3D LiDAR Quality Control System
Real-time 3D scanning and automated quality inspection for production line pallets with SAP integration
Image represents the actual instrumentation developed for this project. Technical details have been abstracted for confidentiality purposes.
Challenge
Large pallet inspection requires rapid dimensional analysis without stopping production. Manual inspection is slow and inconsistent. The manufacturer provided only a command manual—no software interface. Transform a 2D LiDAR into a real-time 3D inspection system with ERP integration and millimetre accuracy.
Solution
Complete machine vision system converting 2D LiDAR to 3D scanner. Custom C/C++ API for real-time acquisition with conveyor synchronisation, Python pipeline for point cloud processing. Real-time validation against SAP database specifications.
Key Technical Features
- • Complete C/C++ API developed from command set manual (no manufacturer software provided)
- • Network-based remote sensor control and configuration
- • Perpendicular mounting on conveyor belt for continuous 3D scanning
- • Real-time polar coordinate acquisition with variable-length ASCII parsing
- • Conveyor velocity synchronisation creating third dimension across time domain
- • Automatic conversion from polar to XYZ coordinates using displacement measurements
- • 2-3mm accuracy (material-dependent due to optical properties)
- • Dual-language architecture: C/C++ for real-time acquisition, Python for post-processing
- • Point cloud processing pipeline: filtering, decimation, optimisation
- • Advanced feature recognition: planes, cubes, volumes, shapes, positions
- • Empty space detection for missing item identification
- • SAP database integration for specification validation
- • Real-time pallet content verification and quality decisions
- • High-resolution scanning of large industrial pallets without line stoppage
Applications
Production Line Quality Control
Automated pallet inspection detecting missing items and configuration errors
Logistics Verification
Real-time validation of pallet contents against shipping manifests
Dimensional Analysis
Volume and shape measurement for quality assurance and billing
Database Integration
ERP system connectivity for automated decision-making and alerts