500 Series Digital Optical Comparators

The VisionGauge® Digital Optical Comparator (Patented & Other Patents Pending) is a fully-digital drop-in replacement for traditional optical comparators. It works directly with your part’s CAD data and doesn’t require and overlays.

The system is extremely easy to use, and thanks to its advanced, patented CAD Auto-Align™ and CAD Auto-Pass/Fail™ tools, operators can compare parts to their CAD data completely automatically, directly on the shop floor.

VisionGauge® Digital Optical Comparators eliminate operator error and can automatically collect complete electronic documentation including measurements, statistics, Pass/Fail results, a high-resolution image of the part with its CAD overlay, etc.

The VisionGauge® Digital Optical Comparator can also be integrated into an automated work cell and controlled via Ethernet or RS-232 communications.

digital optical comparator automatic part alignment

Compared with traditional optical comparators, our VisionGauge® Digital Optical Comparators are competitively priced and offer numerous benefits:

  • Produce a very high contrast image with very sharp edge profiles so that there is no problem viewing it in full daylight
  • Are much more accurate
  • Allow the user to be much more productive and get more work done with a single machine
  • Include our patented CAD  Auto-Align™ and CAD Auto-Pass/Fail™
  • Can compute and display the part’s deviation from nominal and compare it to bi-directional tolerances
  • Work directly with the CAD data so that no overlays / templates / Mylars™ are required
  • Can be used to collect images (either with or without the CAD data overlay and with or without annotations), measurements and data.
  • Can also carry out fully automated measurements (like a video CMM)
  • Can automatically send measurements, statistics and data to Excel™ or other external applications
  • Have a smaller footprint and use less floor space
  • Can be moved much more easily and without requiring re-calibration (i.e. “rolling cart” configuration is standard)
  • Have a much greater optical depth of field, i.e. (“everything is in focus all at once”)
  • Have a longer optical working distance (i.e. more clearance between the part and the lens)
  • Allow you to compare a part to its CAD data beyond the optical field-of-view! (because the CAD data tracks the part and follows the stage motion)
  • Have LED illumination for very stable illumination over a 10 year life. No more bulbs to change!

Standard 12″ travel X-axis stage with 0.5 micron resolution encoder and protective bellows around the 6″ travel Y-axis column. All 3 axes (X, Y and Z) have high-accuracy crossed-roller movements for optimal linearity and positional repeatability and high load carrying capability.

Thanks to their advanced patented technology, VisionGauge® Digital Optical Comparators are much faster, much more accurate and easier to use than traditional optical comparators.

And while traditional optical comparators require an overlay (i.e. a template or transparency), with the VisionGauge® Digital Optical Comparator everything is done electronically so that there are no more templates! You will never again have to buy, print, calibrate, verify, identify, trace, manage, and physically store & retrieve another template. No more template-related costs, delays or errors. The VisionGauge® Digital Optical Comparator works directly with your CAD data.

Digital Optical Comparators work directly with your CAD data. No more overlays.

Through their barcode reader and joystick interface, these systems are extremely intuitive and require only minimal operator training. The system can also be setup to allow on-screen measurements, to collect measurement statistics and to save the image of the part with its superimposed CAD drawing, etc, etc, etc…

And because they are fully digital, these systems allow you to collect complete digital records of the inspection and measurement operations.

VisionGauge® Digital Optical Comparators are very robust. They are perfect for both the shop floor and the Quality Control lab.

VisionGauge® Digital Optical Comparators are complete, ready-to-run Windows-based solutions and are delivered network-ready.

They are available in both horizontal and vertical configurations. They have industry standard dovetail mounting grooves for easy part fixturing.

VisionGauge® Digital Optical Comparators are available with transmitted (i.e. back) and / or reflected (i.e. front) illumination. All illumination is LED-based for very stable and repeatable illumination conditions over a very long life (no more bulbs to replace!). Furthermore, the illumination is programmable and computer-controlled. Everything is done through a single simple and intuitive software interface!

VisionGauge® Digital Optical Comparators have power focus & auto-focus!

They are available in industry standard 5X, 10X, 20X, 50X and 100X optical configurations, in either single or multi-mag configurations. Many other configurations are also available. We can configure a system to meet your specific requirements!

An optional high-resolution LASER module is also available for depth & height measurements.

VisionGauge® Digital Optical Comparators are competitively priced and have a very simple yearly calibration procedure that you can carry out yourself.

Please contact us for more information including a detailed spec sheet, a “Frequently Asked Questions” document, pricing, etc…

Standard 12" travel stage

Standard 12″ travel X-axis stage with 0.5 micron resolution encoder and protective bellows around the 6″ travel Y-axis column. All 3 axes (X, Y and Z) have high-accuracy crossed-roller movements for optimal linearity and positional repeatability and high load carrying capability.

Hard chrome plated X-axis stage, made of hardened tooling steel and with dual standard dovetail grooves for easy part fixturing.

