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In-Sight Laser Profiler

The In-Sight laser profiler is a measurement system used to verify dimensionality for gauging, inspection, and ID applications. The In-Sight laser profiler is configured using the In-Sight EasyBuilder user interface. This intuitive, easy-to-use software makes it simple for manufacturing and quality engineers to develop, deploy, and support accurate and reliable measurements on the factory floor.

In-Sight Laser Profiler Features

The In-Sight laser profiler is a measurement system used to verify dimensionality for gauging, inspection, and ID applications. The In-Sight laser profiler is configured using the In-Sight EasyBuilder user interface. This intuitive, easy-to-use software makes it simple for manufacturing and quality engineers to develop, deploy, and support accurate and reliable measurements on the factory floor.

 

Set up and deploy in 4 easy steps

  1. Acquire Profile—With a click of a button, profile optimization technology renders the most accurate outline of your part.
  2. Locate Object—Sophisticated object detection technology minimizes the need for costly fixturing and ensures measurements are performed in the correct location.
  3. Measure—Flexible In-Sight laser profiler toolset extracts features, constructs reference points, counts key features, and verifies whether a product has been manufactured within tolerance.
  4. Communicate Results—Measurements are sent to a PLC or an overall pass/fail is sent directly to a discrete output. Profiles and measurements can be stored on a controller for downstream analysis or quality control logging.

 

Monitor production line activity from anywhere on the factory floor

The In-Sight laser profiler offers mobile, platform-independent visualization for accessing HMIs (human machine interfaces) from anywhere on the network. An HTML-based user interface allows users to monitor production line activity from any laptop, tablet, smart phone or other mobile device.

 

Trusted technology for reliable, repeatable results

The In-Sight laser profiler system combines Cognex displacement sensor heads with the In-Sight VC200 vision controller. Using industry-leading algorithms, the system extracts the profile, performs highly accurate measurements and analyses the results. Advanced vision tools provide an accurate surface location even if the surface has defects.

Supported Cognex DevicesDS1050, DS1101, DS1300, DS925B, DS910B
Job/Program Memory8GB non-volatile flash memory. Unlimited storage via remote network device
Image Processing Memory2GB SDRAM
Cooling SystemFanless design
Inputs8 optically isolated discrete inputs
Outputs16 optically isolated discrete outputs
Camera Ports12 RJ-45 dedicated Ethernet ports for connecting directly to support laser displacement sensor heads, additionally supplying Power over Ethernet5
LAN Port21 RJ-45 Ethernet port, 10/100/1000 BaseT with auto MDIX. IEEE 802.3 TCP/IP Protocol. Dedicated port for connecting to wide area network
USB Ports31 host USB 3.0 port (5 Gb/sec.) and 2 host USB 2.0 ports (480 Mb/sec.) ports for connecting a storage device. USB drives should be formatted with a FAT32 file system
SD Card Slot1 SD card slot for saving images, run time files and results. SD cards should be USH-I or USH-II and formatted with a FAT32 file system
Video Out Port1 locking HDMI port that provides connection to a display device
I/O Terminal Connectors16–26 AWG, solid or stranded wire. Torque 0.25 Nm (2.2 in-lb)
24VDC Power Connector14–18 AWG, solid or stranded wire. Torque 0.6 Nm (5.3 in-lb)
Status LEDsPWR LED, LED 1, LED 2
HousingAluminum, steel sheet metal, injection-molded housing
MountingFour bottom and four backside M4 x 0.7 threaded mounting holes. The vision controller may be optionally mounted using the accessory wall mounting bracket (BKT-WALL-VC200-01) or to a 35×15 mm DIN rail, using the accessory DIN rail mounting bracket (BKT-DIN-VC200-01)
Dimensions178.8 mm (7.04 in) x 142.1 mm (5.59 in) x 75.1 mm (2.96 in)
Weight1.45 kg (3.2 lb)
Current3.5A (maximum)
Voltage24VDC ±10%
Power Consumption84W (maximum)
Operating Temperature40 °C to 45 °C (32 °F to 113 °F)
Storage Temperature-30 °C to 80 °C (-22 °F to 176 °F)
Humidity10%–85%, non-condensing (Operating and Storage)
Altitude2,000 m (6565 ft)
ProtectionIP30
Shock (Storage and Shipment)30 G, per IEC 60068-2-7EA
Regulatory ComplianceCE, FCC, KCC, TÜV SÜD NRTL, RoHS

