Flatness measurement with multi-dimension control units and LVDT linear transducers

digicheck measures flatness with lvdt probes and multi-dimension electronic controller

Flatness measurement is a method used for measure flatness of a surface or a piece.

It is an important part of many industrial processes and can be done with different techniques. One of the most common methods for measuring flatness is theuse of LVDT probes and linear transducers. This method has become increasingly popular due to its high accuracy and reliability.

For measurements obtained from LVDT probes and linear transducers, amulti-dimension control unit, to ensure uniformity across multiple parts or surfaces to be measured. This control unit uses multiple sensors placed on the surface to be measured, obtaining readings from each sensor at different points on the surface. The acquired data is then compared with predetermined values, which allow to obtain accurate measurements with minimal variations between the various measurement points.

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DL1 series LED illuminators for vision systems and optical inspection benches

LED lighting is a technology that is becoming increasingly important in machine vision systems.

LED lights are very efficient, economical and reliable, and can be used to illuminate specific areas in an environment with precision.

Plus, LEDs are more durable than other traditional light sources, so you won't have to worry about replacing bulbs every year.

One way LEDs are used in computer vision is to create a strobe light.

This type of illumination can be used to allow you to control the speed of the process and identify objects or parts of interest within the image.

The use of strobe light also offers the possibility of detecting invisible defects during the production process and measuring their dimensions with precision.

Modern machine vision systems often combine LED illumination with high-resolution sensors such as linear industrial cameras, infrared cameras or high-speed cameras.

They can also incorporate advanced equipment such as lenses and objectives that provide sharp images from various angles without the need for mechanical handling of the device.

Additionally, this technology can be used in conjunction with digital image processing and artificial intelligence (AI) to support skilled applications such as manufacturing accounting or predictive maintenance in a modern Industry 4.0 environment.

Vision systems play a crucial role in modern industry. On the one hand, they allow companies to control the quality of their products and to optimize complex processes such as industrial and logistic ones.

On the other hand, vision systems support advanced applications such as Industry 4.0, artificial intelligence (AI), image processing (IP) and so on.

As a result, it's no surprise that companies come looking for innovative and technologically advanced solutions to make the most of their vision systems.

LED illuminators are a great example of such innovative solutions: this technology is now widely used in industries such as automotive and electronics, where it is essential to control the product in terms of quality and precision.

LED illuminators offer advantages over other types of lighting traditionally used in this sector: first of all, longer life and more stable performance. In addition, the LED illuminators have very fast turn-on times, making them ideally suited for industrial linear and 3D cameras that require minimal time for measuring and processing the images acquired in rapid mode.

Another commonly used method in industrial vision is strobe lighting – also known as flash lighting – which is mainly used to instantly identify defects on objects thanks to the particular configuration of the light emitted by this type of semiconductor lamp.

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LED vision illuminators are devices used in factory automation and machine vision applications that provide uniform, well-balanced light throughout the scene.

LED technology is one of the most advanced in existence, providing high brightness lighting with low energy consumption and with the possibility of adjusting the color of the light.

LED illuminators also offer greater thermal stability, allowing these devices to operate in extreme conditions and at high temperatures.

LED Vision Illuminators are specifically designed to provide optimal illumination within the camera's field of view.

These light sources are available in a variety of colors including white, red, green and blue and can be easily dimmed remotely to change the hue of the light depending on the needs of the application.

LED illuminators have many advantages over traditional artificial light sources. First of all, being very energy efficient, they allow to reduce the overall costs of industrial operation or visual monitoring.

Furthermore, LED illuminators are available in different forms as recessed lamps or portable units that can be easily installed within industrialized structures and integrated into existing plant engineering without having to modify production lines.

LED lighting systems are an important component of the operation of vision systems, and their technology, use and installation are of great importance for maintaining the correct functioning of the machine.

The quality of the lighting is essential for the quality and efficiency of the system. LEDs offer very high brightness and highly reliable performance, with low temperatures and fast execution.

