How can the total height of an axle journal be reliably measured if the surface is uneven due to the casting process?
This question arises in many manufacturing processes, especially before axle pins are assembled or further processed. High-precision height measurement is crucial for the quality of the subsequent assembly.
In the past, this measurement task was often solved with 1D laser point sensors. A single laser point scans the surface of the component and provides a height value. However, this process quickly reaches its limits with unmachined castings: The rough and uneven surface means that the laser point hits different measuring points – which can lead to measurement deviations and unstable results.
A robust solution is the use of a 2D/3D profile sensor MLSL123 in Smart mode. Instead of detecting just a single point, the sensor projects a laser line across the component and simultaneously measures a large number of points along that line. This captures the entire surface of the axle journal.
The component is positioned under the sensor so that the laser line runs centrally over the journal. In this way, a complete height profile of the component is created. The decisive advantage: The measurement is not based on a single point, but on many measured values along the surface.
The evaluation is carried out directly on the sensor with the uniVision software. The “Measure” module is used here. Two measurement lines are defined for altitude determination:
These two lines are selected via the measurement function. The sensor then automatically calculates the total height of the axle journal and transmits the measured value directly to the higher-level controller.
A major advantage of profile measurement is the averaging of the measuring points along the surface. The natural unevenness of the casting structure is taken into account so that individual outliers do not falsify the result.
In this way, a measuring accuracy of up to 0.1 mm can be achieved – even with untreated castings.
The height measurement of axle pins clearly shows how important it is to choose the right sensor technology. While point-based measurement methods reach their limits for rough surfaces, profile measurement enables stable and precise recording of component height.
The combination of a 2D/3D profile sensor MLSL123 in smart mode, integrated uniVision evaluation and direct communication with the control system creates a reliable solution for quality control in production.
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