All Digital Optical Comparators Archives

Super-Extended Travel Configurations

Fir Tree Auto-Pass/Fail Inspection

The Super-Extended Travel Configuration 500 Series VisionGauge® Digital Optical Comparator is a precision system designed specifically to inspect and measure big and heavy parts. They have up to 60” of travel and support loads of up to 300 lbs!

Parts are set on the system’s X-Axis stage, which is built using precision rails and is set on a floor-mounted granite base. The camera is mounted on the Z-axis and the entire assembly, along with the front and back illumination, move up and down on the Y-Axis. In this way, the Y and Z axes are completely disconnected from the rugged granite-base-mounted X-axis that supports all of the part’s weight. The axes have 0.25µm resolution encoders for high-accuracy positional feedback.

This innovative configuration is designed to provide optimal rigidity and eliminate any mechanical deflections. Everything is optimized to allow the system to produce very accurate measurements of long and heavy parts.

Advantages
Features

Advantages

500 Series Super-Extended Travel Configuration Advantages

The system provides all of the advantages of the 500 Series VisionGauge® Digital Optical Comparator and includes additional benefits that make it stand out from the competition:

Fully-automated: no operator-dependent variation!
Fast and accurate performance delivering very high throughput
Extremely easy-to-use for operators and programmers: Little or no programming, i.e. “I’ve got a part, I’ve got a CAD file, and I’ve got a minute”
Features VisionGauge’s patented CAD Auto-Align™ & CAD Auto Pass/Fail™ tools
Automatically computes and displays a part’s deviation from nominal and compare it to bi-directional tolerances
Produces a beautiful and very high-resolution, high-contrast image with very sharp edge profiles. You can see very fine details very clearly
Works directly with CAD data so no templates or overlays are necessary – compare a part to its CAD file beyond the optical field of view (because the CAD data tracks the part and follows the stage motion)
Very robust and shop-floor-ready
Has all-LED illumination (for very stable & repeatable illumination conditions, very stable & repeatable results, low heat, low power consumption and no bulbs to change)
Can collect full inspection & measurement data and automatically create reports including digital images & records with the CAD overlay and the deviations from nominal, measurements, statistics, etc…

The system is powerful and widely-applicable – capable of solving a vast number of applications across many industries. In particular, the Industrial Gas Turbine (IGT) / Power Generation industry greatly benefits from the use of this system for inspection of fir trees / root forms on buckets. We can also design and build oversized systems to meet unusual or one-of-a-kind requirements.

Super-Extended Travel 500 Series VisionGauge® Digital Optical Comparator inspecting fir tree / root forms on buckets — Fir Tree / Root Form Inspection with the Super-Extended Travel 500 Series VisionGauge® Digital Optical Comparator

Features

The VisionGauge® Digital Optical Comparator 500 Series Super-Extended-Travel Configuration is designed to inspect large and heavy parts with performance, reliability, and high-accuracy in mind.

60″ of travel for large parts, supporting up to 300 lb loads
Precision components designed for optimal stability and performance for heavy parts across the entire range of travel
0.25µm resolution encoders provide high-accuracy positional feedback
Includes VisionGauge®’s advanced measurement and inspection toolset to carry out fully-automated measurements, including proprietary software tools for direct CAD-to-Part comparison
With the system’s large depth of focus, “everything is in focus at once”, and the large field-of-view means you can see more of the part at once.
The long working distance gives more clearance between the part & the lens
Power-Focus and Auto-Focus keep part edges crisp for very accurate measurements
Super-high resolution monitor allows you to see all the details of the image at once
Extremely easy to use software interface
Automated image/data collection and a wide array of reporting and data exchange features

Super-Extended Travel and Oversized Systems Gallery

VisionGauge® Digital Optical Comparator Super-Extended-Travel Configuration
48"x24"x12" Super-Large XYZ Travel VisionGauge® system
48"x24"x12" Super-Large XYZ Travel VisionGauge® system

Contact us with your requirements for more information on how the VisionGauge® Digital Optical Comparator 500 Series Super-Extended-Travel Configurations are suited to solve your application.

VisionGauge® Disk Inspection and Measurement Systems

Turbine and compressor disk fir-tree slots and root forms are generally manufactured through broaching, wire cutting, or milling along with follow-up deburring and rounding operations. These features have complex geometries and very tight tolerances that are difficult to achieve. In particular, the pressure surfaces that constitute the critical point of contact between the blade roots and disc during operation are subject to very narrow tolerances in the order of 10–20 µm.

