with Displacement Sensors

Improving
Productivity
 Fundamentally, displacement sensors are used to measure changes in distance,

but this is not their sole purpose. Throughout every industry displacement sensors are used to

increase productivity through quality, tact, and yield improvements.

This document discusses how these improvements are made possible.

What Are Displacement Sensors?

A displacement sensor measures the change in an objects size from a predetermined reference.

Small Near
Small

Large

1D and 2D displacement sensors typically operate on two measurement principles: Laser Triangulation and Trubeam.

1D Laser Triangluation 2D Laser Triangulation 1D/2D Thrubeam

What Are They Used for?

Typical Applications

Height and Height Difference Thickness Outer Diameter Width Meandering

Gap and Clearance Warpage and Flatness Run-Out and Vibration Positioning Angle

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 Inspecting for Loose Bearing Seals Measuring Injector Outer Diameter

Measuring the Outer Diameters of Extrusion Moldings Measuring Sealant Coating Profile

Why Use Them?

Even though they are used for measurement and inspection, the objective of using displacement sensors is not measurement.

We provide a product that optimally meets our customer’s requirements.

1 2 3
Cost Reduction Tact Improvement Quality Improvement

3
 Objectives for Using Displacement Sensors 1

Cost Reduction

Reducing Inspection Man-Hours

Inspecting for Loose Bearing Seals

Conventional Method Visually Inspect All Items

Problem

Inspection took too long. Concern that visual

inspection leads to incorrect detection.

Product Used

LJ-V Series 2D Laser Displacement Sensors

Result

All items are inspected automatically.

The number of inspection man-hours is
reduced and inspection accuracy is improved.

Reducing Maintenance Costs

Measurement of the Outer Diameter of Steel Pipe

Conventional Method Laser Scan Micrometer System for Measuring Outer Diameters

Problem

Since the sensor head contains moving parts regular maintenance is required due to bearing wear
and other factors.

Product Used

LS-9000 Series Thrubeam Optical Micrometers

Result

The LS-9000 Series uses a steady state LED

this greatly reduces the frequency of
maintenance, which in turn, reduces cost.

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 Improving Yields
Measurement of Terminal Dimensions

Conventional Method Electronic Inspection After Unit Assembly

Problem

SInce the parts are inspected after assembly,

time and material is lost on rejected parts.

Product Used

TM-3000 Series Thrubeam 2D Measurement

Systems

Result

Individual parts are inspected prior to assembly,

reducing defective end products.

Reducing Material Costs

Measurement of Noodle Thickness

Conventional Method Sample Inspection Using Vernier Calipers

Problem

Changes in the environment during production and moisture content cause irregularities in noodle
thickness. Vernier calipers were used to measure thickness and adjustments were made to the
equipment. However, it was not possible to control thickness irregularity, leading to losses in material.

Product Used

LK-G5000 Series 1D Laser Displacement Sensors

Result

Inline measurement and equipment control enable

automatic thickness adjustment. Making noodles
a uniform thickness reduces material costs.

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 Objectives for Using Displacement Sensors 2

Tact Improvement

Shortening Inspection Time

Measurement of PCB Warpage

Conventional Method Contact Probes

Problem

This required stopping the target and removing connecting contacts, which took too much time.

Product Used

LK-G5000 Series 1D Laser Displacement Sensors

Result

Laser displacement sensors use non-contact

measurement, so they can measure without
needing to stop the target. This greatly reduces
inspection time.

Measurement of Multiple Points on the Outer Diameter of Processed Goods

Conventional Method Sample Inspection With a Micrometer

Problem

Inspection time would vary greatly depending on

the experience level of the operator. Inspection took
even longer when multiple locations were inspected.

Product Used

TM-3000 Series Thrubeam 2D Measurement

Systems
Result

Simply placing the target between the sensor

heads allows the system to instantaneously
measure multiple locations.
This greatly reduces inspection time and
eliminates human error.

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 Reducing Tooling Change Time
Measurement of Multiple Points on the Outer Diameters of Injectors

Conventional Method Camera

Problem

Re-tooling took time because the camera and

lighting had to be adjusted each time a product
was changed.

Product Used

TM-3000 Series Thrubeam 2D Measurement

Systems

Result

Since the TM is a pre-calibrated measurement

system, adjustments do not need to be made
when switching from one part to another.

Height Measurement of Terminals in Electrical Components

Conventional Method 1D Laser Displacement Sensor

Problem

As measurements were taken at a single point, any deviation in the targets position caused the
measurement location to be moved as well. Because of this problem, time was required for position
adjustment.

Product Used

LJ-V Series 2D Laser Displacement Sensors

Result

Since this is a line laser, thanks to an automatic

correction function there is no need to worry about the
measured location being displaced, even if the position
of the target changes. This improves work efficiency by
eliminating the need for severe position adjustment.

