
Deployed four-head laser metrology for steel-bar cross sections, with CAD comparison and PLC integration

Delivered System
We deployed a laser measurement portal that reconstructs steel-bar cross sections from four synchronized views. Laser heads arranged around the bar trigger simultaneously, supplying complementary measurements to an industrial PC. The processing pipeline filters the readings, assembles the full profile, and compares it with CAD geometry to evaluate deviations. Profinet communication delivers inspection results to the PLC, connecting metrology with production controls. Protective housing and air-based lens cleaning support acquisition in the industrial environment. Calibration and site testing covered alignment, reconstructed geometry, repeatability, response time, and surface-dependent acquisition across the completed measurement workflow.


Defined full cross-section inspection
We established cross-section reconstruction and CAD comparison as the core inspection workflow. Four complementary laser views capture the profile around the steel bar, with measurement references and acceptance criteria defined through calibration and trials under site conditions.
Installed a synchronized laser portal
We installed four laser heads around the bar with simultaneous triggering and industrial PC processing. The system filters and reconstructs their measurements, while protective housing and air-based lens cleaning support acquisition. Mechanical alignment and calibration established the shared measurement reference.


Connected CAD comparison to the PLC
We implemented comparison between reconstructed cross sections and CAD geometry, then connected inspection results to the PLC through Profinet. The data exchange carries measurement and decision information, with acquisition quality included in the interpretation of reported profile deviations.
Completed calibration and site testing
We tested reconstructed geometry, repeatability, response time, and surface-dependent acquisition under actual site conditions. Calibration and alignment checks were complemented by housing and lens-cleaning tests, completing validation of the physical portal, processing pipeline, and PLC data exchange.

