Thickness and Width Measurement with SinceVision's Advanced Sensor Technology

In industries like semiconductor manufacturing, automotive production, and aerospace engineering, precision is non-negotiable. Measuring the thickness of a wafer, the width of a tire tread, or the step height of a watch part is crucial. Even a tiny error, like a micron, can cause product failure, safety issues, or expensive recalls.

Thickness and width measurement sensors are key for quality control. They help manufacturers keep consistency, meet standards, and improve processes. However, selecting the right sensor technology is a nuanced decision. Factors like material type, environmental conditions, required accuracy, and measurement speed all play a role.

This guide shows how SinceVision’s advanced sensors solve challenges. These include laser displacement sensors, spectral confocal sensors, and 3D laser profilers. These sensors provide unmatched precision for industrial applications.

Factors to Consider When Choosing a Sensor

Before selecting a sensor, ask these critical questions:

1. Material Properties:

a. Is the material reflective, transparent, or textured?

b. Does it have uneven surfaces or complex geometries?

2. Environmental Conditions:

a. Are there temperature fluctuations, vibrations, or dust?

3. Accuracy Requirements:

a. What tolerance level is acceptable (e.g., microns vs. millimeters)?

4. Measurement Speed:

a. Is the process static or dynamic (e.g., high-speed production lines)?

5. Contact vs. Non-Contact:

a. Will physical contact damage the material?

Types of Sensors for Thickness and Width Measurement

1. Laser Displacement Sensors

How It Works: It emits a laser beam to measure the distance between the sensor and target surface.

SinceVision’s Solutions:

  SG5025: Provides a 590kHz sampling frequency and ±0.02% linearity. It's perfect for high-speed tasks, such as measuring tire tread width.

  SD33-50: Achieves 5μm accuracy on black, reflective surfaces (e.g., watch components).

Best For:

  Non-contact measurement of opaque materials.

  High-speed production lines (e.g., automotive assembly).

2. Spectral Confocal Displacement Sensors

How It Works: It uses chromatic aberration to measure thickness by analyzing reflected wavelengths.

SinceVision’s Solutions:

  SCI04025: Provides 0.8μm accuracy and works at 33kHz. It remains unaffected by shiny surfaces like semiconductor wafers.

  SCI01045: Measures transparent materials (e.g., glass, films) with 1μm precision.

Best For:

  Transparent or highly reflective materials.

  Multi-layer thickness measurement (e.g., smartphone screens).

3. 3D Laser Profilers

How It Works: It scans surfaces with laser lines to create 3D profiles for width and step height analysis.

SinceVision’s Solutions:

  SRI7300: It captures 20kHz line frequency and achieves 0.05mm accuracy. This makes it great for detecting tire defects.

  SR8020: It has thermal drift compensation. This keeps calibration block measurements stable at 0.5μm/℃.

Best For:

  Complex geometries (e.g., welded seams, machined parts).

  Environments with temperature fluctuations.

Applications Across Industries

1. Semiconductor Manufacturing

Challenge: Wafers require sub-micron thickness uniformity to ensure chip reliability.

Solution: SinceVision’s SCI04025 spectral confocal sensor measures wafer thickness with an accuracy of 0.8μm. It works well, even on reflective surfaces. Its ±25° angular tolerance accommodates uneven surfaces.

2. Automotive Production

Challenge: Detecting tread wear or sidewall defects in tires without slowing production.

Solution: The SRI7300 3D profiler scans tires at 20 kHz. It finds defects as small as 0.05 mm. It also reads OCR characters for traceability.

3. Aerospace Engineering

Challenge: Measuring composite material thickness in vibration-prone environments.

Solution: The SG5025 laser sensor offers a 590kHz sampling speed. Its rugged design ensures reliable data even in tough conditions.

4. Consumer Electronics

Challenge: Ensuring consistent thickness of smartphone screens and battery foils.

Solution: The SCI01045 spectral sensor measures clear materials with 1μm precision. This helps avoid assembly problems.