In machine vision applications and factory automation, LED illuminators offer considerable flexibility in illuminating the objects scanned by the system. Thanks to their small size, they can be positioned to create a constant lighting pattern over the entire surface of the object. Furthermore, due to the very low energy consumption that LEDs have compared to other types of lighting, they are particularly suitable for industrial environments that have to manage large production volumes with very long cycles.

LED illuminators are also perfect for situations where interference between different devices must be avoided: for example when it is necessary to separate different illuminated areas by different partitions on the same piece.

LED machine vision lighting systems have become an essential component in machine vision and industrial automation applications. LED illuminators offer many advantages over traditional lights, including greater accuracy and quality in the image. This is due to their high brightness, lower energy content and longer life of the light source. An LED illuminator can be placed directly on the object to be inspected or on any sensitive component that requires illumination, providing a coherent beam of light for accurate measurement.

LED illuminators can be used for even the most demanding applications thanks to a wide range of features: customizable design, intelligent device surface temperature control, integrated over-voltage/over-current protection, ultra-slim wide angles and high luminous performance.

The illuminator can be customized with different shell sizes and shapes according to the type of project required. This would make it easy to build the final product without having to modify the original hardware. In addition, all RODER models are equipped with CE-certified drivers for the correct operation of electrical appliances and fire-resistant self-extinguishing structures to ensure constant operation in harsh conditions.

Dimensional checks with multi-quota control units and LVDT linear transducers

MODULCHECK series dimensional and geometric control systems allow the measurement and determination of conformity of mechanical parts and discrete objects using objective measurement procedures that can be easily managed even by non-expert personnel. The innovative architecture on which the MODULCHECK system is based allows the creation of dimensional and geometric test benches (static or dynamic) using easily available equipment and sensors and easily editable during setup or directly in production also by the end customer.

MODULCHECK systems are suitable for measurements directly on the production line and also managed by unqualified personnel. The visualization interface has been deliberately made simple and easy to consult but without renouncing the powerful mathematical functions intended for the analysis of dimensional and geometric characteristics. 

All production data are stored in a local database with the possibility of transferring or synchronizing with existing databases (SQL, XML or CSV) for a complete and reliable analysis of data in real time.

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Artificial vision systems for the control of defects on continuous products in the production line

Machine vision is a key technology for Industry 4.0 and the inspection of defects in continuous products on the production line.

With the help of vision systems, such as LED illuminators, industrial and linear cameras, image processors and artificial intelligence, greater accuracy in identifying product defects can be achieved.

Computer vision-based systems can help companies to identify any problems early during the production phase.

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LASER scanner for dimensional and geometric control of continuous products in the production line

Laser scanning systems are a type of inspection technology used in the manufacturing industry to provide an accurate measurement of the shape and size of products.

Laser technology offers unmatched accuracy when inspecting and measuring complex contoured products, including 3D profiles. Additionally, the speed and reliability with which a laser can perform inspections make it ideal for production lines where speed is of the essence. Laser systems can be used for a variety of applications including dimensional and geometric inspection of continuous products on automated production lines.

A laser beam scanner mainly consists of a laser source, an optical module and a control device. The light source sends a focused beam of high energy onto the surface of the product under investigation. The optical module converts the reflective beam into an electrical impulse which is then processed by a control device. The device allows the laser system to take accurate dimensional and geometric measurements of the product, as well as verify the presence or absence of specific structural properties such as irregular geometries or dimensional variations within defined tolerances.

The main advantage of using laser scanning technology over conventional techniques is accuracy. Since laser scanners can capture detailed information with pinpoint accuracy, there is no need for repeated manual inspections that consume valuable time in automated production lines. The data collected by the sensors can then be viewed as 3D graphs and analyzed to identify any anomalies during the production process before they affect the functionality and performance of the finished product.

The capability of laser scanning technology is not limited only to dimensional inspection but also includes the measurement of the three-dimensional surface of the object under examination and the digital processing of the same data; which will allow industrial operators to easily identify any problems related to the quality of the single piece before it reaches the final stage of the process, thus reducing fatal times due to human error and avoiding too expensive and inefficient and large-scale maintenance solutions.