To ensure that the disk slots match up perfectly with the corresponding turbine blade shapes and provide proper performance, it is essential to accurately control the shape, position, orientation and alignment of the disk slots.

Fir trees with variable tolerances during turbine blade inspection

The VisionGauge® Disk Inspection & Measurement System is designed specifically for this. The system’s patented CAD Auto-Align™ and CAD Auto-Pass/Fail™ tools are unique technologies that allow the system to produce results of very high accuracy, completely automatically and with absolutely no operator dependence or subjectivity. It is fast and can carry out 100% inspection of 100% of the slots on every disk.

Some capabilities of the VisionGauge® Disk Inspection & Measurement System include:

Fully automated profile inspection
Completely automated knife edge setup
Radial length/Z plane distance inspection
Centerline inspection
Slot spacing inspection
Supports cone & helix angles
Verification of pressure face flatness/slot perpendicularity inspection

VisionGauge® Disk Inspection & Measurement Systems can also be used to carry out complete reporting, data capture, and analysis, including:

VisionGauge®’s powerful CAD Auto Pass/Fail™ Analysis mode makes it very easy to review non-conforming profiles. It allows the operator to automatically snap directly onto failed edge points, thus increasing efficiency when verifying out-of-spec regions.
Data for every inspected slot is automatically registered in its respective Data Group. Additionally, results can be quickly & easily reviewed as the system automatically returns to a specific slot’s location by simply double-clicking on the corresponding Data Group entry.

Advantages

5 axes of motion (X, Y, Z, Rotary, Tilt) to properly view slots at all angles, increment from slot-to-slot, etc.
Fully-automated operation.
No operator-to-operator variation
Quickly, easily and accurately inspect 100% of a disk’s slots
Easy to program (can use your CAD data directly!)
Fast, accurate & easy-to-use
Extensive set of VisionGauge® advanced high-accuracy inspection and measurement tools
Straightforward operator interface: barcode-reader and joystick
Intuitive software
Patented & patent pending technology with powerful & innovative software tools
Sharp, clear & ultra-high resolution image!
Extended optical depth of field and extended working distance for maximum flexibility!
Automatically create reports and collect measurements, statistics, images and other data for complete documentation
Automatic image & data collection with built-in SPC and data-exchange capabilities
Fast and intuitive “operator review” mode to quickly revisit out-of-tolerance areas
High-precision movements on all axes
High load capacity (for large & heavy disks)
Robust shop-floor design

VisionGauge® Disk Inspection and Measurement System Pass/Fail results

The system’s patented CAD Auto-Align™ & CAD Auto-Pass/Fail™ tools
allow you to automatically check the slot profile, get deviations from nominal, etc…

These very accurate tools produce results that are completely operator-independent

Features

High-resolution precision optics to resolve very fine details with great clarity.
Standard systems include 12″ X-axis travel, 12″/24″ Y axis travel, 12″ Z-axis travel with extended travels available to accommodate large disks.
A (tilt) axis range from – 40 deg to +40 deg, B (rotary) axis range from 0 deg to +360 deg.
All axes have closed-loop encoder feedback.
All axes include high-accuracy preloaded crossed-roller movement.
Includes both bi-telecentric transmitted (i.e. back) illumination and reflected (i.e. front) illumination with Ultra-bright, computer-controlled and programmable LED’s.

VisionGauge Disk Inspection and Measurement System

Sample Images

VisionGauge®'s Roll Pin distance measurement tool — Measure roll-pin distance, slot spacing, etc…

turbine broach radius measurement with VisionGauge®

turbine disk root form prepared for inspection

Technical Specifications may be found in the downloadable data sheet.

VisionGauge® Standalone Inspection & Measurement System

The VisionGauge Standalone Inspection and Measurement — The VisionGauge® Standalone Inspection and Measurement System’s main unit can be installed in any orientation: horizontally, vertically, upside-down… however best suits the space in your automation cell.

The VisionGauge® Standalone Inspection & Measurement System is a high-accuracy measurement system designed specifically for automation applications. The system is widely-applicable and extremely general purpose, and it can be easily dropped into an existing automated cell.

Our VisionGauge® OnLine software includes Remote Program Communications, an extensive set of communication protocols over a variety of interfaces (via TCP/IP over ethernet, digital I/O’s, COM port, etc.) for full 2-way handshaking (with a robot or cell controller, for example), error/result reporting, and remote control over automated program operations.

