Extrusion Inspection and Measurement

VisionGauge® Digital Optical Comparators are the perfect solution for the inspection and measurement of extrusions

  • Automatically compare difficult-to-inspect extrusions against their CAD data (no more overlays!)
  • The system has no limitations as to part geometry.
  • The system’s proprietary CAD-Auto-Align™ tool automatically lines up the CAD to the part, along one or multiple datums
    or by doing an overall “best fit”.
  • The system’s proprietary CAD-Auto-Pass/Fail™ tool automatically produces an operator-independent PASS/FAIL result.
  • The system works equally well on both fixtured and unfixtured parts.
  • Demonstrated accurate, repeatable and operator-independent results, directly on the shop floor!
  • The system supports both uniform and variable tolerances. You can apply tighter tolerances in critical areas and looser
    tolerances elsewhere.
  • Automatically measure and display deviations from nominal and quickly identify out-of-tolerance areas.
  • Automatically collect measurements, statistics, images and other data for complete documentation
  • Much faster than traditional approaches and completely eliminates operator subjectivity!
  • The system is extremely to use: it can be setup so that – for the operator – everything is done using the barcode reader.
  • The system is perfectly suited to overcome the difficult challenges of extrusion inspection.
Extrusion measurement of curvature and thickness performed on the VisionGauge Digital Optical Comparator.
Front (reflected) illumination allows you to clearly see internal and surface features, along with the part's outer profile. The system also has a broad set of high-accuracy measurement tools.
Comparing an extrusion cross-section to its CAD data to obtain a Pass/Fail result on a VisionGauge Digital Optical Comparator.
Automatically compare a part to its CAD data and get an accurate, repeatable and operator-independent PASS/FAIL result.
An extrusion cross-section inspected on the VisionGauge Digital Optical Comparator.
The system produces extremely crisp and clear super-high-resolution images. You can see all of the fine details on your part!

The VisionGauge® Digital Optical Comparator is the new standard for carrying out fast and accurate inspections in the extrusion industry.

Download a .pdf version of this VisionGauge® Digital Optical Comparator Application note here.

Extrusions Inspection and Measurement

Cooling Holes Inspection / Cooling Hole Measurement and Verification

 The 700-Series VisionGauge® Digital Optical Comparator is the Perfect Solution for EDM- and LASER-Drilled Holes and Slots Inspection and Measurement

The VisionGauge® Digital Optical Comparator is widely used by manufacturers across a broad range of industries (including aerospace and power generation) to inspect and measure EDM- and LASER-drilled cooling holes and slots:

  • Automatically verify hole presence & accurately measure hole location
  • Supports both round and shaped holes
  • 5 axes of motion (X, Y, Z, Rotary, Tilt) to properly view parts from all sides & angles
  • Quickly, easily, and accurately inspect 100% of the holes on your parts
  • Robust shop floor design
  • Can output the hole offsets which can be used to modify EDM drilling programs
  • Mounting system allows your parts to go directly from the EDM drilling machine to the inspection and measurement system without re-fixturing (quick & easy and also minimizes stack-up error, etc…)
  • The system can be supplied with the same working envelope as your EDM drill. If you can drill it, we can check it!
  • Holes can be checked either one at a time, looking straight down each hole’s nominal axis (ideal for coated parts, to minimize errors due to coating thickness variations) or multiple holes can be checked at once, viewing them at an angle (which is even faster and well suited for uncoated parts or parts with a uniform coating thickness)
  • The system has an extended depth of field, so that everything is perfectly in focus regardless of the part’s geometry (even in areas of very high curvature) as well as a very long working distance (so that there is lots of clearance between the part and the entire optical system to comfortably accommodate large and unusually-shaped parts)
  • Extremely powerful “adaptive” feature-detection software tools are able to accurately find and locate EDM-drilled holes on different surfaces, with different reflectivity, at different viewing angles, etc…
  • Specialized software tools are especially well suited to deal with burrs and splatter
  • Automatically create reports and collect measurements, statistics, images and other data for complete documentation
  • Fast and intuitive “operator review” mode allows the operator to quickly revisit out-of-tolerance areas, etc…
  • The ideal system for inspection and measurement of cooling holes on aircraft engine and IGT (Industrial Gas Turbine) components (blades, vanes, heat shields, shrouds, etc.). Parts can be either (ceramic) coated or uncoated.

