Extended Dynamic Range: Real-World Impact of Improved HDR in 3D Scanning

Typically, the farther you scan, the blurrier it gets.

Industrial 3D scanning has been hitting a wall: you can either scan accurately or scan far. The PhoXi 3D Scanner Gen3, though, breaks through this limitation thanks to a plethora of improvements like blue laser technology or extended dynamic range.

Thanks to the latest improvements, now you can automate truck loading, deep palletizing, and large-scale assembly. 

But what’s the dynamic range in the first place? 

What is Dynamic Range in 3D Scanning

Dynamic range in 3D scanning represents the ratio between the strongest and weakest light signals that a sensor can effectively capture and process. 

Measured in decibels (dB), this specification directly determines a scanner's ability to extract meaningful 3D data from challenging scenes, particularly at extended distances.

In structured light 3D scanning devices like the PhoXi 3D Scanner, a laser projector creates patterns on target objects while cameras capture the reflected light to calculate 3D coordinates. 

The challenge lies in physics. As distance increases, the projected light spreads out and weakens according to the inverse square law, while reflected signals become increasingly faint.

The Distance Problem

The fundamental physics working against long-range 3D scanning include:

• Signal degradation: Light intensity decreases with the square of the distance.
• Noise interference: Ambient light sources compete with the structured light patterns.
• Exposure challenges: Distant objects require longer exposures, increasing motion blur risk.
• Signal-to-noise ratio decline: Weak signals become lost in background noise.

This creates what engineers call the "overexposure vs. underexposure dilemma" - settings that capture distant objects often oversaturate nearby surfaces, while settings optimized for close objects fail to detect distant features.

How PhoXi 3D Scanner Gen3 Achieves Improved Dynamic Range

The PhoXi 3D Scanner Gen3 achieves improvement in dynamic range extension through a multi-component engineering approach that addresses every aspect of the signal capture and processing chain.

Multi-Component Engineering Approach

1. Blue Laser Projection Technology

The transition from red to blue laser projection delivers multiple physics-based advantages:

• Shorter wavelength benefits: Blue laser light has a shorter wavelength compared to red, providing less noise through finer speckle structures and spectral noise patterns that disturb captured data less.
• Enhanced scattering: Shorter wavelengths scatter more effectively on a larger variety of surfaces, improving pattern readability across diverse materials
• 50% projection energy boost: The redesigned generation with blue laser projection unit delivers 50% more light energy within the same laser safety class, improving signal strength at distance

2. Advanced 5.1MP Sensor Technology

The new sensor architecture incorporates several critical improvements:

• Enhanced sensitivity: Better signal capture capability for weak reflections from distant objects
• Improved signal-to-noise ratio: Advanced pixel design reduces noise interference
• Extended dynamic range capability: Hardware-level support for processing signals across a much wider intensity range

3. High Dynamic Range Processing

Sophisticated algorithms built directly into the device provide:

• Real-time HDR processing: Advanced software and sensor-level processing that handles extreme signal variations
• Multi-exposure HDR: A single, detailed image for complex scenes with mixed distances.
• Noise suppression: Advanced filtering techniques that preserve weak signals while eliminating interference

4. Optimized Optical System

Complete redesign of optical components includes:

• Improved lenses: Enhanced light collection efficiency and better focus across extended ranges
• Advanced optical filters: Optimized filtering for blue laser wavelengths and ambient light suppression
• Better light transmission: Reduced optical losses throughout the entire light path

Real-World Performance: Up to 6+ Meters Distance

The previous generation of PhoXi 3D Scanner established industry benchmarks with reliable scanning up to more than 4 meters. 

The Gen3 extends this capability to 6+ meters with experimental demonstrations reaching several tens of meters when scanning volumes are opened up.

Wonder how to open up the scanning volume? Here’s the quick guide by Tomas Michalik:

https://www.youtube.com/watch?v=8tfiTNibys4&feature=emb_logo

Experimental Results

Opening up the scanning volume isn’t just a theoretical concept. We’ve already demonstrated real-world applications using this technique: 

• 17-meter trailer scanning: Automated truck loading systems successfully detect foreign objects across the full length of shipping trailers
• Deep palletizing operations: Systems operating from 5.2-meter heights while maintaining precision for 2.6-meter tall stacks
• Large field-of-view applications: Single-sensor solutions replacing complex multi-sensor configurations

How Can Your Application Benefit From Extended Dynamic Range

1. Simplified System Architecture

Traditional Multi-Sensor Approach:

• Multiple 3D scanners requiring precise calibration
• Complex data stitching algorithms
• Increased failure points and maintenance requirements
• Higher initial costs and integration complexity

PhoXi Gen3 Single-Sensor Solution:

• Complete coverage with one device
• Eliminated calibration complexity between sensors
• Reduced hardware costs and installation time
• Simplified maintenance procedures

2. Enhanced Application Flexibility

Logistics Applications:

• Automated Truck Loading Inspection: The ability to scan 17+ meter trailer interiors enables complete foreign object detection before loading operations, eliminating the need for multiple sensors or manual inspection processes.
• Deep Palletizing Systems: Sensors mounted 5.2 meters above operations can accurately guide collaborative robots through complex palletizing tasks on 2.6-meter stacks, enabling fully automated warehouse operations.
• Large Container Handling: KLT (tote) manipulation systems benefit from extended range scanning of thin edges, allowing large industrial robots to handle multiple layers efficiently while maintaining precision.

