In a real-world production process, the engineer may need to compare profile scans generated from manufactured parts to a “golden” contour, in order to measure variation and identify non-conformance.

For example, industrial extruders produce a continuous stream of material with a designated target shape. Using a Gocator® laser line profiler and the built-in Profile Template Matching tool, we can compare the extruder output material against the desired, “golden” shape in order to ensure 100% part quality.

A Smart 3D Laser Profiler In Action

The Gocator laser line profiler scans the extruded material and generates a 3D profile.

The sensor scans the target and generates a 3D profile.

Notice the surface defect in the scanned part. This is the surface variation we want to detect using the Profile Template Matching tool.

In the browser-based Gocator interface, we apply the Profile Template Matching tool to align the live 3D profile to a master or “golden” template profile. Once the tool is applied, it returns measurements that represent any variation (i.e., surface defects) between the live profile and the master.

Notice that in the data viewer, the three profiles are rendered in a preset color scheme. The master profile is rendered in white, the aligned profile is rendered in blue, and the live profile is rendered in red.

We then have the option to output the data as either an Aligned or Difference profile to other tools for measurement.

The Result

When the aligned profile closely matches the master profile, the resulting difference profile registers minimal variation (i.e., within specified tolerance) and part conformance is verified. The sensor classifies this as a Pass.

However, when the aligned profile deviates from the master profile, as in the case of the surface defect on our original scan target, the variation is recorded in the resulting difference profile and part non-conformance is detected. The sensor records this as a Fail.

Benefits of Profile Template Matching

The built-in Profile Template Matching tool is able to accurately verify whether individual parts are in conformance with a master or “golden” part in order to ensure 100% quality control. Variation between the scanned part and the master is automatically captured and tagged with a Fail control decision that the sensor can seamlessly communicate to external factory machinery.

The Profile Template Matching tool also provides robust inspection on parts regardless of their position and angle (the tool even corrects for rotation). And, in addition to being able to handle small position and angle variation in the transport system itself, the tool allows you to easily inspect parts with complex or curved shape.

Try out the new Profile Template Matching tool for yourself in the latest Gocator Firmware.