 

Notes:

  1. To ensure reliable communication using 1000 BaseT operation, the Ethernet cable must not exceed 100 meters.
  2. To ensure reliable communication using 1000 BaseT operation, the Ethernet cable must not exceed 100 meters.
  3. Maximum USB port speeds are listed. Actual speeds are dependent on the USB device, which are typically lower.
  4. To ensure sufficient ventilation, the vision controller must be mounted with 50 mm of clearance above the vision controller and 50 mm of clearance on both sides. If an adjacent device also produces heat, additional space or cooling is required if air space around the vision controller exceeds 45 °C (113 °F).
  5. DS925B and DS910B heads only.

DS1000 Series Displacement Sensor Head Specifications

 DS1050DS1101DS1300
Dimensions93.3 mm to 115.2 mm (H) x 50 mm (W) x 167.06 mm (L)
Weight700 g
Operating Temperature0ºC to 50ºC (32ºF to 122ºF)
Storage Temperature-10ºC to 60ºC (-14ºF to 140ºF)
Maximum Humidity85% (non-condensing)
HousingIP65 (with Cognex recommended IP65 Ethernet and power I/O cables)
Shock50 gs (11 ms half-Sine pulse)
Vibration8 gs (10-500 Hz for 30 minutes)
DiscreteTrigger input voltage limits: – 24 VDC – +24 VDC Input ON: > 10 VDC (>6mA) Input OFF: < 2 VDC (<1.5 mA)
Encoder Input SpecificationsDifferential: A+/B+: 5-24V (50 kHz max) A-/B-: Inverted (A+/B+) Single -ended: A+/B+: 5-24V (50kHz max) A-/B-: +0VDC=½(A+/B+)
Power SupplyVoltage: +24 VDC (22-26 VDC) Current: 500 mA max
Scan RateUp to 18KHz
SoftwareCognex Designer software
EthernetGigabit Ethernet interface Integrated link and traffic LEDs Standard M12-8 connector
Certificationscertification
AccessoriesEthernet cable: 5m, IP65-rated Power: + I/O + Encoder cable, IP65-rated Mounting bracket Stainless steel enclosure, IP69K-rated for the food industry
VC5 ControllerIntel i5 processor, Precision I/O Real Time Communication, 207 mm (H) 132.6 mm (W) x 229.5 (L)

DS1000 Series Displacement Sensor Head Model Comparison

SpecificationsDS1050DS1101DS1300
Near Field of View (mm)436490
Far Field of View (mm)79162410
Clearance Distance (mm)87135180
Measurement Range (mm)76220725
Laser Class2M2M2M
Resolution X (mm)0.059-0.0900.079-0.1810.101-0.457
Resolution Y (mm)0.004-0.0140.010-0.0520.016-0.265
Linearity±0.16% FS±0.16% FS±0.16% FS

DS1000-FOV

DS900 Series Displacement Sensor Head Specifications

EmptyDS910BDS925B
Dimensions96 mm (H) x 33 mm (W) x 85 mm (L)
Weight380 g
Operating Temperature0ºC to 45ºC (32ºF to 113ºF)
Storage Temperature-20ºC to 70ºC (-4ºF to 158ºF)
Maximum Humidity5-95% (non-condensing)
HousingIP65 (with Cognex recommended IP65 Ethernet and power I/O cables)
Laser Power8mW (class 2M) 405nm wavelength
Encoder Input SpecificationsSingle-ended quadrature encoder. A+/B+ voltage limits: +5 VDC (TTL); +30 VDC (HTL) Input ON: > 2.4 VDC (TTL); > 11 VDC (HTL) Input OFF: < 0.8 VDC (TTL); < 3 VDC (HTL) A-/B-: +0VDC
Power SupplyVoltage: +24 VDC (11-30 VDC) Current: 500 mA max IEEE 802.3af Power over Ethernet
Scan Rate1.39 kHz
SoftwareIn-Sight VC Explorer with EasyBuilder
EthernetGigabit Ethernet interface Standard M12-8 female connector
Certifications 
AccessoriesEthernet cable: 5m, IP65-rated Power: + I/O + Encoder cable, IP65-rated
VC5 ControllerIntel i5 processor Precision I/O Real Time Communication 207 mm (H) 132.6 mm (W) x 229.5 (L)