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 Objectives for Using Displacement Sensors 3

Quality Improvement

Device Control Improves Quality

Thickness Measurement for Film Coating Process

Conventional Method Using a Microscope Offline

Problem

Device control could not be used as automatic

measurement was not possible.

Product Used

SI-F Series1D Laser Displacement Sensors

Result

Quality is improved by enabling real-time

measurement of film thickness and feeding
back measured values to the device to
optimally control output flow and pressure, as
well as transport rate.

Gap Measurement When Welding

Conventional Method Operator Aligns Materials Prior to Welding

Problem

Target position displacement could cause

defective welds.

Product Used

LJ-V Series 2D Laser Displacement Sensors

Result

Weld accuracy is improved by measuring the

distance to the target and its profile in real time,
and by feeding this data back to the welder.

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 Inspection of All Items Strengthens Product Assurance
Measurement of the Outer Diameter of Fine Lines

Conventional Method Sample Inspection With a Micrometer

Problem

Not inspecting all items leads to the possibility

of defective products getting through.

Product Used

LS-9000 Series Thrubeam Optical Micrometer

Result

Simply installing in the equipment enables inspection of

all items. The inspection system is enhanced by outputting
a signal if thickness tolerance is exceeded, making it
possible to quickly respond to sudden equipment errors.

Eliminating the Problem of Damage Caused by Contact

Measurement of Brake Disk Run-Out

Conventional Method Dial Gauge

Problem

There was concern that contact with the target

could cause damage.

Product Used

LK-G5000 Series 1D Laser Displacement Sensors

Result

There is no concern about damaging the product,

as run-out is inspected without contact. Inspection
can be performed in an environment close to
actual usage conditions, as measurement can be
carried out even at high rotation speeds.

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 Lastly, we would like to introduce the latest measurement and inspection method.
The issue of detection difficulty is increasing along with the emergence of high-precision products and stricter accuracy requirements.

Inline 3D Measurement Image Processing System

Image processing using 3D measurement data has been made possible by capturing profile
data obtained from LJ-V Series 2D laser displacement sensors in an image processing system.

LJ-V Series Image Processing System

3D Data Image Processing Results

Profile data is captured in an image processing system. The image processing system converts
height data into an image with 256 shades of intensity, enabling many types of processing.

Image processing of height data expands the range of inspection content, with applications
ranging from highly accurate measurements using tilt correction, and measurements of
volume or average height difference, to using profile data for appearance inspections including
comparison with a master profile or inspection for scratches and dents.

Before Correction After Correction

Automatic Correction, Even if the Target Is Tilted Volume Measurement

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 Development of 3D Measurement and Inspection
Has Made Improvement “Possible”

Success Stories of Conversion to 3D

Inspection for Indentations On a Curved Surface

Conventional Method 2D Laser Displacement Sensor

Problem
The curved surface made it impossible
to properly detect indentations by height
difference.

Product Used

LJ-V Series 2D Laser Displacement Sensors

+ Image Processing System

Result

Inspection accuracy is significantly improved by

extracting only those points that deviate (such
as indentations) from curve data.

Character Recognition (OCR) on a Casting

Conventional Method Camera

Problem

Light adjustment was difficult when the surface

of a casting or other target was rough or
coloration was not uniform.

Product Used

LJ-V Series 2D Laser Displacement Sensors

+ Image Processing System

Result Image After Extracting Height

(Based on Free Curved Surface)
Height Image + OCR
The amount of time required for adjustment has
been reduced, as inspection using profile data
has made it possible to eliminate such effects
as color irregularity and surface roughness.

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 Displacement Sensor and Dimension
Measurement System Lineup
1. Reflective Model Measurement Systems 2. Thrubeam Model Measurement Systems

1. Reflective Model Measurement Systems

LK-G Series LT-9000 Series
Ultra High-Speed/ Double-Scan
High-Precision Laser High-Precision Laser
Displacement Sensor Measurement Systems

High Speed High Precision

Wide Range Double-Scan

12 Head Connections Film Thickness

SI Series LJ-V Series

Micro Head Model Ultra High-Speed, Inline
Spectral Interference Profile Measurement
Laser Displacement Systems
Sensors 2D 3D
Small Size Ultra High-Speed

Zero Heat Generation Multi-Point

2. Thrubeam Model Measurement Systems

LS-9000 Series TM Series
High-Speed/High-Precision High-Speed 2D Optical
Digital Dimension Micrometers
Measurement Systems
2D
New Method
Multi-Point Measurement
High Precision

Long Service Life

Ultra High-Speed

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Copyright (c) 2016 KEYENCE CORPORATION. All rights reserved. MeasureProductivityUP-KA-TG-US 1116-1 611D68