Linear Axis Enables Precise Measurement of Large Parts in Seconds

The ZScan 3D multisensor system from senswork performs high-resolution, seamless, and three-dimensional scans of large components and compares the results to the CAD model — determining production quality in record time. The precision axis enabling this speed was supplied by Jenaer Antriebstechnik (JAT).
senswork, a specialist in industrial image processing, developed ZScan as an ultra-fast 3D multisensor scanner that measures large components inline — up to 1.5 × 0.7 × 0.5 meters — in just seconds. The system uses multiple triangulation sensors in freely arranged spatial positions, allowing it to capture objects virtually free from shadowing.
The technology combines a high-precision linear axis with a multisensor head featuring up to eight profile scanners. Thanks to the sensors’ angled setup and mirrored placement, ZScan can even capture hard-to-reach optical areas such as undercuts and shadow zones

Strong Partnership

While searching for a suitable drive technology partner, senswork CEO Rainer Obergrußberger found JAT through online research. Headquartered in Jena, JAT develops high-precision drive systems for lasers, lenses, and sensors, capable of sub-micrometre-level dynamic movement. Since July 2020, senswork and JAT have been collaborating.

“The biggest challenge was achieving the required running precision of the axis,” explains Marco Schwarz, Sales Engineer at JAT.

To meet this demanding requirement, JAT engineered a custom overhead-guided linear axis. Built on a granite base and powered by an ironless linear motor with a 2-meter stroke, the system integrates a high-resolution Functional Safety measurement system to ensure precise and safe synchronization.

This configuration delivers a path accuracy of ±5 µm across the entire stroke and a tilting error of only a few µrad.

“We contacted numerous suppliers, but JAT gave us the strongest confidence they could meet our requirements,” says Obergrußberger.

Data processing is handled by VisionCommander, senswork’s powerful software that offers flexible 3D tools: CAD comparison, alignment methods (RPS, BestFit, 3-2-1), volume measurement, position detection, and the identification of deformation or defects.

A New Approach to 3D Inline Measurement

ZScan simplifies traditionally time-consuming tactile measurements. This new form of 3D inline inspection enables applications that were previously only possible in dedicated metrology labs.
For example, in busbar manufacturing, ZScan automatically detects shape deviations. The benefit: Fast, inline measurement enables automated adjustment of feed and bending angles per segment through real-time CAD comparison.

In automotive aluminum die-casting, ZScan captures RPS-aligned measurement points on components, allowing them to be corrected based on actual data, eliminating the need for expensive gauge-check fixtures. Components also no longer require surface treatment (e.g., powder spray) prior to measurement.
As of August, ZScan is in full operation at one of the world’s largest aluminum die-casting manufacturers, delivering major value to the customer thanks to JAT’s high-precision drive system.