The VisionGauge® Standalone Inspection & Measurement System includes all of VisionGauge®’s advanced inspection and measurement tools, including our patented CAD Auto-Align, CAD Auto Pass/Fail, and the patent-pending Tooth Checker tool, making it perfect for automatically carrying out very high-accuracy inspections and measurements.

The mobile cabinet containing controls, user interface and I/O connections for the system — Remote cabinet with controls, user interface & I/O connections

Advantages

Advantages of VisionGauge® Standalone Inspection & Measurement Systems

In addition to its versatility, the VisionGauge® Standalone Inspection and Measurement System has many benefits compared to existing technology. Our adaptable software intelligence in automation means there is less reliance on operators and more focus on software and tools. This model combines advanced software and precision optics to offer greater speed, accuracy, and efficiency compared to older measurement devices.

Additional advantages of using our video inspection measurement systems and equipment include:

Access to VisionGauge®’s full imaging, inspection, and measurement toolset
Ready to integrate into any existing process
Fully-automated programs with multiple options for error/result/status reporting (Digital I/O signals, TCP/IP commands, etc.)
Eliminates variations between operators
Automatic electronic documentation of all inspection results
Save floor space
Compatible with existing part-positioning equipment, robotic components, and automated cells over a variety of interfaces
Intuitive, user-friendly interface
Exclusive, proprietary software and tools and world-class Application and Technical Support

Features

Additional Features

The benefits of using a VisionGauge® system are evident in its state-of-the-art inspection and measurement features – particularly its intuitive image analysis technology and sub-pixel accuracy. Our video measuring equipment has features that make it one of the best quality control solutions for a wide variety of industries. Medical device manufacturing, military & defense, aerospace, automobile manufacturers, and many more can use this system to improve daily operations.

The VisionGauge® Standalone Inspection and Measurement System’s features include:

High-resolution optics and imaging
Configurable in any orientation for easy integration
3 different types of LED illumination
- Transmitted back illumination
- Reflected off-axis illumination
- Reflected coaxial illumination
Exclusive patented VisionGauge® software and tools like CAD Auto-Align™ and CAD AutoPass/Fail™
Greater depth of field for better focus
Long working distance
10x or 20x magnification
High-contrast, high-quality images
Easy communication with automated cells with full two-way handshaking over a variety of interfaces
Data collection and exchange capabilities including Pass/Fail, data manipulation, charting, and statistics
and much more…

Technical Specifications may be found in the downloadable data sheet.

Overview Video

Additional Information

What Is a Video Inspection Measurement System?

A computerized video measuring system inspects live images of manufactured parts, often using a computer-aided design (CAD) file as a reference. Older systems may have required extra physical components like templates and overlays. Using digitized CAD data directly eliminates the need for those resources. When comparing a part to its design specifications, performing measurements, performing defect detection, etc., the system collects data and may generate a Pass/Fail result. Manufacturers use that information to conduct quality control processes.

Controlling the quality of the parts you produce is crucial. Modern measurement devices are faster, more powerful, and more accurate than traditional models. The efficiency and reduction of operator errors associated with using modern video inspection equipment outweigh the cost of a video measuring system.

The VisionGauge® Standalone Inspection and Measurement System is a versatile solution for your automation and inspection needs. Precise and convenient, the standalone model serves as a drop-in device for robot-controlled, automated cells. Combined with ease of installation, this system can solve a vast array of of applications and works well for general purpose inspections.

Contact Us for More Information

Video measuring system costs depend on your supplier and the customizations required to solve your application, such as the size, magnification, and type of illumination. Choose a video measuring system supplier who understands your business’s needs and offers quality control solutions to properly solve your application. VISIONx, Inc. strives to provide our customers with cost-effective inspection equipment with the best technology available. We’ll work with you to choose equipment, customize it to match industry-specific requirements, and provide maintenance and support to ensure your video measuring system continues to function as expected. Our Application Support is able to assist with recommendations for improvement, future reconfigurations, and solving new applications with the same system.

Contact us with your application details to learn more about the VisionGauge® Standalone Inspection and Measurement System.

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 any overlays or mylars.

Enhanced with patented technology and sub-pixel accuracy, this optical contour projector will allow you to perform high-accuracy measurements, automatically compare parts against their CAD drawings, and speed up your inspection process.

The system is robust and extremely easy to use, and with 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 or in a Quality Control lab.

