2D/3D profile sensors, Angle measurement, Load securing

Precision in load securing: Automated angle measurement for edge protection profiles

Effective edge protection is the backbone of load securing. It stabilizes pallets and prevents strapping bands from cutting into cardboard boxes. However, quality depends on the accuracy of the angle. Whether paper or metal: if the internal angle deviates too much from the required 90°, the fit suffers. On the other hand, if the outer angle is too large, it increases the circumference of the load and unnecessarily increases material consumption during wrapping.

The challenge: Manual sampling vs. process reliability

Until now, many manufacturers have relied on manual measurements. However, with required tolerances of +/- 3°, this is time-consuming and prone to errors. An automated solution not only ensures quality, but also pays for itself in a very short time thanks to minimized waste and optimized material usage.

A technical 2D schematic drawing in shades of blue. On the left is a 90° angle that fits perfectly on the piece goods. On the right is an angle whose outer angle is too small, causing the packaging to be non-flush and the circumference to be artificially enlarged. — Precision counts: While the 90° angle (left) offers optimum protection, an external angle that is too small (right) leads to increased material consumption. The numbering shows the angular edge protector (1), the packaging (2) and the piece goods (3).

The technical implementation: 2D/3D profile sensors

The solution is based on a wenglor 2D/3D profile sensor MLSL in combination with a machine vision controller. The measuring principle follows an efficient workflow:

Detection: The laser profile sensor is mounted above the production line and scans the profile as it passes through.
Algorithm: The “Measure” module is defined in the uniVision software. Two virtual measuring lines record the edges of the edge protector.
Calculation: The “Add intersection point” tool determines the actual angle value from these lines.
Control: If the deviation exceeds the defined tolerance, the system visualizes the error value in red and sends a pulse to the PLC to immediately eject the faulty part from the process.