Laser scanners are measurement and control machines that allow companies to detect the quality of products on the production line. The use of this tool allows to obtain a higher precision in measurement and a higher speed, compared to the use of other methods of inspection. Laser technology also offers the possibility of performing precise dimensional and geometric inspections on products continuously.

These features make laser scanners ideal for inspecting products on a production line faster and more effectively. One particularly important advantage is that many items can be checked at the same time, saving valuable time. For example, companies can use this technology to immediately detect if there is an incorrect assembly, if there has been a defect during the production process or if there has been a dimensional change in the finished product. Furthermore, it is possible to constantly monitor the quality of the product during the production process ensuring that the final quality meets the standards set by the company.

Laser scanners also offer some additional benefits such as the ability to read embossed barcodes or 3D matrix QR codes presented on the parts to be inspected, as well as the ability to read heat marks previously printed on the surface of the material to be inspected. This will allow companies not only to provide real-time feedback on the current status of the product, but also to track essential information relating to the origin and identification of the material used in the production process.

Additionally, thanks to advances in industrial electronics and computer technology, modern laser systems are more accurate and reliable than ever before. The systems incorporate advanced features such as anti-interference algorithms to avoid errors caused by artificially generated light sources or by impulses from other industrial machines. All collected data is transmitted directly to the dedicated software without human intervention to analyze and process them.

Copyright by RODER SRL - All rights reserved - Application note AN0018

LVDT linear transducers for dimensional and geometric control

I LVDT linear transducers allow precision measurements on mechanical parts or on any object that can be measured with a contact probe.

Combined with special signal amplifiers they allow the measurement of dimensional characteristics (thicknesses, widths, positions, heights, diameters, ovality) and geometric (flatness, parallelism, perpendicularity, oscillation, eccentricity and coaxiality) with millesimal precision even on complex mechanical parts.

LVDT transducers with spring drive system (with fixed mechanical preload) or LVDT linear transducers with pneumatic drive particularly suitable for automatic measuring systems.

Some families of LVDT probes can be made with a vacuum-based displacement mechanism.

Transducers with radial cable exit, with axial cable exit or with quick connection and disconnection systems are possible.

RODER manufactures complete "turnkey" systems consisting of LVDT probes, amplifiers and electronic controllers, data acquisition systems, software for statistical and mechanical control specially designed.

RODER measurement systems find applications in many industrial sectors: precision mechanics, sheet metal working, plastic moulding, electro-medical, metallurgical and iron and steel.

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Digital radius and diameter gauge DIACHECK-CT series

The DIACHECK-CT series digital radius and diameter gauge allows direct and instantaneous reading of internal or external radii or diameters in a range between 100 and 10000 mm.

Il High precision digital radius and diameter gauge of the DIACHECK-CT series is designed to measure the radius of cylindrical objects such as pipes, profiles and calenders quickly and accurately.

This measuring instrument allows the measurement of the radius of curvature or, of the internal or external diameter of a certain part using the method of measuring the circumference based on three points.

Technical features

This radius gauge allows direct and instantaneous reading of inside or outside radius values ​​for a wide range of curves, profiles, diameters and cylindrical objects.

  • Comfort: there is no need to cut out templates to find out the radius of a curve, nor to remove the piece from the machine to measure it and not even to extract the part from its installation location (for example underground pipes, installed tanks, positioned and fixed calenders)

  • Ease of use: it's easy to use and the measurement process is lightning fast. Simply place the gauge inside or outside the curve to automatically obtain the value of the radius of curvature or the diameter of the object.

  • Multi-material: the gauge is suitable for any type of solid material such as steel, wood or plastic materials.

  • High precision: the margin of error on the radius is only 0,1 mm (the measurement accuracy depends on the superficial quality of the solid to be measured and it is necessary to work on a surface without depressions or with high surface roughness to obtain maximum precision).

  • Field of application: this radius gauge is supplied with different measuring arcs and with different angles of support. The use of the various arcs offers a measurement range between 100 and 10000 mm.