EDM-drilled or Laser-drilled cooling hole measurement and inspection

Quickly, accurately, and easily carry out cooling holes inspection and measurement of round and shaped holes.

Automatically Verify Hole Presence and Location

measurement and inspection of EDM- and LASER-drilled drilled holes and slots

Supports Both Round & Shaped Holes, Anywhere on the Part!

The 700-series VisionGauge® Digital Optical Comparator is a very cost-effective, perfectly adapted solution for the measurement and inspection of EDM-drilled holes. It is rapidly becoming the new standard in the industry!

Download a .pdf version of this VisionGauge® Digital Optical Comparator Application Note here.

Laser- and EDM-Drilled Cooling Holes Inspection and Measurement

Inspection of Flexible Automotive Seals and Trim

The Perfect Solution For the Inspection of Automotive Seals (e.g. door trim, weather seals, etc…)

  • Automatically compare difficult-to-inspect flexible automotive seals and trim against their CAD data (no more overlays!)
  • The system’s proprietary CAD Auto-Align™ tool automatically lines up the CAD to the part, along one or multiple datums or by doing an overall “best fit”.
  • The system’s proprietary CAD Auto-Pass/Fail™ tool automatically produces an operator-independent PASS/FAIL result.
  • The system works equally well on both fixtured and unfixtured parts.
  • Demonstrated accurate, repeatable and operator-independent results, directly on the shop floor!
  • The system supports both uniform and variable tolerances. You can apply tighter tolerances in critical areas and looser tolerances elsewhere.
  • Automatically measure and display deviations from nominal and quickly identify out-of-tolerance areas.
  • Automatically collect measurements, statistics, images and other data for complete documentation
  • Much faster than traditional approaches and completely eliminates operator subjectivity!.
  • The system is extremely easy to use: it can be setup so that – for the operator – everything is done through the barcode reader.
  • The system can easily deal with part distortion. It is perfectly suited to overcome the difficult challenges of flexible automotive seal and trim inspection.
flexible automotive seal inspection and CAD overlay comparison on a VisionGauge® Digital Optical Comparator
automotive seal inspection and CAD overlays on a VisionGauge® Digital Optical Comparator
Comparing a flexible automotive seal against its CAD data

The system produces an extremely crisp and clear super-high-resolution image. You can see all of the fine details on your part!

Automotive trim inspection on a VisionGauge Digital Optical Comparator

Front (reflected) illumination allows you to clearly see internal and surface features, along with the part’s outer profile.

CAD Auto-Align and CAD Auto-Pass/Fail tools for flexible automotive components inspection

Automatically compare a part to its CAD data and get an accurate, repeatable and operator-independent PASS/FAIL result.

The VisionGauge® Digital Optical Comparator is the new standard for inspecting flexible extruded seals in the automotive industry.

Download a .pdf version of this VisionGauge® Digital Optical Comparator Application note here.

 Inspection of Flexible Automotive Trim and Seals – Automotive Component Inspection

New Min/Max Tool for Automatic Part Alignment – Application Note

The VisionGauge® Digital Optical Comparator’s new “Min/Max” software tool is the perfect solution for automatically aligning a part using a rotary stage. The tool can be setup to rotate the part and find the position that either minimizes or maximizes a dimension.

