InteliSENS PFG4030-i4

Profile Flaw Gauge

The InteliSENS PFG uses four laser profile gauges positioned at 90° intervals, alternating 405 nm and 450 nm wavelengths to minimize interference. Based on laser triangulation, each gauge projects a laser line whose deformation is captured by a high-speed camera. Analysis of these reflections generates precise 3D surface data, enabling accurate flaw detection and profiling.

  • Real-time display of thickness, outer diameter, concentricity, and out-of-roundness data.
  • Fast scanning speed and highly accurate measurements overcomes the limitation of traditional lump and neck detection technology
  • User-friendly interface
  • Multiple communication protocols
  • Four 3D laser triangulation devices ensure complete surface coverage while minimizing optical interference
  • Measured parameters logged for storage and analysis
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Measurement Principle

Four 3D laser triangulation devices each project a laser line onto the object’s surface. The surface topography deforms these lines, and a high-speed imaging camera captures the reflected light patterns. The PFG analyzes the position of the reflected laser lines, and calculates the distance to each corresponding surface point, to create a precise cross-section coordinate data set. As the object moves, the PFG continuously samples these laser line profiles, generating stacked cross-sectional profiles. An integrated high-precision SL gauge or an external speed sensor provides velocity measurements critical for 3D representation of the surface. The resulting 3D point cloud is analyzed to provide visualization of real time profiles, flaws and measurement of relevant geometrical attributes

Performance

PFG4030-i4
Maximum Size 30 mm
(1.20 in)
Minimum Size 0.3 mm
(0.012 in)
Flaw Height Accuracy 3%
Measurement Accuracy 30 µm
Scan Speed Up to 19,000 scans/s

Connectivity

2x digital inputs

1x Speed Pulse Input

1x Analog Speed Input

4x Relay Ouputs

1 x RS232 / RS422 / RS485

1 x iBUS Port

1 x Ethernet port

Wi-Fi for gauge configuration and diagnostics.

Product Add-On Hardware

±10 Vdc output of diameters eccentricity, or errors. Updated rate: 1ms

Proportional Integral feedback controller for diameter

Electrical and Operating Requirements

Power Supply
100 – 240 VAC (50 – 60 Hz)
Power Consumption
100 Watts
Operating Temperature
5 – 45 C° (41 – 113 F°)
Environmental Protection
IP 65

Size & Weight

PFG4030-i4 Height
1580 mm (62.2 in)
Width
310 mm (12.20 in)
Thickness
515 mm (20.2 in)
Weight
100 kg (220.46 lb)