Why Non-Contact Sensors Outperform Traditional Methods

Traditional contact tools like calipers or micrometers pose limitations:

1. Risk of Damage: Physical contact can scratch delicate materials.

2. Speed Limitations: Unsuitable for high-speed lines.

3. Human Error: Manual measurements lack repeatability.

4. SinceVision’s non-contact sensors eliminate these issues by offering:

5. Micron-Level Accuracy: Up to 0.8μm precision with spectral sensors.

6. High-Speed Data Capture: Up to 590kHz sampling for real-time feedback.

7. Material Versatility: Measure glass, metals, plastics, and composites.

Overcoming Measurement Challenges

1. High-Reflectivity Surfaces

Problem: Reflective materials like polished metals distort laser measurements.

Solution: Spectral confocal sensors (e.g., SCI04025) use wavelength analysis unaffected by reflectivity.

2. Transparent Materials

Problem: Lasers pass through glass or films, causing inaccurate readings.

Solution: Spectral sensors measure multiple layers simultaneously.

3. Temperature Fluctuations

Problem: Thermal expansion alters measurements.

Solution: The SR8020 3D profiler uses real-time thermal drift compensation.

Case Study: Tire Surface Defect Detection

Customer: A leading tire manufacturer faced a 15% rejection rate due to undetected sidewall defects.

Solution: SinceVision deployed the SRI7300 3D laser profiler to scan tires at 20kHz. The system identified defects as small as 0.05mm and read OCR codes for batch tracking.

Result:

  Rejection Rate: Reduced to 2%: Saved $1.2M annually in waste.

  Faster Inspections: Cut inspection time by 50%.

Why Choose SinceVision?

SinceVision is a global leader in sensor and machine vision technology. When you need precision and performance, we excel. SinceVision has a strong history of success. We have installed over 100,000 sensors around the world. Our sensors support important industries like automotive and semiconductors. We have strong experience. It shows we can offer reliable and effective solutions, even in tough environments.

At SinceVision, we understand that every application is unique. We provide custom solutions. We tailor our sensor and camera setups to fit your measurement challenges. SinceVision has solutions for all your needs. Whether you want precise measurements, quick image capture, or detailed surface analysis, we’ve got you covered.

Innovation is at the heart of SinceVision. We are dedicated to R&D leadership. This helps us stay ahead in non-contact measurement technology. We always expand what's possible. Here are some of our groundbreaking product achievements:

• SR8000: The industry's fastest sampling speed at 67 kHz.

• SR7000: The industry's first X-axis with 3200 points.

• SR9000: The industry's first X-axis with 6400 points.

Beyond cutting-edge technology, SinceVision is dedicated to providing exceptional support to our customers. Our global support network provides 24/7 technical help and on-site calibration services. This means you can count on our products and expertise anytime, anywhere.

SinceVision is an active member of leading industry organizations, including the European Machine Vision Association (EMVA), the Association for Advancing Automation (A3), and the China Machine Vision Industry Union (CMVU). This shows our promise to deliver top solutions for the machine vision industry. We aim to shape the future of automation.

In conclusion, SinceVision is the perfect partner for businesses wanting top machine vision solutions. We have proven expertise and custom solutions. Our R&D leadership and global support help customers succeed. We are committed to working with the industry, so our customers can reach their goals confidently.

Conclusion: Elevate Your Precision with SinceVision

SinceVision’s thickness and width measurement sensors are the best for accuracy, speed, and reliability. They are used in everything from semiconductor wafers to aerospace composites. We use advanced laser and spectral technologies. This helps manufacturers reach zero-defect production and meet strict industry standards.

Please visit the product page for more information. For sales inquiries, visit our contact page.

More resources:

1. Download the Product Catalogue, Technical Guide, Manual, and Software

2. Transforming Manufacturing with Spectral Confocal Displacement Sensors

3. Role of Laser Displacement Sensors in Photovoltaic Manufacturing