DS900 Series Displacement Sensor Head Model Comparison

SpecificationsDS910BDS925B
Near Field of View (mm)9.423.4
Far Field of View (mm)10.729.1
Clearance Distance (mm)52.553.5
Measurement Range (mm)825
Laser Class2M2M
Resolution X (mm)0.0073–0.00840.0183–0.0227
Resolution Y (mm)0.0010.002
Linearity±0.16% FS±0.16% FS

DS900-FOV

The In-Sight Laser Profiler performs precise, repeatable measurements for a wide variety of industries.

Automotive

Ideal for a wide range of automotive applications including: inspecting the thickness of clutch plates, measuring the area of weld seams, checking the position of sun roof adhesive and inspecting engine block alignment.

Airbag compartment cover gap measurementAutomotive_Airbag-Dashboard
Bearing inspectionAutomotive_Bearing-Inspection
Brake pad inspectionAutomotive_Brake-Pad
Car seat wrinkle detectionAutomotive_Car-Seat-Wrinkle
Clutch plate inspectionAutomotive_Clutch-plate
Engine block alignment inspectionAutomotive_Pick-Place-Robotics-Alignment
Engine block piston head height inspectionAutomotive_PistonHeight
Flush and gap measurementAutomotive_Flush-Gap
Sunroof adhesive inspectionAutomotive_Sun-Roof-Adhesive
Tire tread profile measurementAutomotive_Tire-Tread
Weld seam inspectionAutomotive_Weld-Inspection

Consumer Products

To ensure adherence to specifications, manufacturers rely on measurements sensors to: identify defects on continuously-formed extrusions, verify correct fiber cable winding and inspect the tongue and grooves on lumber.

Angled sheet metal inspectionConsumer_AngledSheetMetal_withProfile
Dry wall surface defect detectionConsumer_Drywall
Extrusion inspectionConsumer_Extrusion
Fiber cable winding inspectionConsumer_Fiber-Cable
Position and tracking verificationConsumer_Position-Tracking-Webs
Rivet inspectionRivetInspection_withProfile
Surface wrinkle detectionConsumer_Wrinkle-Inspection-Webs
Tongue and groove inspectionIn-Sight-laser-profiler-carousel-6

Electronics

The electronics industry relies on micron-level accuracy when performing inspections on very small components such as: verifying the correct button height, coplanarity of connector pins and inspecting SIM card flushness.

Button height inspectionElectronics_Button-Height
Component verificationElectronics_Components
Coplanarity pin inspectionElectronics_CoplanarityPins
Housing dimension inspectionElectronics_Housing-dimensions
Keyboard flatness measurementElectronics_KeyboardFlatness
Screw insertion depth checkElectronics_ScrewInsertion_withCloseup
SIMM tray flushness inspectionElectronics_SIMMTrayFlushness_withCloseup
Substrate in pocket inspectionElectronics_SOOP_Substrate
Terminal height measurementElectronics_Terminal-Height
Terminal height measurementElectronics_MobileCutoutDepth

Food and Beverage

Ensuring consumer safety and quality is important in the food and beverage industry. Laser profilers measure food items to prevent undercooking, verify the proper placement of caps and ensure packaging seals are intact.

Food portioning verificationFoodBev_CheesePortioning
Food uniformity inspectionHotDog_withProfile
Injection molded cup inspectionFoodBev_K-CupInspection
Package seal inspectionFoodBev_PackageSeal