Micro-Epsilon launches next-generation 4K laser scanners with breakthrough Green Laser Technology

The new 4K sensor matrix redefines what is possible in inline measurement with up to 4,224 points per profile. Line point resolution is down to 6 µm and a z-axis linearity of
< 0.8 µm (0.005%) enables even the finest structures to be captured with outstanding clarity, while maintaining high-speed performance across varying surfaces and lighting conditions.

With a 10 kHz profile frequency and 25 million points per second, the scanCONTROL LLT8500 offers the highest measuring rate in its class.

A clear leap forward: Green Laser Technology

The introduction of 520 nm green laser technology represents a significant performance leap over traditional red and blue laser solutions.

Operating close to the peak quantum efficiency of the receiver, the green laser delivers:

• Exceptionally stable signals with minimal noise
• Superior performance on challenging surfaces such as shiny metals, PCBs, and organic/translucent materials
• Shorter exposure times for faster measurement cycles
• Increased repeatability and process reliability

The result is consistently accurate measurement in applications where conventional laser technologies struggle, dramatically expanding the range of viable inspection tasks.

The LLT8x00 series can operate as a standalone SMART 3D sensor with onboard evaluation or as a high-speed 3D data source for external processing.

For onboard SMART 3D evaluation, Micro-Epsilon’s 3DInspect software tool allows users to configure measurement programs, analyse point clouds, and extract features directly within the sensor environment. Alternatively, calibrated point cloud data can be exported for processing using the customer’s own image processing software or existing vision processing tools.

Precise real-time 3D scans for maximum process reliability

3D laser scanners from Micro-Epsilon capture surfaces, geometries and height differences with extremely high precision, even during rapid movements. As a result, they outperform conventional image processing technologies and ensure maximum process reliability in challenging industrial applications. Here are some typical applications:

Pin inspection on connectors

In the automated production of cable harnesses and connectors, precise positioning and completeness of the pins are critical quality factors. Even slightly bent, missing or misaligned pins can cause contact issues and system failures. The scanCONTROL sensors scan the connector surface and generate a highly accurate height or profile image of the entire pin row. The number, position and flatness of the pins are reliably checked – quickly, consistently and with high resolution. Inspection is fully integrated into the production process without interrupting the flow of materials.

Presence detection and flatness inspection on PCBs

To ensure reliable assembly and further processing of printed circuit boards, it is essential to verify the presence and flatness of the components. Minor height deviations can cause soldering defects, contact issues or mechanical stress. Their exceptionally high z-resolution enables scanCONTROL sensors to detect even the smallest differences in height. This allows for the precise measurement of presence, height profiles and coplanarity, even in very small structures. The measuring programs are stored directly on the scanner and transmitted to the PLC.

Precise 3D geometric inspection of cylindrical battery cells

In the production of cylindrical cells, precise positioning and alignment of the individual cells are critical to quality and safety. Cells that are installed at an angle or positioned too low or too high carry the risk of short circuits, poor electrical contact or mechanical damage during the rest of the manufacturing process. The scanCONTROL LLT8x00 sensors capture the cell geometry in high resolution and verify both the correct alignment and the exact installation height of each individual cell. This ensures that all cell tops fall within production tolerances.

Inspection of the mesh structure of stents

Quality control for stents demands the highest standards of precision and reliability. Even the smallest defects in the mesh can compromise the implant’s function and safety. The scanCONTROL 8x00 sensors enable high resolution, inline inspection directly within the manufacturing process. They detect the intricate mesh structure, defects, geometrical deviations, deformations and surface irregularities. Defective stents are detected early and removed before they enter downstream processes.

Inline inspection of adhesive beads

In modern manufacturing processes, particularly in the automotive, packaging and electronics industries, the application of adhesives is a critical quality factor. The scanCONTROL 8x00 laser scanners are used for precise monitoring of the adhesive application. The compact scanners are mounted in a fixed position or directly on the robot and measure the height, width and position of the bead. This allows for immediate quality control and enhances process reliability.

Optimum cooling for high ambient temperatures

All scanCONTROL 8x00 models can be equipped with additional heat sinks. Options include passive heat sinks, active heat sinks with fans, or a connection to the customer’s own cooling solutions. This means the sensors can be used reliably even in challenging production environments such as in steel manufacturing or welding applications.

Automatic weld seam inspection

The scanCONTROL scanners are used in the welding process to continuously monitor the weld seam in real time. The sensor detects the seam geometry and generates a height or cross-sectional profile. The results are immediately fed back to the process control system, enabling corrections to be made during the process or defective welds to be detected early on.

For more information on the scanCONTROL LLT8x00 series, please visit scanCONTROL 8500 | Micro-Epsilon or call the Micro-Epsilon sales department on +44 (0)151 355 6070 or email info@~@micro-epsilon.co.uk