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Non-Contact Thickness, Width and Diameter Measurement

In many industrial areas, measuring width and thickness is essential. Factors such as material properties, color variations and object sizes play a decisive role in product selection. Modern technologies offer versatile solutions for accurate and efficient measurement to meet the requirements of different applications.

Advantages at a Glance

Measurement Data for Regulating Production

Fast and early detection of quality variations

Increased material efficiency in further production steps

Display of optimization potential after production changes

The Difference Between Profile and Point Sensors

Profile Sensors

Optional surface inspection by recording the entire width
Detailed representation of material thickness by recording surface profiles
Width measurement using laser line

Point Sensors

Provide information on the object thickness at a specific point
Suitable for applications requiring continuous monitoring at a fixed point
Point measurement of material thickness by laser point

What Can Be Measured?

Width and thickness measurement of webs and plates

Width, height and diameter of profiles

Measuring Arrangements

The measuring principle can be divided into two methods: the measurement with one sensor against a defined background and the differential measurement using at least two sensors.

Single-Sided Thickness Measurement

Contactless width measurement

Measurement with one sensor

Object thickness measurement on a solid background

P3PC laser distance sensor width and thickness measurement

Two-Sided Thickness Measurement

Contactless width measurement

Measurement with a pair of sensors

Offsetting of the individual measurement results provides the object thickness

Width Measurement with Sensor Pairs

Contactless width measurement

Measurement with multiple sensor pairs in “tracks”

Measurement via software

Sectors and Industries which Use Thickness and Width Measurement

Steel Industry
Woodworking Industry
Electronics Industry
Food Industry
Building Materials Industry
Plastics Industry
Paper Industry
Automotive Industry
Hygiene Industry
Glass Industry

Thickness and Width Measurement of Steel Thickness

Challenge:
In the metalworking industry, accurate measurement of steel thickness across the entire width of the material is critical for quality assurance and specifications. The challenge is to use precise sensors that detect the smallest measurement variations and ensure compliance with the target width.

Solution:

Thickness Measurement with Annealed Metal

Challenge:
Thickness measurement of annealed metal plays a crucial role in industrial processes such as metal or steel production. The extremely high temperatures present a challenge as they could damage conventional sensors due to the heat or affect their accuracy. Due to the glowing surface, red laser light penetrates deep into the surface and can make measurements unreliable.

Solution:

Thickness and Profile Measurement

Challenge:
In highly complex production environments, profile measurement is a particular challenge. They require precise detection of chipping, subsidence and damage in the micrometer range.

Solution:

Diameter and Ovality Check on Steel Pipes

Challenge:
After welding metal pipes in the steel industry, a 360° measurement of the pipe is carried out to ensure quality in order to check the diameter, roundness and degree of ovality.

Solution:

Measurement of Washers

Challenge:
Measuring washers requires precise control of both the inner and outer diameter. The B60 smart camera enables reliable and accurate measurements and ensures that every washer meets quality standards.

Solution:

Diameter Measurement of Screws

Challenge:
When measuring screws, one of the challenges of quality control is to ensure that the screws have the correct diameter. This requires precise measurement methods to meet tolerances and ensure product quality.

Solution:

Thickness Measurement of Parquet Planks

Challenge:
Planks must be milled to the exact width when making parquet floors. The wood surfaces vary in color and degree of gloss. Adherence to the specified width is crucial for the installation of the planks.

Solution:

Parquet Edge Measurement

Challenge:
During the production of parquet, the boards’ quality in terms of geometry has to be assured continuously during operation. The better the edges of the boards match, the higher the quality of the parquet.

Solution:

360° Measurement of Tree Trunks

Challenge:
Measuring tree trunks is an extremely demanding task. Factors such as the irregular shape of the trunks and possible surface irregularities can make the measurement difficult. The cross-sectional area of tree trunks is determined by means of a 360° measurement in order to achieve an optimal cut timber.