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

Contact us today for more information about our 500 Series Digital Optical Comparators and our optical comparator prices.

Advantages

Advantages of Our Profile Projector

As the only completely digital optical comparator on the market, the 500 Series is powerful and versatile enough to measure both small and large parts.

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

They produce a very high contrast image with very sharp edge profiles so it is easily viewed in full daylight.
They are much more accurate.
Users are much more productive and get more work done with a single machine.
Our patented CAD Auto-Align™ and CAD Auto-Pass/Fail™ tools and our patent-pending Tooth Checker™ tools are included.
The part’s deviation from nominal can be computed, displayed, and compared to bi-directional tolerances.
Review, report, and label Auto Pass/Fail cross sections with Advanced Analysis and Reporting tools
Work directly with the CAD data so no overlays / templates / Mylars™ are required.
Collect images (with/without the CAD data overlay and annotations), measurements, and data.
Execute fully automated measurements (like a video CMM).
Automatically send measurements, statistics, and data to Excel™ or other external applications.
The systems have a smaller footprint and use less floor space.
They can be moved much more easily without requiring re-calibration (i.e. “rolling cart” configuration is standard).
They have a much greater optical depth of field, i.e. (“everything is in focus all at once”).
They have a longer optical working distance (i.e. more clearance between the part and the lens).
You can 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).
The systems have LED illumination for very stable illumination over a 10 year life. No more bulbs to change!

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, and 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… 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 competitively priced and have a very simple yearly calibration procedure that you can carry out yourself.

Its automation capabilities and user-friendly design make the 500 Series the fastest optical comparator in the industry. We’ll be happy to set up a configuration that meets your job requirements and helps you increase inspection productivity. Please contact us for more information including a detailed spec sheet, a “Frequently Asked Questions” document, pricing, etc…

Features

500 Series Additional Features

The 500 Series VisionGauge® Digital Optical Comparator comes standard with a 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.

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

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. Furthermore, the illumination is programmable and computer-controlled. Everything is done through a single simple and intuitive software interface!

The 500 Series comparators have power focus and auto-focus capabilities. 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 with custom workholding and fixtures, additional rotary stages, stage travel adjustments, coax illumination, and other digital optical comparator accessories. We can configure a system to meet your specific requirements!

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

VISIONx offers both horizontal and vertical digital optical comparators. The systems include industry standard dovetail mounting grooves for easy part fixturing. A super-extended-travel configuration is also available, specifically designed for high-accuracy inspection of large and heavy parts.

Standard 12″ travel X-axis stage with protective bellows around the 6″ travel Y-axis column. All 3 axes (X, Y and Z) feature high-accuracy crossed-roller movements for optimal linearity and positional repeatability.

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

The octant-based illumination produces extremely uniform off-axis illumination to completely remove shadows even on parts with complex and unusual geometry.

Reflected (i.e. front) illumination module or optional Octant-based Reflected Illumination

Overview Video

500 Series Configurations Gallery

VisionGauge® Digital Optical Comparator 500 Series Vertical Configuration
VisionGauge® Digital Optical Comparator Super-Extended-Travel Configuration
48"x24"x12" Super-Large XYZ Travel VisionGauge® system
VisionGauge® Digital Optical Comparator 500 Series Horizontal Configuration

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 5.5″ x 3.3″).

They have an extended depth-of-field for tall parts (as high as 4″) 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-Alignment Overlay 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 optical comparator that still provides a large working envelope. This system is especially well suited for lower volume applications.

These optical inspection systems offer operator-driven, manual stage movement across 3 axes and are available in both horizontal and vertical configurations. Despite it being a small optical comparator, the system is performance-oriented with high-resolution, precision optics and ultra-bright LED computer-controlled illumination for sharp and clear images. A single high-resolution monitor is provided to see the entire image at once, with a secondary monitor as an option.

The 400 Series is a very cost-effective, full-featured inspection and measurement system that has all of the advanced, patented VisionGauge® software capabilities, including CAD Auto-Align™ and CAD Auto-Pass/Fail™ software tools, and our patent-pending Tooth Checker™ tool for fast, accurate, and operator-independent Part-to-CAD comparison. Compare parts to their CAD file beyond the optical field-of-view, across the entire stage travel! Results are easy to report with automatic image & data collection and built-in SPC and data-exchange capabilities.

An optional laser module enhances height/depth measurement capabilities in the Z axis, and additional customizations are also possible to solve your application.