Innovative and versatile

  • Battery Powered LCD Digital Display: comfortable reading of the measured value with the possibility of transferring the measured value to a acquisition system based on Bluetooth interface.

  • Practical: it is small and light and can be easily used for different measurements by simply changing the measuring head.

  • Transport: An aluminum case with internal foam protection is available to store and protect the meter when not in use. Convenient to carry and shock resistant.

  • Two units of measurement: you can choose whether to measure in millimeters or inches just press the unit conversion button.

  • Ideal for large radii: the measuring tool can measure radii up to 10 meters with the highest precision.

Typical applications

  • Measurement of bend radius of bent pipes.

  • Measure of outer diameter of pipes and ducts (even if already positioned or buried).

  • Measure of internal diameter of ribs and large pipes.

  • Measure of radius of curvature of curved sheet metal.

  • Diameter measurement of large tanks or silos, both during the construction of the individual parts and during assembly and positioning.
diacheck instrument for measuring the diameter, angle and radius of curvature of pipes, tanks, ribs, plates.
  • Measurement of the radius of curvature of molded or thermoformed plastic parts.

  • Measurement of the radius of curvature of laminated and curved beams.

  • Shape measurement of stamped details or curved sheet metal intended for the furniture sector.

  • Measurement of glass curvature or artifacts with complex geometric shapes.

  • Verify e comparison of the mathematical model of geometric shapes produced by CNC.

  • Verification of bending of pipes and fittings.
diacheck instrument for measuring the diameter, angle and radius of curvature of pipes, tanks, ribs, plates.
  • Measurement of glass curvature and mating profiles.

  • Measure of the rcurvature of car bodies and sheet metal parts for the automotive sector.

  • Measurement of diameter of ribs for tunnels or for construction.

  • Measurement of the radius of curvature of cement and concrete products.

  • Measurement of the radius of curvature or the diameter of parts intended for the naval sector or the construction of large structures.

diacheck instrument for measuring the diameter, angle and radius of curvature of pipes, tanks, ribs, plates.
  • Measurement of the bending radius of profiles during processing on profile bending machines, bending machines and forming systems.

  • Measurement of the diameter of pipes and of the coupling taper for the hydrocarbon, water and liquid transport sector.

  • Measurement of the degree of taper of mating flanges for pipes or tanks.

  • Measurement of the diameter or radius of curvature of calendered or welded products.

  • Verify proper fit of parts during mating and sealing.

SB-1000 series LASER micrometers for non-contact diameter and width measurement

Laser micrometers for diameter and width measurement on the production line. The measurement of diameter and width with laser micrometers allows the control of the dimensions of continuous products directly on the production line, without contact and in maximum safety for the operator.

laser micrometer for diameter and ovality measurement on wires, pipes, cables, bars and rods
  • LASER micrometers for diameter measurement and ovalization on cylindrical parts directly in production line or in the metrological laboratory.

  • Measurements of wires, pipes, cables, bars, plugs, extruded and drawn parts.

  • Comparison with tolerance thresholds and alarms for reporting a non-compliant product.

  • Possibility of transmitting the data to an external PLC or to a data acquisition system or to a management system.

  • Applications on drawing, profiling, extrusion, grinding, automatic assembly lines.

SB-1000 series LASER micrometers

laser micrometer for width and edge position measurements of belts and carpets

A wide range of application modes to make high-precision measurements with ease.

The SB-1000 Series consists of a range of high precision intelligent sensors, which guarantee high performance at low cost and are equipped with the most advanced functions for operation on the production line.

The technology and functions developed for high precision measuring instruments ensure high levels of accuracy.

The solid construction of the SB-1000 series devices makes it possible to use them even in harsh environments. Easy to use, they allow you to perform fast and stable measurements.

The newly developed optical system enables high levels of stability and measurement accuracy to be achieved.

Multiple wavelength LASER micrometers

laser micrometer for edge and position measurement on belts and carpets

In traditional lasers, the transmission beam produces a pattern a
accumulation points. This is an interference problem specific to the laser, caused by the fact that it has only one wavelength. Thanks to the use of a multi-wavelength laser, the RDSB series sensor does not exhibit this unwanted behavior. Since the shadow projections that form on the CCD are sharper, the sensor maintains a high level of stability, even with hard-to-detect targets such as transparent objects.