Common examples include the following:

Rotary stage and workholding for turnkey runout measurement application.
Rotary stage and workholding for turnkey runout measurement application.
In this case, the Min/Max tool is used to align the flats on the part perfectly horizontally, completely automatically

 

Automatic alignment of a turbine blade fir tree
Automatic alignment of a turbine blade fir tree

 

With this new Min/Max tool, it’s extremely easy to setup an automated routine for the alignment of any kind of part. Also, results are extremely repeatable. This advanced tool uses high-order interpolation for very accurate subsampling. This means that the position of best alignment can be found very accurately, at any orientation (not just at the sampled orientations).

This new tool is completely integrated with all of the VisionGauge® Digital Optical Comparator’s other tools so that all of its results can easily be recoded, transmitted, databased, sent to Excel™ or any other data capture application, put in a report, etc…

This new Min/Max tool further increases the wide range of applications that can easily and reliably be solved using the VisionGauge® Digital Optical Comparator.

Click to view this application note as a downloadable .pdf.

Orthopedic Implant Inspection and Measurement

The Perfect Solution for Orthopedic Implant Inspection

There are many reasons why the VisionGauge® Digital Optical Comparator is widely used by orthopedic implant manufacturers to inspect and measure medical implants and devices:

  • Automatically compare parts to their CAD data (no more overlays!)
  • With its patented CAD Auto-Align™ and CAD Auto-Pass/Fail™ tools, the system can inspect and measure parts completely automatically!
  • Demonstrated accuracy down to +/-0.0001″ in real-world applications, directly on the shop floor!
  • Eliminate operator subjectivity!
  • Much faster than traditional approaches.
  • Because the system doesn’t require any programming, it is especially well adapted for small lots & quick part changeover.
  • Automatically collect measurements, statistics, images and other data for complete documentation.
  • The system is not limited to the camera’s field-of-view; It can compare a part to its CAD data across the entire stage travel. So even large parts can be checked at high magnification, with very fine resolution.
  • With its extended optical depth-of-field and Auto-Focus tool, the system is perfectly suited to deal with the challenges of orthopedic implant inspection.
  • Different types of adapted computer-controlled LED illumination are available to eliminate glare and make defects stand out. The system works extremely well on both metal & plastic parts!
  • Automatically measure and display deviations from nominal and quickly identify out-of-tolerance areas.
Knee implant inspected with auto pass/fail on a VisionGauge Digital Optical Comparator
orthopedic implant inspection of a plate with CAD Auto-Pass/Fail on a VisionGauge Digital Optical Comparator
Inspection and measurement of a plastic part on a VisionGauge Digital Optical Comparator
VisionGauge® Digital Optical Comparators also work extremely well inspecting plastic parts!

VisionGauge® Digital Optical Comparators are perfect to inspect a wide range of orthopedic implants and devices: knees, hips, plates, shoulders, and many more…

Hip stem inspection (orthopedic device) and measurement on a VisionGauge Digital Optical Comparator with CAD Auto-Align.
Orthopedic forging inspection on a VisionGauge Digital Optical Comparator
The systems are also widely used in the inspection of forgings.

The VisionGauge® Digital Optical Comparator is the new standard for inspecting orthopedic implants in the medical industry.

Download a .pdf version of this VisionGauge® Digital Optical Comparator Application note here.

Inspection and Measurement of Orthopedic Devices and Implants

Turbine Blade Fir Tree Root Form Inspection and Measurement

The Perfect Solution For the Inspection and Measurement of Turbine Blade Fir Tree Root Forms 

There are many reasons why the VisionGauge® Digital Optical Comparator is widely used by manufacturers in the aerospace and power generation industries to perform turbine blade fir tree root forms inspection and measurement:

  • Automatically compare turbine blade fir tree root forms against their CAD data (no more overlays!).
  • The system can completely automatically inspect and measure turbine blade fir tree root forms with its proprietary CAD Auto-Align and CAD Auto-Pass/Fail tools (Patents Pending).
  • Demonstrated accuracy down to +/-0.0001″ in real-world applications, directly on the shop floor!
  • The system supports both uniform and variable tolerances. You can apply tighter tolerances on pressure faces and looser tolerances elsewhere.
  • Eliminate operator subjectivity!
  • Much faster than traditional approaches.
  • Automatically collect measurements, statistics, images and other data for complete documentation.
  • The system is not limited to the camera’s field-of-view; It can compare a part to its CAD data across the entire stage travel. So even large parts can be inspected at high magnification.
  • With its extended optical depth-of-field and Auto-Focus tool, the system is perfectly suited to deal with the challenges of turbine blade fir tree root form inspection.
  • Automatically measure and display deviations from nominal and quickly identify out-of-tolerance areas.
Apply tighter tolerances on pressure faces and looser tolerances elsewhere for turbine blade fir tree inspection and measurement
Variable Tolerances Support is Ideal for Turbine Blade Fir Trees
Proprietary CAD Auto-Align and CAD Auto-Pass/Fail tools simplify fir tree root form inspection and measurement
Proprietary CAD Auto-Align and CAD Auto-Pass/Fail tools

The VisionGauge® Digital Optical Comparator is rapidly becoming the new standard for the inspection and measurement of turbine blade fir tree root forms in the aerospace and power generation industries.

Download a .pdf version of this VisionGauge® Digital Optical Comparator Application note here.

Turbine Blade Inspection and Measurement of Fir-Tree Root Forms for Aerospace and Power Generation Parts

Turbine Disk Inspection

The Perfect Solution For Turbine Disk Inspection

There are many reasons why the VisionGauge® Digital Optical Comparator is widely used by manufacturers in the aerospace and power generation industries for the inspection of turbine disks:

  • Automatically compare turbine disk fir trees directly against their CAD data (no more overlays!).
  • With its proprietary CAD Auto-Align™ and CAD Auto-Pass/Fail™ tools (Patents Pending), the system can inspect turbine disks completely automatically!
  • Demonstrated accuracy down to +/-0.0001″ in real-world applications, directly on the shop floor!
  • The system supports both uniform and variable tolerances. You can apply tighter tolerances on pressure faces and looser tolerances elsewhere. Tolerances can be made to vary gradually between different zones.
  • Also ideal for the inspection of blisks, EDM slots, and other aerospace engine components.
  • Eliminate operator subjectivity!
  • Much faster than traditional approaches.
  • Automatically collect measurements, statistics, images, and other data for complete documentation.
  • The system is not limited to the camera’s field-of-view; It can compare a part to its CAD data across the entire stage travel. So even large parts can be checked at high magnification.
  • With its extended optical depth-of-field and Auto-Focus tool, the system is perfectly suited to deal with the challenges of turbine disk inspection.
  • Automatically measure and display deviations from nominal and quickly identify out-of-tolerance areas.
Fir trees with variable tolerances during turbine blade inspection
Variable tolerances support is ideal for turbine disk fir trees
inspection of a blink with VisionGauge Digital Optical Comparator
Also ideal for the inspection of blisks and EDM slots
Auto Pass/Fail inspection of a turbine disk fir tree with CAD Auto-Pass/Fail™
Proprietary CAD Auto-Align™ and CAD Auto-Pass/Fail™ tools

The VisionGauge® Digital Optical Comparator is rapidly becoming the new standard for inspecting turbine disks in the aerospace and power generation industries.

Download a .pdf version of this VisionGauge® Digital Optical Comparator Application note here.

Turbine Disk Inspection for Aerospace and Power Generation Parts

Automatic Bone Screw Inspection and Measurement

VisionGauge® Digital Optical Comparators are the perfect solution for automatic bone screw inspection and measurement.