Solution:

Length Measurement of Wooden Battens

Challenge:
Before the packaging process, cut and planed wood battens are precisely measured for length in large sawmills. In-line length measurement presents a particular challenge as it requires continuous and accurate measurement throughout the production process. This ensures that each batten meets exact specifications before it is packaged and shipped.

Solution:

Width Measurement of PCBs

Challenge:
The width measurement of PCBs requires accurate identification and measurement of the narrow edges of the PCB, as these often make up a substantial part of the overall width. Electronic PCBs require extremely accurate measurements, as even small deviations can affect the function of the entire circuit.

Solution:

Height and Width Control of Waffles

Challenge:
In waffle production, accurately measuring the height and width of the tread is a particular challenge. Precise quality control is essential to ensure the highest standards.

Solution:

Width and Height Measurement of Chocolate

Challenge:
Chocolate can be very thin, especially when making chocolate bars or sheets. This requires sensors that can offer very high accuracy to detect even slight thickness differences.

Solution:

Width and Thickness Measurement of Pasta Dough

Challenge:
In food production, it is often necessary to measure the thickness of dough in real time as it passes through the production process. This requires sensors that are fast and accurate enough to measure the dough as it moves.

Solution:

Thickness Measurement of OSB Panels

Challenge:
OSB panels consist of pressed wood chips arranged in layers. This structure can result in the thickness not being the same everywhere, especially at the edges or in areas where the pressing is uneven.

Solution:

Measuring the Material Thickness of Polystyrene Insulation Boards

Challenge:
Wood fiber insulation boards can vary in density and structure, making thickness measurement challenging. To guarantee consistent quality, the thickness of these boards for the construction industry must be measured with accuracy.

Solution:

Mineral Wool

Challenge:
Mineral wool consists of fine fibers that are processed into a loosely knitted mat or nonwoven. Mineral wool can be produced in different densities.

Solution:

Width and Height Measurement of Plasterboard

Challenge:
The surface of the plasterboard can be rough or uneven, and the thickness at the edges can vary. To achieve reliable results, it is therefore important to perform the measurements at representative points of the board.

Solution:

Flatness Testing of Tiles

Challenge:
The surface of the tiles can be shiny or rough, which can make the accuracy of the measurements difficult. Continuous quality control is therefore essential to ensure high precision.

Solution:

Non-Contact Thickness Measurement of Rubber Mats

Challenge:
Thickness measurement of rubber mats is a particular challenge, as the black material reflects little light. To enable accurate measurements, a sensor with adjustable exposure time should be used, which can be upgraded to laser class 2.

Solution:

Sheet Thickness

Challenge:
In film production, continuous monitoring of the thickness in the process is crucial to ensure consistently high product quality. The challenge is to detect the glossy and transparent film.

Solution:

Thickness Measurement of Materials

Challenge:
In the plastics industry, consistent fabric thickness is fundamental to high-quality products. Variations lead to deformations, so continuous monitoring is essential.

Solution:

Thickness Measurement of Paper

Challenge:
In papermaking, precise thickness measurement is critical for many industrial applications, including quality control, print production and the packaging industry. Factors such as the surface finish, color and reflections of the paper must be carefully considered.

Solution:

Width Measurement of Carton

Challenge:
Width measurement of carton in the paper industry is crucial to determine the exact width across the entire surface. The challenge here is to use precise sensors that detect the smallest measurement fluctuations and ensure compliance with the target width.

Solution:

Gap and Offset Measurement in Body Construction

Challenge:
Achieving uniform circumferential gap dimensions is a challenge in the fully automated assembly of components such as tailgate, engine hood, roof and side doors. This is made possible by the “best-fit” process, which ensures that all parts are optimally aligned to each other and thus meet both aesthetic and functional requirements.

Solution:

Profile and Diameter Check on Car Tires

Challenge:
Car tires on fleet vehicles are often in good condition so that they can continue to be used. To precisely determine the tread depth, diameter and radius of these tires, special test systems are used with profile sensors installed on the sides and overhead. During rotation, the tires and their tread are measured with micrometer accuracy by laser triangulation.