Automotive Applications:

• High-Mounted Bin Picking: Large industrial robots can now work with deep bins while sensors maintain safe clearance distances, eliminating collision risks and improving operational safety.
• Side Panel Detection: Complete field-of-view coverage enables localization of mounting holes and simultaneous inspection capabilities, simplifying complex assembly processes that previously required multiple vision systems.
• Post-Stamping Part Picking: Sensors can be positioned at safe distances from stamping operations while maintaining the field of view necessary to handle diverse part geometries from a single stamping line.
• Large Subframe Inspection: Giga Press and hyper cast automotive components require multi-perspective scanning for quality control, burr detection, and dimensional verification - applications now enabled by extended range capabilities.

To learn more about the application our 3D sensors covers in automotive industry, watch the 3D Vision & AI Robotics webinar we did in collaboration with inVISION Days:

3. Operational Advantages

The extended dynamic range translates to significant operational improvements:

• Flexible sensor positioning: Safety clearances from robotic systems no longer compromise scanning capability.
• Mixed object handling: Single systems can process both small precision parts and large assemblies.
• Reduced cycle times: Elimination of multi-sensor coordination reduces scanning time.
• Improved reliability: Fewer system components mean fewer potential failure points.

The Physics Behind the Performance

Let’s break down how we could achieve this. 

Signal Strength

The 20dB dynamic range improvement represents a dramatic enhancement in signal processing capability. 

In practical terms, this translates to roughly 100 times improvement in the sensor's ability to distinguish useful signals from background noise.

This improvement has direct real-world implications:

• Distance capability: Reliable scanning extends from 4 meters to 6+ meters
• Signal robustness: Maintained precision across the entire extended range
• Material versatility: Improved performance on challenging surfaces at distance

Ambient Light Suppression Integration

The extended dynamic range works synergistically with Photoneo's Ambient Light Suppression (ALS) 3.0 technology. The combination enables:

• Outdoor scanning capability: Direct sunlight conditions no longer prevent reliable 3D data capture
• Variable lighting tolerance: Systems maintain performance as ambient conditions change throughout operational periods
• Multi-environment flexibility: Single configurations work reliably across diverse lighting scenarios

The technical implementation uses clever sensor operation techniques and processing algorithms to eliminate ambient light influence by several orders of magnitude.

It effectively "turns off" environmental lighting interference.

Industry Applications and Use Cases

Logistics and Warehousing

• Trailer Inspection Systems: Automated truck loading operations require verification that trailers are empty before loading begins. The PhoXi Gen3's ability to scan the full 17-meter length of shipping trailers eliminates the need for multiple sensors or manual inspection processes, significantly improving operational efficiency.
• Advanced Palletizing Operations: Deep palletizing systems benefit dramatically from extended range capabilities. Sensors mounted 5.2 meters above operations can guide collaborative robots through complex stacking operations while maintaining the precision necessary for stable pallet construction.
• Parcel Processing: Fast dimensioning and defect detection systems in high-volume logistics operations require the flexibility to handle packages of dramatically different sizes within the same scanning volume. Extended dynamic range enables single-sensor solutions for mixed-size operations.
• Mixed Palletizing: Multi-perspective scanning requirements in mixed palletizing operations benefit from the ability to use red and blue sensors simultaneously, reducing scanning time by 50% while maintaining complete coverage.

Automotive Manufacturing

• Deep Bin Picking: Large industrial robots working with deep bins require sensors positioned at safe clearance distances. The extended range capability maintains precision and complete field-of-view coverage even when sensors are mounted well above the working area.
• Quality Inspection of Large Components: Giga Press and hyper cast automotive components represent a new class of manufacturing challenges. These large, single-piece castings require comprehensive inspection for burrs, dimensional accuracy, and surface quality. Multi-perspective scanning with extended range sensors enables complete quality verification.
• Complex Part Localization: Side panel detection and similar applications often require localization of specific features (mounting holes) while maintaining awareness of the complete component geometry. Extended range and improved completeness enable comprehensive understanding that was previously impossible with single sensors.
• Assembly Verification: Large automotive assemblies require verification systems that can capture complete geometric relationships while maintaining safe distances from active production equipment.

Emerging Applications

• Solar Panel Inspection: The combination of extended dynamic range and ambient light suppression enables outdoor inspection applications previously impossible with structured light systems.
• Rail Industry Applications: Train wheel inspection and pantograph monitoring systems benefit from the ability to maintain safe distances while capturing precise geometric data.

How Implementation Works 

Easy Integration Features

The PhoXi Gen3 makes extended range capabilities accessible through user-friendly interfaces:

One-Click Calibration Volume Extension: The "Open Calibration Volume" functionality allows users to extend scanning range beyond default parameters with a single button click, accessible through:

• PhoXi Control graphical user interface
• API integration
• GigE Vision protocols

Flexible Configuration Options: Multiple resolution options ensure existing users of previous generations can upgrade while maintaining familiar operational parameters, while new installations can take full advantage of extended capabilities.

System Design Benefits

Mounting Flexibility: Extended range capability provides significant flexibility in sensor positioning, enabling:

• Safe clearance optimization around robotic systems
• Reduced mechanical complexity in sensor mounting systems
• Improved accessibility for maintenance and service

Scalable Architecture: Systems can be configured with single sensors for most applications, with multi-sensor configurations available for the most demanding scenarios. The red and blue laser options enable truly simultaneous scanning without interference.