There are many reasons why the VisionGauge® Digital Optical Comparator is widely used by medical device manufacturers for automated  inspection and measurement of bone screws:

  • Automatically compare bone screws against their CAD data
  • With its proprietary CAD Auto-Align™ and CAD Auto-Pass/Fail™ tools (Patents Pending), the system can check screws completely automatically, regardless of their orientation!
  • Eliminate operator subjectivity!
  • Automatically collect measurements, statistics, images and other data for complete device history information
  • Thanks to the system’s extended depth-of-field, the entire screw can be in focus even at the helix angle (no need to constantly refocus)!
  • Measure the bone screw’s thread major and minor diameters and other characteristics, completely automatically and to a very high accuracy
  • With the optional rotary stage, you can automatically measure the helix angle, very accurately!
  • The system is perfect for bone screw inspection and measurement directly on the shop floor
Proprietary CAD-Auto-Align and CAD-Auto-Pass/Fail tools for bone screw measurement
Proprietary CAD-Auto-Align and CAD-Auto-Pass/Fail tools
Multiple bone screws ready for automated inspection on the VisionGauge Digital Optical Comparator
Load multiple screws onto the system to have them all inspected completely automatically
Automatic inspection and measurement of threads and other dimensions of a bone screw
Automatically measure bone screw dimensions
CAD Auto Pass/Fail and CAD Auto-Align tools on the VisionGauge Digital Optical Comparator inspecting threads and other features of interest on bone screws.
Check all the features of interest on the screws

For bone screws inspection and measurement on the VisionGauge® Digital Optical Comparator, some manufacturers use horizontal configurations, while others use a vertical configuration. The decision to use one or the other is generally based on fixturing considerations. The hard chrome plated stage, made from hardened tooling steel, has industry standard dual dovetail grooves that make it compatible with existing mounting fixtures, and a drop-in replacement for traditional optical comparators. Rotary stages are also an option that can be added to these systems.

Download a .pdf version of this VisionGauge® Digital Optical Comparator Application note here.

Automated Bone Screw Thread Inspection and Measurement

6-Point Iterative Alignment – Application Note

6-Point Iterative Alignment on the VisionGauge® 700 Series 5-Axis Inspection & Measurement System

 

To be able to report the absolute location of a feature (such as cooling holes) on a part, a measurement system needs to know the location of the datums relative to which these locations are expressed. Five-axis parts use a six-point datum structure to set the position along the three Cartesian axes as well as the rotation about each of these three axes.

There are two different approaches to establish these datums. The first approach consists in using a fixture that physically comes into contact with the six datum points. And because the fixture is generally designed to easily line up with the un-rotated Cartesian axes (along the fixture’s straight edges, for example or using locator holes, tooling balls or other appropriately-designed simple features), it is quite simple to “zero out” the system’s 5 axes of motion (i.e. X, Y, Z, A and B). So with this first approach, the fixture physically sets the location of the datums in space.

With the second approach, a generally simpler fixture is used to only roughly position the part. So with this approach, features on the fixture are still used to “zero out” the system’s 5 axes of motion, but the resulting coordinate system is only approximate. For every part, the system still needs to accurately locate the datums and mathematically re-orient the part (in a way analogous to how a physical 6-point fixture physically reorients the part in space).

The VisionGauge® Digital Optical Comparator’s “Part Reorientation” tool is a powerful and intuitive tool to carry out 6-point iterative alignment. It uses the 700 Series’ LASER module to accurately locate the part’s surface at the datums, even on parts with complex geometries. The tool converges quickly to a stable and accurate solution. And it is extremely simple to then apply the corrections to part inspection programs. The tool also allows you to set limits on the corrections (to ensure collision-avoidance, for example).

The VisionGauge® Digital Optical Comparator's 6-point iterative alignment tool accurately locates the 6 datum points on the part and mathematically "reorients" the part accordingly, along all of the part's 6 degrees of freedom
The VisionGauge® Digital Optical Comparator’s 6-point iterative alignment tool
accurately locates the 6 datum points on the part and mathematically “reorients”
the part accordingly, along all of the part’s 6 degrees of freedom
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.