Advantages

Advantages of 400 Series Desktop Inspection and Measurement Systems

This versatile benchtop optical comparator has the ability to automatically obtain images, gather data, and generate reports, making it one of the most convenient tools you can place in your machine shop or manufacturing facility. New technology and a wide range of benefits offer an advantage over traditional comparators and other optical inspection systems.

The 400 Series VisionGauge® Digital Optical Comparator is compatible with countless applications, and presents many additional advantages including:

Compact table top design with up to a 12″ x 12″ envelope to accommodate a variety of parts and fixtures
Intuitive software with a user-friendly interface and efficient performance
High-resolution, precision optics and repeatable computer-controlled LED illumination for high-contrast, crisp imaging
Single magnification optics with extended depth-of-field and long working distance provides maximum flexibility
Optical accuracy better than +/-0.00015″ (i.e. 4 μm)
Proprietary VisionGauge® measurement and inspection technology, including CAD Auto-Pass/Fail™, CAD Auto-Align™, and Tooth Checker™ for operator-independent Part-to-CAD results
Automatically create reports and collect measurements, statistics, images and other data for complete documentation
Robust design with no consumable parts
Automatic image & data collection with built-in SPC and data-exchange capabilities

Features

Our optical inspection technology is continuously improving, with new innovations solving all types of industrial inspection applications with increasing speed and accuracy. Despite its compact size, the 400 Series VisionGauge® Digital Optical Comparator has the same powerful software toolset as larger optical inspection devices.

Additional features include:

VisionGauge®’s extensive set of software tools for image analysis and sub-pixel accurate measurements
Available in Vertical and Horizontal configurations
Manual stage movement and inspection on 3 axes
0.25 micron resolution encoders on the X and Y axes
Ultra-bright, repeatable LED computer-controlled illumination
A single high-resolution monitor allows the entire image to be viewed at once, with an optional secondary monitor
Optional LASER module for Z-axis height measurements
Customizable optical configurations and custom workholding available

Overview Video

Sample Images

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

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

Additional Information

What Are Optical Inspection Systems?

An optical inspection system is a machine/device that uses visual methods to check manufactured parts/items against their designed product specifications. It may employ a number of different inspection techniques to obtain data about surface defects and dimensional defects, perform measurements, perform absence/presence detection, and much more.

VisionGauge® Digital Optical Comparators / Profile Projectors replace older, traditional optical comparators. Dated machines have less accurate and less efficient technology, and traditional optical inspection equipment may require multiple overlays and mylars to compare parts. Using a part’s CAD file directly eliminates the need for other tools. VisionGauge®’s advanced software and patented tools can easily solve a vast array of applications with greater accuracy and efficiency. The best model for each industry depends on specific requirements of your application.

Learn More About Optical Measurement Systems for Industrial Inspection

The 400 Series VisionGauge® Digital Optical Comparator has advanced features and benefits that make it a cost-effective tool for quality control of your manufacturing operations, regardless of your industry. Whether operating manually or automating part inspections, our systems make it easy to check parts, obtain Pass/Fail results, and collect detailed data reports. Contact us with the details of your application for our benchtop optical measurement system prices.

Request more information about the 400 Series VisionGauge® Digital Optical Comparator below.

700 Series 5-Axis Inspection and Measurement Systems

The 700 Series VisionGauge® Digital Optical Comparator is a 5-Axis Inspection and Measurement System that is widely used by manufacturers across a broad range of industries (including aerospace and power generation) to check EDM- and LASER-drilled holes and slots. It is the ideal solution for the automatic inspection of parts with complex geometries. The 5 axes of motion (X, Y, Z, Rotary, Tilt) allow parts to be secured to an industry-standard chuck and positioned accurately to view the part from all sides and angles.

Cooling Hole Inspection - Verifying Presence, Shape, and Location

The system is able to automatically verify hole presence and accurately measure hole location. The 700 Series VisionGauge® Digital Optical Comparator is adaptable and supports both round and shaped holes, different surface types with different reflectivity, different viewing angles, etc… VisionGauge® OnLine’s advanced toolset permits programs to locate features with high accuracy and automatically obtain results with a Pass/Fail conclusion based directly on the part’s CAD file specifications. The program can also output the hole offsets, which can then be used to modify EDM drilling programs.