Hard chrome plated X-axis stage, made of hardened tooling steel and with dual standard dovetail grooves for easy part fixturing on a Digital Optical Comparator
Digital Optical Comparator reflected illumination module

Reflected (i.e. front) illumination module

VisionGauge Digital Optical Comparator system in Vertical configuration with optional 5th monitor on the right side
VisionGauge Digital Optical Comparator system in Vertical configuration with optional 5th monitor on the right side... We can configure a system to meet your requirements!

 Overview Video:

500 Series VisionGauge® Digital Optical Comparators

300 Series Field-of-View Systems

The 300 Series VisionGauge® Digital Optical Comparators are extremely cost effective Field-of-View Systems that are ideal for smaller parts (up to 1.7″ x 1.2″).

They have an extended depth-of-field for tall parts (as high as 1.1″) and a long working distance that provides ample clearance and room to work between the part and the lens.

They produce a stunning super-high-resolution image to carry out fine, detailed inspections.

Three different types of LED illumination are standard: collimated back, front off-axis (i.e. “dark field”) and front on-axis (i.e. “bright field”). This allows the system to produce crisp, sharp edges and perform beautifully even when working with hard-to-image materials (for example: shiny, reflective or even translucent surfaces) and difficult geometries (such as deep holes).

VisionGauge® Digital Optical Comparators are complete, ready-to-run Windows-based solutions. They are delivered network-ready and include on-site installation, NIST-traceable calibration & training.

The 300 Series Field-of-View Systems are desktop instruments that have all of the functionality of the 500 Series VisionGauge® Digital Optical Comparators, with the sole exception that they are limited to smaller parts.

Overlay before CAD Auto-AlignmentOverlay after CAD Auto-Alignment

Proprietary CAD Auto-Align™ and CAD Auto Pass/Fail™ tools work almost instantly
and produce very accurate, operator-independent results
Diameter FOV measurement on a VisionGauge Digital Optical Comparator
Fast and accurate automated measurements
FOV distance measurement on a VisionGauge Digital Optical Comparator
Reverse Engineering a part on a VisionGauge Digital Optical Comparator
Reverse Engineer a part...
Desktop Configuration Dimensions of a 300 Series VisionGauge Digital Optical Comparator
Main unit overall dimensions (Model # VG300DOC-30V-20X)
Desktop Configuration Base Plate Dimensions of a 300 Series VisionGauge Digital Optical Comparator
All-purpose mounting hole pattern for easy & flexible part fixturing (in the case where parts are to be fixtured)
Quickly and easily check flexible and other hard-to-inspect parts against their CAD data on a VisionGauge Digital Optical Comparator
Quickly and easily check flexible and other hard-to-inspect parts against their CAD data
300 Series VisionGauge® Digital Optical Comparators – Field-of-View Systems

400 Series Desktop Inspection and Measurement Systems

The 400 Series VisionGauge® Digital Optical Comparator is a state-of-the-art inspection and measurement system. It’s a compact desktop system that still provides a large working envelope. The 400 Series is a very cost-effective, full-featured system that has all of the advanced, patented VisionGauge® software capabilities. This system is especially well suited for lower volume applications.

Available in both Horizontal and Vertical Configurations.

CAD Auto-Align™, CAD Auto-Pass/Fail™ result on the VisionGauge Digital Optical Comparator
Patented VisionGauge® CAD Auto-Align™ and CAD Auto-Pass/Fail™ tools provide fast, accurate and operator-independent results
Profile tolerance Pass/Fail on the VisionGauge Digital Optical Comparator
The perfect solution for checking profile tolerances!
High-accuracy measurement tools on a Digital Optical Comparator
The system has a broad set of high-accuracy measurement tools
back-illumination of a part on a Digital Optical Comparator
front-illumination of a part on a Digital Optical Comparator
Both front- and back-illumination are available. Works well on different surfaces and materials, including metals & plastics

 Overview Video:

400 Series VisionGauge® Digital Optical Comparators – Desktop Inspection and Measurement Systems

700 Series 5-Axis Inspection and Measurement Systems

The system comes with an industry-standard chuck mounted on the system’s double-rotary stage assembly.

Other mounting systems are also supported.

double-rotary stage assembly on a VisionGauge Digital Optical Comparator

Ideal for aircraft engine and gas turbine blade cooling holes inspection and measurement

 Overview Video:

The 700 Series VisionGauge® Digital Optical Comparator 5-axis inspection and measurement system is the ideal solution for the automatic inspection of parts with complex geometries.
The 700 Series VisionGauge® Digital Optical Comparator 5-axis inspection and measurement system is the ideal solution for the automatic inspection of parts with complex geometries. The Extended 24" x 24" x 24" travel machine with trunnion configuration for big and heavy parts is shown above.
700 Series VisionGauge® Digital Optical Comparator – 5-axis Inspection and Measurement Systems