Especially when inspecting complex components such as battery cells, maximum precision is a must in order to prevent safety risks such as short-circuits and overheating. This is where senswork comes in. ZScan® Easy, the company’s innovative 3D measurement system, is taking quality assurance to a whole new level – and flexible profile technology from item plays a key role in this product innovation.
In modern industrial production, precise and flexible measurement systems have long since gone from being an optional extra to an absolute must. From the automotive industry to electronics production, companies are facing ever-increasing demands relating to quality assurance and process reliability. This isn’t just a question of efficiency – the ability to adapt quickly to new requirements is vital, too.
A customised 3D measurement system
Since it was founded in 2011, senswork GmbH has established itself as a leading supplier of industrial image processing solutions and optical measurement systems. With sites in Burghausen and Munich in Germany, as well as branches in the USA, China and Singapore, the company supports a large number of well-known customers from the automotive, medical technology and electronics sectors, amongst others.
The ZScan® Easy 3D measurement system developed by the optical image processing specialist is a smart solution to the challenges of modern production. The system’s fast and precise inline measurement of components such as battery cells incorporates reliable quality assurance directly into the production line. What makes ZScan® Easy so special is its modularity – a feature that is made possible by our Line XMS profiles.
Design and operating principles of the ZScan® Easy measurement cell
The ZScan® Easy 3D measurement system is a perfect example of modular engineering. Its machine cabin has been designed to ensure flexible integration into different production lines. This cabin offers optimum protection against external influences, such as dust or changing light conditions during imaging. The top part is the process section, which is equipped with surface scanners that can perform a precise three-dimensional scan of components such as battery cells, without any shadowing. With up to eight scanners in each system, large components can be scanned in just a few seconds and analysed using up to 12 million measurement points. The top part of the cabin has two swing doors made of acrylic glass that provide easy access for positioning the components to be inspected. Our Line XMS Door Profiles play an important role in this context, ensuring the doors combine stability and secure closing with a slender and robust design.
The ZScan® Easy 3D measurement system is a perfect example of modular engineering – for flexible integration into different production lines.
The bottom part of the cabin is the supply section, which accommodates the technical equipment and cabling. It, too, has doors for access purposes. A Pivot Arm assembly with a monitor that displays the measurement values is attached at the side and benefits from intuitive operation. The integrated 3D surface scanners can scan components measuring up to 2.0 m x 2.0 m x 1.5 m. In just a few seconds, these scanners generate a high-resolution 3D image that is transferred directly to the production line. The resulting instant quality assurance is a key advantage, especially when expensive components such as lithium-ion batteries are being manufactured.
Innovative technology – the benefits of Line XMS profiles
Thanks to their smooth surfaces and integrated cable conduits, our profiles combine good looks with clear functional benefits. They keep cabling neat, tidy and clean, ensure good stability and offer the possibility of directly incorporating operating elements such as pushbuttons. senswork regarded these aspects as crucial for developing a customisable system that meets the highest quality standards. Our modular components ensure the machine cabin can be designed with outstanding flexibility and tailored perfectly to a variety of production environments. One big plus point of our Line XMS profiles is integrated cable routing. Besides looking neat and tidy, this also reduces the amount of installation work required. Practical Cover Profiles reliably cover and therefore protect the cables. The profiles’ smooth, unbroken surfaces are easy to clean, and they also prevent unwanted accumulations of dust and particles.
Technical details – Ball Joints and LED signalling technology
Another highlight are the Ball Joints being used, which provide flexibility by making it possible to point the scanners in different directions. A simple Clamp Lever ensures the desired angle can be set with speed and precision – a key advantage when it comes to optimum scanner positioning and accurate measurements.
The colours and flashing patterns of the LEDs can be customised using the IO-Link Controller.
What’s more, our LED signalling technology makes the system more user-friendly by providing a clear indication of how the relevant process is progressing. LED Strips that can be integrated into the profile groove are able to light up either in sections or along their full length, meaning the status of the measurement cell is immediately apparent. The colours and flashing patterns of the LEDs can be customised using the IO-Link Controller, offering visual assistance when monitoring and controlling processes. These ingenious solutions don’t just make the ZScan® Easy 3D measurement system a technically innovative solution, but also an efficient and user-friendly one.
The success factor of teamwork – our collaboration with senswork
The cooperation between item and senswork demonstrates just how productive and efficient partnership-based collaboration can be. The company has been putting its trust in our components since 2021 – and with good reason. Our short lines of communication and close coordination make for quick and focused project implementation. Thanks to our reliable logistics – a further plus point – all the necessary components are supplied promptly. This is a real advantage in times when flexibility in production is becoming increasingly important.
Short lines of communication and close coordination make for quick and focused project implementation.
Daniel Müller, who is in charge of design engineering at senswork, emphasises that collaboration is really straightforward. “The sheer variety and quality of item products makes our work a whole lot easier. We can make changes independently and have access to a wide-ranging portfolio that keeps offering us new possibilities,” he explains. This excellent flexibility was a key factor when designing ZScan® Easy. It is also the starting point for implementing further, future-focused projects using AI for image processing and image analysis at the company’s Innovation Lab in Munich. This demonstrates that our modular system ensures excellent efficiency and creates the basis for advanced solutions.
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