Solution:

Thickness Measurement of Diapers

Challenge:
During the thickness measurement of diapers, the quality requirements are also tested. Due to the different material densities, it must be determined in the final test whether the diapers meet the specifications.

Solution:

Thickness Measurement of Sanitary Towels

Challenge:
The quality control of sanitary towels involves checking the thickness. The thickness of the sanitary towel is measured to ensure that it meets the specified specifications. If the measurement deviates from the specifications, the product is rejected.

Solution:

Thickness Measurement of Glass Disks

Challenge:
Glass thickness measurement is an important quality control measure in glass production and processing. Due to the transparent and reflective properties of glass, special measuring techniques are required.

Solution:

Width Measurement Solutions at a Glance

Laser distance sensor double layer detection

P3 Laser Distance Sensors Triangulation

The contactless laser triangulation sensors work according to the angle measurement principle, which enables reliable and highly precise measurement in the close range up to 1,000 mm. The triangulation sensors deliver stable measured values regardless of colors, shapes, rough and textured surfaces.

Ultrasonic Distance Sensors

Distance sensors are suitable for the detection, differentiation and measurement of objects using ultrasound. Different operating modes, such as synchronous, multiplex or through-beam mode, can be set via the display or centrally via IO-Link, and different output variants and formats enable a wide range of possible applications.

Smart Cameras and Vision Sensors

Smart cameras and vision sensors solve a wide range of industrial image processing tasks. The highly modular hardware platforms in combination with high-performance machine vision software enable tailored adjustment for all machine vision applications.

Fiber-Optic Sensors

Fiber-optic sensors are ideal for detecting small parts. They use plastic or glass fiber-optic cables, which can also be used in hard-to-reach places due to their high flexibility.

2D/3D Profile Sensors

Sensors of this type measure profiles of objects such as weld seams or glue beads and check roundness or gaps using laser triangulation. Red or blue laser light, open interfaces and various performance classes are available.

Width Measurement with Sensors

	Products	Advantages of sensors for width measurement	Product links
	P3 laser distance sensors triangulation	Width measurement without an analysis module Simple initial start-up Display of measured values directly on the display For accurate measurements
	Fiber-optic sensors	Contactless measurement Can be used in hard-to-reach places
	Ultrasonic distance sensors	Material and color independent Resistant to contamination Large measuring range

Products
P3 laser distance sensors triangulation	Fiber-optic sensors	Ultrasonic distance sensors
Advantages of sensors for width measurement
Width measurement without an analysis module Simple initial start-up Display of measured values directly on the display For accurate measurements	Contactless measurement Can be used in hard-to-reach places	Material and color independent Resistant to contamination Large measuring range
Product links

Width Measurement with Machine Vision

	Products	Benefits of machine vision for width measurement	Product links
	2D/3D profile sensors	Micrometer accuracy measurement Wide range of measurements Calibration and synchronization possible Width measurement possible with only one sensor
	Smart cameras and vision sensors	Capture small parts with high-resolution images Thickness measurement without manual intervention Evaluation of the images directly on the camera

Products
2D/3D profile sensors	Smart cameras and vision sensors
Benefits of machine vision for width measurement
Micrometer accuracy measurement Wide range of measurements Calibration and synchronization possible Width measurement possible with only one sensor	Capture small parts with high-resolution images Thickness measurement without manual intervention Evaluation of the images directly on the camera
Product links

Flyers for Width Measurement Products for Download

P1XD Product Flyer (902 KB)

This document provides an overview of the P1XD series fiber-optic amplifiers.

P3 Series Product Flyer (2 MB)

This document provides an overview of the P3 series laser distance sensors.

Ultrasonic Sensors Product Flyer (995 KB)

This document contains the product flyer for the ultrasonic sensors.

B60 Smart Camera Product Flyer (968 KB)

This document contains the product flyer for the B60 smart camera.

weCat3D 2D/3D Profile Sensors Product Flyer (3 MB)

This document contains the flyer for 2D/3D profile sensors.

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