single sensor. Conversely, using different sensors for different types of defects is time-consuming and costly, and as a result, it becomes a major barrier to automating the inspection process. Even though optical comb sensors can detect a very wide range of defects, optical comb sensors and optical cameras are still complementary in their detection capabilities. For example, a two-dimensional blemish can be detected by an optical camera, but not by an optical comb sensor. A foreign object made of the same material cannot be detected by an optical camera because there is almost no color difference, but it can be detected by an optical comb sensor. Having both an optical comb and an optical camera operating hand in hand in a single system would thus be a significant breakthrough in the world of visual inspection.
This is exactly what XTIA, in collaboration with its partner JUKI, offers with its hybrid solution: a fully automated system integrating both a 12 Megapixel optical camera and a high-resolution S40 optical comb sensor. The system maximizes resolution in all three directions for an optimal visual inspection and defect detection process. Furthermore, by taking advantage of the very high speed of the optical camera, our hybrid system can reduce the number of defects that needs to be scanned in 3D by the slower optical comb sensor, thereby greatly reducing the cycle time of the overall automated inspection process.
Defect and particle detection
The complementary relationship between the Optocomb laser and the optical camera provides a perfect detection capability and reliability.
The above discussion is based on our extensive know-how, XTIA being the Japan no.1 in the field of optical inspection for the automotive industry.
It is only a general discussion and may vary depending on the material of the workpiece and inspection conditions.