with Displacement Sensors
Improving
Productivity
Fundamentally, displacement sensors are used to measure changes in distance,
but this is not their sole purpose. Throughout every industry displacement sensors are used to
increase productivity through quality, tact, and yield improvements.
This document discusses how these improvements are made possible.
What Are Displacement Sensors?
A displacement sensor measures the change in an objects size from a predetermined reference.
Small Near
Small
Large
1D and 2D displacement sensors typically operate on two measurement principles: Laser Triangulation and Trubeam.
1D Laser Triangluation 2D Laser Triangulation 1D/2D Thrubeam
What Are They Used for?
Typical Applications
Height and Height Difference Thickness Outer Diameter Width Meandering
Gap and Clearance Warpage and Flatness Run-Out and Vibration Positioning Angle
2
Inspecting for Loose Bearing Seals Measuring Injector Outer Diameter
Measuring the Outer Diameters of Extrusion Moldings Measuring Sealant Coating Profile
Why Use Them?
Even though they are used for measurement and inspection, the objective of using displacement sensors is not measurement.
We provide a product that optimally meets our customer’s requirements.
1 2 3
Cost Reduction Tact Improvement Quality Improvement
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Objectives for Using Displacement Sensors 1
Cost Reduction
Reducing Inspection Man-Hours
Inspecting for Loose Bearing Seals
Conventional Method Visually Inspect All Items
Problem
Inspection took too long. Concern that visual
inspection leads to incorrect detection.
Product Used
LJ-V Series 2D Laser Displacement Sensors
Result
All items are inspected automatically.
The number of inspection man-hours is
reduced and inspection accuracy is improved.
Reducing Maintenance Costs
Measurement of the Outer Diameter of Steel Pipe
Conventional Method Laser Scan Micrometer System for Measuring Outer Diameters
Problem
Since the sensor head contains moving parts regular maintenance is required due to bearing wear
and other factors.
Product Used
LS-9000 Series Thrubeam Optical Micrometers
Result
The LS-9000 Series uses a steady state LED
this greatly reduces the frequency of
maintenance, which in turn, reduces cost.
4
Improving Yields
Measurement of Terminal Dimensions
Conventional Method Electronic Inspection After Unit Assembly
Problem
SInce the parts are inspected after assembly,
time and material is lost on rejected parts.
Product Used
TM-3000 Series Thrubeam 2D Measurement
Systems
Result
Individual parts are inspected prior to assembly,
reducing defective end products.
Reducing Material Costs
Measurement of Noodle Thickness
Conventional Method Sample Inspection Using Vernier Calipers
Problem
Changes in the environment during production and moisture content cause irregularities in noodle
thickness. Vernier calipers were used to measure thickness and adjustments were made to the
equipment. However, it was not possible to control thickness irregularity, leading to losses in material.
Product Used
LK-G5000 Series 1D Laser Displacement Sensors
Result
Inline measurement and equipment control enable
automatic thickness adjustment. Making noodles
a uniform thickness reduces material costs.
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Objectives for Using Displacement Sensors 2
Tact Improvement
Shortening Inspection Time
Measurement of PCB Warpage
Conventional Method Contact Probes
Problem
This required stopping the target and removing connecting contacts, which took too much time.
Product Used
LK-G5000 Series 1D Laser Displacement Sensors
Result
Laser displacement sensors use non-contact
measurement, so they can measure without
needing to stop the target. This greatly reduces
inspection time.
Measurement of Multiple Points on the Outer Diameter of Processed Goods
Conventional Method Sample Inspection With a Micrometer
Problem
Inspection time would vary greatly depending on
the experience level of the operator. Inspection took
even longer when multiple locations were inspected.
Product Used
TM-3000 Series Thrubeam 2D Measurement
Systems
Result
Simply placing the target between the sensor
heads allows the system to instantaneously
measure multiple locations.
This greatly reduces inspection time and
eliminates human error.
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Reducing Tooling Change Time
Measurement of Multiple Points on the Outer Diameters of Injectors
Conventional Method Camera
Problem
Re-tooling took time because the camera and
lighting had to be adjusted each time a product
was changed.
Product Used
TM-3000 Series Thrubeam 2D Measurement
Systems
Result
Since the TM is a pre-calibrated measurement
system, adjustments do not need to be made
when switching from one part to another.
Height Measurement of Terminals in Electrical Components
Conventional Method 1D Laser Displacement Sensor
Problem
As measurements were taken at a single point, any deviation in the targets position caused the
measurement location to be moved as well. Because of this problem, time was required for position
adjustment.
Product Used
LJ-V Series 2D Laser Displacement Sensors
Result
Since this is a line laser, thanks to an automatic
correction function there is no need to worry about the
measured location being displaced, even if the position
of the target changes. This improves work efficiency by
eliminating the need for severe position adjustment.