The system provides extremely powerful and innovative software tools for robust component detection, including specialized tools well suited to deal with burrs and splatter. The “Part Reorientation” tool provides the ability to execute full 6-point iterative alignment, and VisionGauge®’s fast and intuitive ‘Operator Review’ mode allows operators to quickly revisit any out-of-tolerances areas. VisionGauge® also supports automatic image and data collection for complete electronic documentation and data-exchange.

The VisionGauge® Digital Optical Comparator is a very cost-effective, perfectly adapted solution for checking EDM- and LASER-drilled holes and slots. It is rapidly becoming the new standard in the industry!

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

Automatically verify hole presence and accurately measure cooling hole locations.

Advantages

Advantages of the 700 Series VisionGauge® Digital Optical Comparator

You will find many benefits to using the 700 Series 5-Axis Inspection and Measurement System during the manufacturing process compared to traditional devices or other computerized vision measuring systems. This system goes well-beyond simply producing a report on each part and can significantly enhance the quality of your shop’s inspection operations.

Advantages of incorporating the 700 Series VisionGauge® Digital Optical Comparator into your shop include:

Quickly, easily, and accurately inspect 100% of the holes on your parts.
The system is easy to program, allowing you to use your CAD data directly and hole positions from your drilling programs.
The operator interface is intuitive, including a barcode-reader and joysticks.
The system supports both round and shaped holes on various surfaces.
Hole offsets can be output, providing feedback to EDM drilling programs.
The mounting system allows parts to go directly from the EDM drilling machine to the inspection system without re-fixturing – a quick and easy process that minimizes stack-up error.
Our system can be equipped with the same working envelope as your EDM drill.
The system is capable of performing 6-Point Iterative Alignment.
Check holes one at a time, looking straight down the hole’s nominal axis, or check multiple holes at once viewing them at an angle (depending on your inspection speed requirements and your part’s coating characteristics).
The system’s dual-source illumination module provides lighting at different angles of incidence (i.e. both near-vertical and low-oblique) for wide applicability across a very broad range of part geometries.
Powerful, adaptive feature-detection software tools can accurately locate drilled holes on different surface types (different reflectivity characteristics, different viewing angles, etc.).
VisionGauge®’s advanced toolset can easily deal with burrs and splatter.
Automatically create reports and collect measurements, statistics, images and other data for complete documentation.

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

Other mounting systems are also supported.

The new "Gen 2" trunnion setup for the double-rotary assembly of the 700-series VisionGauge Digital Optical Comparator.

These systems are ideal for aircraft engine and gas turbine blade cooling holes inspection and measurement

Features

The 700 Series VisionGauge® Digital Optical Comparator uses innovative tools and software to optimize quality control and reduce operator error. Our solutions have quality features that make comparators like the 700 Series 5-Axis Inspection and Measurement System stand apart from traditional inspection equipment.

Additional features include:

Motion on five axes (X, Y, and Z axes, plus rotary and tilt) to inspect complex parts
User-friendly interface with direct CAD-to-Part comparison
Includes VisionGauge®’s vast selection of advanced feature-detection and measurement tools
High-resolution optics and imaging
Ultra-bright computer-controlled LEDs present stable illumination with sharp contrast
An extended depth of field allows everything to be perfectly in focus, regardless of the part’s geometry, even in areas of high curvature.
A long working distance gives lots of clearance between the optical system and the part to easily accommodate large and unusually-shaped parts.
The system has a robust shop floor design.
Automatic reports, image collection, statistics, data collection, and data exchange
Intuitive “Operator review” mode to easily evaluate inspection program results
The system comes with an industry-standard chuck mounted on the system’s double-rotary stage assembly, with other mounting systems also supported.

VisionGauge® Digital Optical Comparators are the only industrial vision systems that are fully digital, entirely automated, and outfitted with the groundbreaking CAD Auto-Pass/Fail™ and CAD Auto-Align™ capabilities.

Overview Video

Applications

Featured Applications:

Images

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 with a single monitor.

Cooling hole location/detection on coated and un-coated part surfaces

Ideal for both coated & un-coated parts

Ring with cooling holes. For the larger rings, it is typical to use an extended-travel 700 series system to check the hole presence and measure the hole location and geometry.

Adapted feature-detection on unique surfaces

Powerful “adaptive” feature-detection software tools are able to accurately find and locate holes on different surfaces, with different reflectivity, at different viewing angles, etc…

Additional Information

What Are Machine Vision Inspection Systems?

