Flexibility and precision for industrial automation – senswork GmbH develops customized solutions in the field of industrial image processing and optical measurement systems. With its state-of-the-art machine cabins and testing systems, the company offers flexible and economical solutions for demanding production environments. For an innovative 3D measuring system for inline measurement of components, senswork uses item's proven profile technology to ensure the highest quality standards and efficiency.
Founded in 2011, senswork GmbH is a leading provider of complete solutions in the field of industrial image processing, optical measurement systems, and automatic inspections. With locations in Burghausen and Munich, as well as international branches in the USA, China, and Singapore, the company serves renowned customers from various industries such as the automotive industry, medical technology, electronics, and food technology.
senswork develops customized solutions such as innovative camera systems and testing devices that are used for automation and quality assurance in modern production processes. At its Munich Innovation Lab, the company focuses on pioneering technologies in the field of artificial intelligence for image processing and analysis. With more than 35 employees, senswork offers everything from a single source - from concept development to integration of the finished solution.
Flexibility is key
The increasing demands in industrial production, especially in the area of quality assurance, require high-precision and efficient measuring systems. These systems must enable a high level of process reliability and be flexibly adaptable to different customer requirements and production environments. In the case of complex components such as battery cells, a number of functional and, above all, safety-related conditions must be met. These can be checked by means of three-dimensional measurement, among other things. This prevents risks such as short circuits and overheating. Against this background, senswork has developed the ZScan® Easy 3D measurement system. It enables complete 3D inline measurement of components such as battery cells in seconds.
Initially developed as a prototype for the international trade fair Control, senswork designed a machine cabin that provides optimum protection against external influences such as dust or changing lighting conditions during image capture and can be optimally adapted to the individual needs of customers. Choosing the right components plays a crucial role in the design. This is where item comes in. Its flexible profile technology offers significant advantages over welded systems, which are rigid and can only be modified with considerable effort.
The ZScan® Easy measuring system has a modular design and can be expanded as required and adapted to specific requirements. This is particularly important because senswork always has to deliver tailor-made solutions for the design of test cells that meet the requirements of different industries – from the automotive industry to electronics production.
Focus on XMS profiles
“We have been an item customer since 2021 and use a variety of designs,” says Daniel Müller, Head of Design at senswork. “For example, we have created numerous machine frames for fixtures from aluminum profiles and also configured workstation systems, expanded them with our testing technology, and delivered them to our customers.” When developing the innovative ZScan® Easy testing system, senswork focused on item's XMS profiles for constructing machine cabins, which impress with their smooth surfaces and attractive aesthetics on the one hand, and their integrated cable ducts on the other. These are another functional advantage of the XMS profiles, as they enable clean cabling.
“Whereas we previously drew on our extensive portfolio and often used standard profiles with corresponding connectors, we primarily used XMS profiles for the construction of the new measuring cell,” explains Daniel Müller. “The cover profiles simply cover the cables integrated into the profiles. This is convenient and visually very appealing.” Control elements such as push buttons, switches, and sockets can be inserted directly into the profiles.
Design and function of the measuring cell
The ZScan® Easy 3D measuring system is available in various sizes and designs, which are customized to meet individual customer requirements. The upper section of the machine cabin contains the visible process level with the surface scanners. Two acrylic glass swing doors allow this area to be opened so that the component to be scanned can be placed inside. The door profiles from the XMS series create stable, precisely closing doors with narrow aluminum frames. Door seal profiles cover the transition between the door and frame to prevent dust deposits. The supply level is located in the lower section, which is also accessible through doors. A portable swivel arm with a display is mounted on the side to show the measured values.
Several 3D surface scanners capture components such as battery cells with virtually no shadowing. With up to eight scanners, products up to 2.0 m long, 2.0 m wide, and 1.5 m high can be captured. The scanners generate a high-resolution 3D image with up to 12 million measuring points. A scan takes only a few seconds, even for large components. The results can be transferred directly to production. This enables reliable quality assurance directly on the production line, which is of fundamental importance, especially for the cost-intensive production of lithium-ion batteries for electric cars. The aim here is to achieve process-reliable production with minimal waste.
Designing with item – smart and economical
The decision to use item components in the design of the ZScan® Easy testing system has proven extremely advantageous for several reasons. One of the main benefits is the modularity of the profiles, which allows senswork to design its measuring systems to be flexible and adaptable. Thanks to the sophisticated XMS profile system, for example, the cabling of the machines could be designed efficiently and neatly. Smart signal technology displays the status of the testing process at all times. LED strips that can be integrated into the profile groove light up either across the entire surface or in segments. Different colors make it immediately clear what stage the process is at. Individual control is provided by the item IO-Link controller. This also makes it convenient and easy to signal the progress of the process.
In addition to freely selectable colors, flashing patterns can also be used. “The ball joints from item are also clever,” says Daniel Müller. “We used them in the upper part of the machine cabin to mount our scanners.” The ball joint allows the scanner to be rotated in different directions. A clamping lever enables the desired angle to be quickly adjusted.
The aluminum profiles are robust and can be used reliably even in demanding industrial environments. At the same time, they are lightweight, making it easy to transport machines and testing systems. Worth mentioning in this context is the lifting roller, which combines a roller with a height-adjustable and non-slip base. With the help of the heavy-duty rollers, the 3D measuring system can be moved to the desired location. There, the integrated base is simply lowered, compensating for minor unevenness and ensuring a secure footing.
Constructive cooperation
The collaboration between senswork and item is characterized by a constructive and cooperative approach that enables the development of customized solutions for demanding industrial applications. “Working with item is very straightforward,” emphasizes Daniel Müller. “The short communication channels and close coordination between our companies enable projects to be implemented efficiently and promptly. The fast delivery times for components also contribute to this.”
senswork particularly appreciates the easy access to detailed product information and design data on the item website. This allows them to quickly make adjustments themselves in order to find the best solutions for specific requirements. “What particularly impresses us is the variety of components and accessories,” adds Daniel Müller. “We also use the profiles and connection technology for fixtures in our Innovation Lab in Munich, for example, or generally for the construction of prototypes. These can be set up quickly and can be modified or expanded just as quickly.”
Ultimately, senswork benefits not only from the standardized products in the item portfolio, but also from its continuous expansion, which ensures flexibility and adaptability in future projects.
Caption 1: senswork is an expert in complete solutions for industrial image processing, automatic inspection, and deep learning (AI).
Caption 2: The company develops devices for measuring and testing workpieces.
Caption 3: With ZScan® Easy, components such as battery cells can be scanned quickly and precisely in 3D. The machine cabin consists of components from item.
Caption 4: Ball joints from item are used in the upper part of the machine cabin, allowing the scanners to rotate in different directions. Smart signal technology enables the visualization of process states.
Press Contact
Hedwig Unterhitzenberger
+49 8677 409958-37
hedwig.unterhitzenberger@senswork.com
senswork GmbH, Gewerbepark Lindach D 3, 84489 Burghausen