Automating Hi-Res Dimensioning and Inspection with Zebra 3D Sensors

For manufacturing and logistics, the ongoing challenge is to optimize productivity, efficiency, and throughput without sacrificing high quality.

Every product needs to meet specific quality standards, which often requires measurement or inspection, but this crucial quality assurance must happen with maximum speed and efficiency, so the flow of production or logistics isn’t negatively impacted.

That can be a huge challenge, especially when you need to inspect, measure, and sort thousands of items and ensure that each product precisely meets the required specifications. It gets even more difficult when those items are on the move on conveyors and on production lines.

To address these demands, 3D imaging technology has become an essential tool. It enables fast, precise, and accurate 3D scanning and measurement of virtually any target object, whether at rest or on the move. It can capture and analyze extremely hi-res images, even in challenging industrial conditions such as poor or uneven lighting, low contrast, or when objects have reflective surfaces or other issues that can make it more difficult to perform precise measurement and inspection.

Some great examples of this technology are Zebra’s 3D sensors for hi-res dimensioning and visual inspection. Zebra’s advanced 3D sensor technology was developed to meet real-world requirements for high-speed, static, and dynamic measurement and inspection while overcoming the traditional limitations of 2D machine vision.

Zebra’s latest 3D sensors can capture up to 2 million 3D points (1680 x 1200) from a single object in as little as 45 milliseconds, even if the object is in motion. This innovation allows for ultra-detailed point clouds, enabling per-pixel measurement, high-speed inspection, and automated depalletization with unmatched accuracy and efficiency.

Zebra’s sensor lineup includes solutions for both stationary and high-speed dynamic applications, with two main product families specifically designed for distinct use cases. Here’s a quick overview of each family of devices, its capabilities, and potential applications.

Zebra 3S40 3D Sensors for Stationary Scanning

Zebra’s 3S40 sensors are optimized for static applications, providing high-speed, large-volume 3D scanning. With the ability to capture 1.5 million points (1440 x 1080) in a 450-millisecond scan, these sensors can accommodate objects of various sizes, making them ideal for tasks such as stationary dimensioning, inspection, or depalletization.

With a working range of up to 6.56 feet (2 meters), the 3S40 covers fields of view (FoV) as small as 28.5 x 20.8 inches (723 x 530 mm) or as large as 5.3 x 4.3 feet (1626 x 1312 mm). The sensors employ 1.5-megapixel structured-light scanning with laser projection. This, along with ambient light suppression, provides optimal image clarity and precision.

This technology allows precise measurement and inspection, even in low-contrast environments, when there are subtle variations in color or texture, and when there is poor lighting, glare, uneven illumination, or reflective surfaces and hotspots on your target objects. Zebra’s 3D sensor technology accounts and adjusts for all of these factors, allowing you to reliably capture the images you need, in virtually any condition.

Zebra’s Aurora™ software, equipped with advanced deep-learning capabilities, can analyze complex 3D scans and tackle machine vision challenges, including detecting irregularities on intricate surfaces. Additionally, Zebra’s 4Sight EV7 controller enables high-speed single or multi-camera setups for even the most demanding applications.

Unlike many other vision systems, Zebra’s software is very simple and easy to use, with a modern interface that includes auto-tuning, video guides, and straightforward controls. With plug-and-play integration, the 3S40 sensor can be effortlessly connected to Zebra’s 4Sight EV7 controller and Aurora software, creating high-density point clouds with minimal setup. Power is supplied via Power-over-Ethernet (PoE) or an optional 24V cable.

Zebra’s 3S40 is also lightweight at just 2 pounds (950 g) and is energy-efficient, and it can be used for a wide range of static imaging applications as well as for use with robotic arms. The hardware is also built to withstand harsh conditions, with IP65-rated waterproof and dustproof sealing.

Zebra 3S80 3D Sensors for High-Speed, Dynamic Imaging

For dynamic environments including target objects in motion, the 3S80 series provides more expansive and enhanced capabilities designed to measure and inspect moving objects as well as static scenes. It includes a patented CMOS sensor and Zebra’s parallel structured-light technology, which work together to enable fast, accurate scanning of both stationary and moving objects, even in problematic lighting conditions or when the surfaces or characteristics of objects are the most challenging.

Zebra 3S80 sensors can acquire up to 2 million 3D points (1680 x 1200) with an extended dynamic scanning range of up to 9.8 feet (3 meters).

For medium-sized objects, the 3S80-4M model provides optimal performance, while the 3S80-4L model is designed for larger items and volumes. At its ideal scanning range, the 3S80-4L can capture hi-res point clouds in areas up to 3.4 x 2.7 feet (1027 x 836 mm), completing each scan in just 45 milliseconds.

This high-speed acquisition ensures that images are free from motion blur, even for items moving quickly along conveyors. The sensors achieve true per-pixel measurement with extreme precision, allowing for high-resolution point clouds in RGB color.

Similar to the 3S40, the 3S80 series also offers easy plug-and-play installation with Zebra’s 4Sight EV7 vision controller and Aurora software. These sensors are compatible with PoE or 24V power sources, supporting the AIA’s GigE™ Vision standard for seamless integration into industrial networks.

Using the 3S80 series is simple. Just connect the device, aim it at the target scene, and start capturing detailed point clouds with no compromise in speed or image quality. Moreover, Zebra’s Aurora software offers advanced deep-learning tools to help solve intricate machine vision tasks, such as detecting irregular surface defects, dimensional issues, or other unique challenges.

Find the Best Solution for Your 3D Imaging Needs.

If you’re interested in learning more Zebra 3D imaging solutions and how to use them to automate your dimensioning and inspections, reach out to our industrial automation specialists at ADI, and we’d be happy to help. As a leading supplier and designer of machine vision and industrial automation solutions, our experts are available to provide guidance, answer questions, and help you identify the ideal solution to meet your specific scanning and imaging requirements.