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Objectives for Using Displacement Sensors 3
Quality Improvement
Device Control Improves Quality
Thickness Measurement for Film Coating Process
Conventional Method Using a Microscope Offline
Problem
Device control could not be used as automatic
measurement was not possible.
Product Used
SI-F Series1D Laser Displacement Sensors
Result
Quality is improved by enabling real-time
measurement of film thickness and feeding
back measured values to the device to
optimally control output flow and pressure, as
well as transport rate.
Gap Measurement When Welding
Conventional Method Operator Aligns Materials Prior to Welding
Problem
Target position displacement could cause
defective welds.
Product Used
LJ-V Series 2D Laser Displacement Sensors
Result
Weld accuracy is improved by measuring the
distance to the target and its profile in real time,
and by feeding this data back to the welder.
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Inspection of All Items Strengthens Product Assurance
Measurement of the Outer Diameter of Fine Lines
Conventional Method Sample Inspection With a Micrometer
Problem
Not inspecting all items leads to the possibility
of defective products getting through.
Product Used
LS-9000 Series Thrubeam Optical Micrometer
Result
Simply installing in the equipment enables inspection of
all items. The inspection system is enhanced by outputting
a signal if thickness tolerance is exceeded, making it
possible to quickly respond to sudden equipment errors.
Eliminating the Problem of Damage Caused by Contact
Measurement of Brake Disk Run-Out
Conventional Method Dial Gauge
Problem
There was concern that contact with the target
could cause damage.
Product Used
LK-G5000 Series 1D Laser Displacement Sensors
Result
There is no concern about damaging the product,
as run-out is inspected without contact. Inspection
can be performed in an environment close to
actual usage conditions, as measurement can be
carried out even at high rotation speeds.
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Lastly, we would like to introduce the latest measurement and inspection method.
The issue of detection difficulty is increasing along with the emergence of high-precision products and stricter accuracy requirements.
Inline 3D Measurement Image Processing System
Image processing using 3D measurement data has been made possible by capturing profile
data obtained from LJ-V Series 2D laser displacement sensors in an image processing system.
LJ-V Series Image Processing System
3D Data Image Processing Results
Profile data is captured in an image processing system. The image processing system converts
height data into an image with 256 shades of intensity, enabling many types of processing.
Image processing of height data expands the range of inspection content, with applications
ranging from highly accurate measurements using tilt correction, and measurements of
volume or average height difference, to using profile data for appearance inspections including
comparison with a master profile or inspection for scratches and dents.
Before Correction After Correction
Automatic Correction, Even if the Target Is Tilted Volume Measurement
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Development of 3D Measurement and Inspection
Has Made Improvement “Possible”
Success Stories of Conversion to 3D
Inspection for Indentations On a Curved Surface
Conventional Method 2D Laser Displacement Sensor
Problem
The curved surface made it impossible
to properly detect indentations by height
difference.
Product Used
LJ-V Series 2D Laser Displacement Sensors
+ Image Processing System
Result
Inspection accuracy is significantly improved by
extracting only those points that deviate (such
as indentations) from curve data.
Character Recognition (OCR) on a Casting
Conventional Method Camera
Problem
Light adjustment was difficult when the surface
of a casting or other target was rough or
coloration was not uniform.
Product Used
LJ-V Series 2D Laser Displacement Sensors
+ Image Processing System
Result Image After Extracting Height
(Based on Free Curved Surface)
Height Image + OCR
The amount of time required for adjustment has
been reduced, as inspection using profile data
has made it possible to eliminate such effects
as color irregularity and surface roughness.
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Displacement Sensor and Dimension
Measurement System Lineup
1. Reflective Model Measurement Systems 2. Thrubeam Model Measurement Systems
1. Reflective Model Measurement Systems
LK-G Series LT-9000 Series
Ultra High-Speed/ Double-Scan
High-Precision Laser High-Precision Laser
Displacement Sensor Measurement Systems
High Speed High Precision
Wide Range Double-Scan
12 Head Connections Film Thickness
SI Series LJ-V Series
Micro Head Model Ultra High-Speed, Inline
Spectral Interference Profile Measurement
Laser Displacement Systems
Sensors 2D 3D
Small Size Ultra High-Speed
Zero Heat Generation Multi-Point
2. Thrubeam Model Measurement Systems
LS-9000 Series TM Series
High-Speed/High-Precision High-Speed 2D Optical
Digital Dimension Micrometers
Measurement Systems
2D
New Method
Multi-Point Measurement
High Precision
Long Service Life
Ultra High-Speed
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Copyright (c) 2016 KEYENCE CORPORATION. All rights reserved. MeasureProductivityUP-KA-TG-US 1116-1 611D68
