Using Zebra 3D for Superior Visual Inspection and Measurement

Performing precise and complex visual inspections and measurements can be challenging, even with 2D machine vision technology. This is especially when the objects you need to inspect and measure are moving on conveyors. Intricate details, surfaces, lighting conditions, contrast, reflections, hot spots and other issues can also make capturing the right details and dimensions in 2D difficult.

This is where 3D laser imaging, scanning and sensing offer a huge advantage. These methods allow you to capture hi-res 3D images, point clouds and measurements that reveal all the features, details and precise dimensions of target objects, whether static or moving. You can also handle poor lighting, reflective or opaque surfaces, low contrast and other factors that would otherwise make the job harder or impossible.

Let’s review three 3D solutions that enable superior visual inspection and measurement, even in the most challenging conditions. You can capture incredibly accurate and detailed maps, color point clouds, and measurements of virtually any object.

Zebra’s AltiZ 3D Laser Profiler

One of the best solutions for 3D imaging is Zebra’s AltiZ 3D laser profiler. This device uses laser triangulation and dual cameras to capture highly detailed 3D surface maps of objects from multiple perspectives. It’s used for visual inspection and dimensioning in many applications in manufacturing, packaging and robotics, including inspecting and measuring objects moving on high-speed conveyors.

With the AltiZ 3D laser profiler, you can detect and capture a target object’s intricate and hidden details and features and precisely measure length, width, height and volume. You can also capture and analyze characteristics such as color, texture, position, and presence or absence.

The profiler’s single-laser, dual-camera system creates detailed surface maps, profiles, point clouds and depth maps, capturing all these features to automatically identify defects, contaminants, irregularities and inconsistencies. It captures 1,984 points per profile at a blazingly fast rate of 11,000 profiles per second.

It also performs high-speed measurements with exact and reliable results, making it a great alternative to 2D and weight-based systems. Those options often can’t detect issues or measure volume and dimensions accurately when objects are moving, or lighting and other conditions aren’t ideal.

AltiZ3D laser profilers are easy to connect and configure with Power over Ethernet (PoE) support, GigE Vision interface, M12 connectors and Zebra Aurora software. There is also an optional 4Sight vision controller, ideal for setting up and working with multiple devices.

For additional details and specs on the AltiZ 3D laser profiler, you can download our spec sheet.

Zebra’s AltiZ 4200 3D Profiler

The Zebra AltiZ 4200 3D profiler is a more compact and higher-resolution profiler for tight fields of view, tight spaces,and ultra-high resolution. It captures over 4,200 points per profile and 14,000 profiles per second, for a total high-speed capture capacity of 42 million points per second.

Its faster capture speeds and ultra-high-resolution profiling are ideal for inspecting and measuring electronics, circuit boards, EV and automotive components, and other parts, assemblies and products that require ultra-fine detail and tight fields of view.

To learn more and see detailed specs on the AltiZ 4200, download our spec sheet as a quick reference.

Zebra’s 3S Series 3D Scanners

When you need the highest-resolution 3D imaging for high-speed inspection and dimensioning of dynamic or static scenes, Zebra’s 3S Series 3D scanners are another great option.

With the 3S80 scanner, you can capture 2 million 3D points at 1680 x 1200 resolution in just 45 milliseconds for objects on the move or at rest. With the 3S40, which is designed for static scenes, you can capture 1.5 million data points at 1440 x 1080 resolution in a 450-millisecond scan.

These devices achieve this extremely hi-res 3D point cloud and data capture with Zebra’s patented parallel structured-light technology and ambient light suppression. They eliminate motion blur and capture extremely precise details, even in bad lighting or low contrast, or when the surfaces or characteristics of objects are opaque, reflective or otherwise extremely challenging.

3S80 sensors have an extended dynamic scanning range of up to 9.8 feet (3 meters). For larger items and volumes, a 3S80-4L model captures hi-res point clouds in areas up to 3.4 x 2.7 feet (1,027 x 836 mm) at its ideal scanning range.

The 3S40 sensor scans objects up to 6.56 feet (2 meters) away, with fields of view ranging from 28.5 x 20.8 inches (723 x 530 mm) to 5.3 x 4.3 feet (1,626 x 1,312 mm).

Similar to Zebra’s AltiZ laser profilers, these devices are extremely easy to connect and use. They offer PoE and GigE Vision support, but you can also use a 24V power cable for power instead. Zebra’s Aurora software includes advanced image libraries and deep-learning AI to help you set up your inspections and measurements faster and more easily. You can also use Zebra’s 4Sight Vision EV7 controller to connect and manage multiple scanners.

To check out Zebra’s 3S Series 3D scanners in more detail, download our quick-reference spec sheet.

Learning More About 3D Inspection and Measurement

To learn more, feel free to connect with our experts at Motion Automation Intelligence. As your one-stop shop for automation products, solutions and engineering, we’re always glad to answer questions, provide recommendations and products, and help you evaluate the latest vision technologies to meet your needs. To get started or request a quote, contact us now.