Vision-based inspection systems are cost-effective solutions for maintaining quality control that involve measuring and inspecting images of manufactured parts. They are commonly employed for industrial and manufacturing applications of all types. Modern industrial vision systems have the ability to generate a Pass/Fail report according to the part specifications programmed into the inspection process, alongside more complex insights.

Computer-aided design (CAD) is often the guiding framework for dimensional measurement using vision systems. VisionGauge® machine vision inspection systems, including the 700 Series 5-Axis Inspection and Measurement System, compare a part directly to its CAD/DXF data and automatically produces a Pass/Fail result and detailed measurement report.

Learn More About Industrial Vision Systems

Manufacturing high-quality parts requires close attention to how well the product complies with its design. Defects impact businesses in any industry, but in high-risk industries like aerospace, medical device manufacturing, military and defense, and others, parts must Pass with tight tolerances. Manufacturers conduct quality inspection and measurements using vision systems to ensure their parts are within specifications.

The VisionGauge® Digital Optical Comparator is the most efficient and accurate way to compare a manufactured part to its CAD file. 700 Series 5-Axis Inspection and Measurement Systems are designed for parts with complex geometries in industrial and manufacturing applications with strict quality standards, such as aircraft engine manufacturing. From engines to cooling holes in gas turbine blades, these industrial vision measuring systems conduct reliable inspections and measurements.

Contact us for more information about the 700 Series 5-Axis Inspection and Measurement System or our other computerized vision measuring systems.

VisionGauge® Digital Optical Comparators

The Fastest, Easiest, Most Accurate Way to Compare a Part to a CAD File™

Optical inspection sets the standard for part verification in major manufacturing industries in today’s high-tech world. We assist leaders in all types of businesses by offering custom automated optical comparators. With increased speed, agility and reliability, our systems allow you to compare parts directly to their CAD data while accurately and efficiently completing inspections and digital optical measurements.

Improving Your Operation’s Production and Efficiency With Digital Optical Comparators

Our VisionGauge® Digital Optical Comparators streamline your manufacturing process by capturing images of manufactured parts and automatically comparing them to their CAD drawings. This ability means you can reliably confirm whether a component is within spec or catch production flaws before they go out the door. These systems provide stunning accuracy, a necessary element in high-demand industries like medical manufacturing, aviation, aerospace, electronics and pharmaceuticals.

Learn about the various applications of our digital profile projectors and see if they’re right for your industry’s quality control.

500-Series-Horizontal-Digital-Optical-Comparator-min

Auto Pass/Fail results using CAD entity segments on a VisionGauge Digital Optical Comparator

How VisionGauge^® Digital Optical Comparators Work

VisionGauge® Digital Optical Comparators measure product consistency by comparing parts directly to their CAD file. This process is a quick, highly-accurate way to check for defects and verify all components conform to quality standards.

Digital profile projectors are precise and intuitive, delivering high-quality results in less time than traditional optical comparators. These machines are easy to use and because they can be fully automated, they operate swiftly and reliably. They also offer a convenient way to streamline inspections, enabling you to speed up operations, increase throughput, and eliminate operator error.

Get more information about how digital optical comparators work and how they improve upon traditional optical comparators.

How a Digital Optical Comparator Can Benefit Your Business

VISIONx’s digital profile projectors offer reports, charts, statistics and more. In addition to being fully digital, our inspection systems glean data straight from CAD drawings, saving time by making inspections simpler and easier to run. VISIONx’s update to traditional optical comparator machines will capture, qualify and report comparison data at the click of a button. Additional benefits of our systems include:

Improved accuracy
Higher throughput with automation
Uses existing CAD data — no more mylars, overlays, charts or templates!
Complete electronic documentation and versatile automated reporting options
Fully digital
Smaller footprint
Use of our proprietary CAD Auto-Pass/Fail™, CAD Auto-Align™ and Tooth Checker™ tools
Ease of use and installation
Fully automated
Groundbreaking technology
Operator-independent results

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Finding the Right System for Your Unique Application

We have multiple digital profile projectors for sale. Our VisionGauge® Digital Optical Comparators use the latest technology and measuring tools to deliver high-quality images, capture reliable data and help you maintain quality control policies. We offer digital comparators in horizontal and vertical configurations to optimize your measuring processes:

Vertical digital optical comparators: Vertical models contain a glass insert on the stage for parts placement. Ultra-bright lighting illuminates the part from beneath the glass, displaying the profile for inspection. These designs are ideal for applications involving objects that sit flat on the glass, like plates or other flat-shaped components.
Horizontal digital optical comparators: Horizontal optical comparator machines contain an X-axis stage with premium steel, chrome plating and highly durable dovetail mounting grooves for quick and repeatable part placement. The component sits on the stage, perpendicular to the lens and Z-axis. While vertical comparators are ideal for flat parts, horizontal models work well for most other geometries.

