To identify this problem and implement a more reliable solution, Donfabs & Consillia constructed a maintenance vehicle that utilized the Micro-Epsilon scanCONTROL laser profile sensor to look for signs of wear. The inspection rides take place outside, so the sensors have to withstand harsh conditions such as dust, oil and rain. Moreover, the target material can be both dull and shiny aluminium or stainless steel, which causes difficult reflection quality.
A total of six scanCONTROL LLT2910-100 laser profile sensors with 100mm wide laser lines are mounted on the sides of the main carriage, looking up, down and from the side at the rails. The wide measurement range in width and depth allowed for great flexibility of each sensor position so that they could be fixed and did not have to move. Due to the functionality of the scanCONTROL Configuration Tools Software, each sensor could be configured for a number of measurements. This made it easy to find measured values for gauge of the guideway, widths of top and bottom rail, as well as height of guideway on both sides. In addition, the software and parameter settings simplified integration. Defining analogue outputs for each measurement point allowed the combination of measurements from each sensor in the host controller to calculate the gauge of the track and the power rail wear measurement.