The parallel processing processor DSP, built into the receiver, allows the sensor to process data at high speeds, thus reducing noise and measurement error levels to a minimum.

Typical applications

  • Edge control and position detection in tape, sheet or panel production lines
  • External diameter measurement of wires, pipes, cables, rods, plugs
  • Method of measuring internal diameter or gap in rings or gaskets
  • Distance measurement between the end of the measurement range and the edge of a target in automatic assembly lines
  • Measurement of width or position in extrusions or irregular profiles.
  • Pin height measurement or correct insertion of components in mounting seats.

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Products for this application

DIACHECK measuring instruments for internal diameter measurements

Measuring instruments with LVDT transducers for diameter, ovality, taper and concentricity measurements of internal diameters. Measuring instruments for use on manual, semi-automatic and automatic measuring benches.

  • Custom measuring pads for precision measurements of internal diameters, ovality, taper and concentricity.
  • Multilevel diameter, ovality, concentricity and taper measurement with a single tool and with a single positioning operation.
  • Measurements of bearing seats, cylinder liners, internal diameters of gears, counterbore and driving seats, ground tubes and precision holes.
  • Measurement survey with manual, semi-automatic or fully automatic positioning on robotic production lines.

Measurement of diameter and taper

The measuring instruments for internal diameters allow the measurement in a single operation of internal diameters, ovalizations, tapers and concentricity.

The new range of RODER DIACHECK series measuring pads allow the measurement of internal diameters of cylindrical parts such as bearing seats, precision counterbore, seats for driving gears.

The DIACHECK series of pads is made up of customized mechanics to accommodate a large number of measurement transducers.

This feature allows the creation of measuring instruments with the possibility of measuring a very large number of dimensional and geometric characteristics in a single operation.

With a single measurement operation it is possible to detect:

  • Upper section diameter 0 °
  • Upper section diameter 90 °
  • Ovalization of the diameter in the upper section
  • Bottom section diameter 0 °
  • Bottom section diameter 90 °
  • Ovalization of the diameter in the lower section
  • Taper of the upper section with respect to the lower section
  • Concentricity of the upper section with respect to the lower section

Measurement stations

control station PCL1208 RODER embedded system for quality control

The PCL1208 control station allows data acquisition and display of the control result.

The visualization takes place on a display with built-in touch screen which also allows the programming of control recipes and the management of any interfaces with the production system.

The PCL1208 control station can be easily integrated into Industry 4.0 systems and can be connected to PLC, HMI and SCADA through Profinet, Profibus, Ethercat, Canbus or Ethernet IP interfaces.

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Products for this application

Stroboscopes for speed measurement and preventive maintenance

Stroboscopes for speed measurement and preventive maintenance in the industrial sector. LED stroboscopes for quality control and inspection of moving objects.

High brightness Xeon portable stroboscopes
  • Measurement applications of print speed and quality in the printing industry, directly on the production line, without downtime or slowing down the process.
  • Applications of observation of repetitive movements for the determination of any assembly errors or preventive wear of moving parts.
  • Measurement visualization on easily readable display and controls designed for easy synchronization of the number of flashes per second with the process under observation.
  • Battery powered models for easy and easy transport or with mains power supply for fixed applications on production lines.

Stroboscopes are tools that allow you to observe and studying an object in motion, which can be rotary or oscillatory, as if it were stationary, as well as measure its speed.

The operating principle is based on the observation, in low light conditions, of the object in constant motion, illuminated by very short flashes of high intensity light.

When you observe a perfectly still image of the object in motion, it means that the flashing frequency of the stroboscope coincides with the speed of rotation or of the oscillatory motion. speed measurement itself, without any contact with the moving mechanism

The main element consists of a special xenon or LED lamp capable of emitting up to 5000 flashes per second, or 300000 per minute. This very high frequency value allows you to observe an object that cyclically moves, vibrates or rotates on its axis even at very high frequencies.

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