If you upgrade an existing optical comparator to a VisionGauge® design, the component’s presentation to the camera will remain the same, meaning replacement is easy in the same horizontal or vertical configuration.

View Our Digital Optical Comparator Models

300 Series

Our 300 Series Field-of-View Systems can help you increase productivity if you manufacture smaller parts for electronics, medical, or similar products. The design boasts an extended depth for objects as high as 4 inches and an extended working area, providing plenty of clearance between the lens and the part.

Several features include:

Small desktop system
User friendly
CAD Auto-Align™
CAD Auto Pass/Fail™
Quality image analysis
High-accuracy measurements

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400 Series

The 400 Series Desktop Inspection and Measurement System is a compact digital optical comparator machine with incredible accuracy and reliable digital optical measurements. With manual movement across three axes, the 400 Series is ideal for lower-volume applications that require precision measurements.

Features of the 400 Series include:

Compact digital optical comparator machine
CAD Auto-Align™
CAD Auto Pass/Fail™
Tooth Checker™ tools
LED illumination
3-axis manual stage motion
Multiple configuration options
Speeds up the review of small parts

The 400 Series VisionGauge Digital Optical Comparator with manual stage motion

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500 Series

The 500 Series Digital Optical Comparator earns its name by setting the standard for optical quality control equipment everywhere. This machine is the most powerful digital optical comparator on the market and can handle almost any demand thanks to its high efficiency, user-friendly design and precision optics.

Features include:

High product volumes
Great for small and large parts
Automated measurements and CAD comparisons
Versatile reporting options
CAD Auto-Pass/Fail™

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500 Series Super-Extended-Travel Configuration

The Super-Extended-Travel configuration of the 500 Series VisionGauge® Digital Optical Comparator delivers reliable, high-accuracy performance for measuring large and heavy parts. The innovative design provides optimal rigidity and minimizes mechanical deflection for various components, including parts in the power generation and gas turbine industries.

Examples of the primary features include:

Ideal for large and heavy parts
60 inches of travel
Supports loads of up to 300 lbs
Compare components beyond the optical field-of-view

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700 Series

Our 700 Series 5-Axis Inspection and Measurement System offers the ultimate solution for work with more intricate electronic or mechanical parts. This measurement system is optimal for complex aviation, aerospace, and power applications.

Features of the 700 Series comparator include:

Captures images on five axes, including X, Y, Z, rotary and tilt
Crystal clear resolution
View reports based on CAD/DXF file comparisons, part feature locations and measurements
Fully Automated
Optimal for complex applications

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Standalone System

If you are looking for an inspection system ready to integrate into your existing process that can take on your most complicated automation applications, you may benefit from the VisionGauge® Standalone Inspection & Measurement System. The Standalone’s design leverages precision optics and advanced software to provide greater efficiency, accuracy, and speed compared to older models.

Product features include:

Ready to integrate into your existing process
Flexibility to configure in a variety of orientations
Features its own control cabinet
User-friendly interface
Fits into any existing automated cell
A versatile all-purpose option

The VisionGauge StandAlone Inspection and Measurement system.

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Disk Inspection System

Turbine_Disk_Inspection_and_Measurement_System-300x230-min

The VisionGauge® Disk Inspection and Measurement System is the ideal solution for companies that manufacture and inspect turbine disks. Our resources will allow you to detect flaws and confidently turn out higher-quality turbine disks.

Examples of features include:

Inspect large or small disks
Fully automated
Measure and verify faster
Five axes of motion
View disk slots from all angles
Equipped with our software
LED computer-controlled illumination
Advanced measuring tools

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Contact Us For More Information

Our VisionGauge® Digital Optical Comparators allow you to speed up your measurement and verification operations, helping you establish a more effective, accurate inspection process for your business. If you’re looking for a system that meets specific job requirements, we also have the inspection technology to offer customized solutions and multiple configuration options.

Please browse our measurement tools and systems to find the perfect solution for your unique application. If you want to learn more about how partnering with the industry’s leading digital optical comparator manufacturer can benefit your business, our experts can guide you. Contact us online today for additional information or to find a purchasing location near you.

You can also check out our frequently asked questions page for more information.