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.

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.

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
500 Series VisionGauge® Digital Optical Comparator - Super-Extended Travel Configuration

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

Custom Workholding and Fixtures

As part of a complete solution, we can design & manufacture custom workholding and fixtures, compatible with our systems and perfectly adapted to meet the requirements of your application.

Over the years, we’ve supplied a number of adapted precision pneumatic, vacuum and manually-operated fixtures to successfully solve applications with various types of parts.

A customized workholding developed to complete a VisionGauge Digital Optical Comparator application

Please contact us with your applications for additional information including detailed spec sheets, a “Frequently Asked Questions” document, pricing, etc…

VisionGauge® Disk Inspection and Measurement Systems

Fir trees with variable tolerances during turbine blade inspection
Variable tolerances support is ideal for turbine disk fir trees
VisionGauge®'s Roll Pin distance measurement tool
Measure roll-pin distance, slot spacing, etc…

Technical Specifications may be found in the downloadable data sheet.

VisionGauge® Disk Inspection and Measurement Systems

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 Communication, 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 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

 Overview Video:

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.

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 check in with you to make sure 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.

VisionGauge® Standalone Inspection and Measurement Systems

VisionGauge® Digital Optical Comparator / Profile Projector Applications

VisionGauge® Digital Optical Comparators are being used by many different companies across a very wide range of industries. Here are some examples of applications we have solved within various industries:

Broached slot inspection

Aircraft and aerospace component inspection and measurement

Medical implant inspection and measurement

Medical device and component inspection

Medical instrument inspection and meausrement

Extrusion inspection and measurement

Cutting tool inspection and measurement

Automotive components and parts inspection and measurement

Industrial gas turbine part inspection (IGT)

VisionGauge® Digital Optical Comparators / Profile Projectors are perfect for both the shop floor and the Quality Control lab.

VisionGauge Digital Optical Comparator inspecting a turned part
turned part
VisionGauge Digital Optical Comparator inspecting a nozzle
VisionGauge Digital Optical Comparator inspecting a nozzle

Inspection of mechanical parts

VisionGauge Digital Optical Comparator inspecting Forging in the Orthopaedics Industry
Forging in the Orthopaedics Industry
Automated Aircraft Engine Impeller Inspection on VisionGauge® Digital Optical Comparator
Automated Aircraft Engine Impeller Inspection
Fir Tree and CAD Overlay in the Aerospace Industry on VisionGauge® Digital Optical Comparator
Fir Tree and CAD Overlay in the Aerospace Industry
Knee Implant and CAD Overlay in the Orthopaedics Industry on VisionGauge® Digital Optical Comparator
Knee Implant and CAD Overlay in the Orthopaedics Industry

VisionGauge® Digital Optical Comparators are also appropriate for color applications.

VisionGauge Digital Optical Comparators are also appropriate for color applications
VisionGauge Digital Optical Comparators are also appropriate for color applications
VisionGauge Digital Optical Comparator inspecting an Extrusion
Extrusion
VisionGauge Digital Optical Comparator inspecting a bonescrew
VisionGauge Digital Optical Comparator inspecting a bonescrew on VisionGauge® Digital Optical Comparator
Bonescrews
Inspections of Spring and other Various Mechanical Parts on VisionGauge® Digital Optical Comparator
Inspections of Spring and other Various Mechanical Parts
Inspection of an Automotive Part (transmitted illumination) on VisionGauge® Digital Optical Comparator
Automotive Part (transmitted illumination)
Inspection of an Automotive Part (reflected illumination) on VisionGauge® Digital Optical Comparator
Automotive Part (reflected illumination)
Inspection of Electronic Assembly / Populated Printed Circuit Board on VisionGauge Digital Optical Comparator
Electronic Assembly / Populated Printed Circuit Board
VisionGauge® Digital Optical Comparator / Profile Projector Applications

VisionGauge® Digital Optical Comparator – Videos

VisionGauge®’s proprietary CAD Auto-Align™ & Auto-Pass/Fail:

VisionGauge®’s patent-pending “Tooth-Checker™” tool is specially adapted to check parts with teeth:

VisionGauge® for fully-automated, high-accuracy bone screw inspection & measurement:

VisionGauge® for automated measurements, to collect data and compute graphs, charts, & statistics:

Some of the benefits of using the VisionGauge® Digital Optical Comparator in the Cutting Tool industry:

The VisionGauge® Digital Optical Comparator 700-series: Perfect for EDM- and LASER-Drilled cooling holes and parts with complex geometries:

The VisionGauge® Standalone Inspection & Measurement System is the perfect drop-in solution for automated cells and automation applications requiring high-accuracy inspection:

The VisionGauge® Digital Optical Comparator in an automated cell:

New VisionGauge® Digital Optical Comparator Tool for Automatic Part Alignment:

This video shows how you can very simply put parts down anywhere on the VisionGauge® Digital Optical Comparator and the system will automatically find and measure them for you, quickly, easily and accurately:

This video shows how the VisionGauge® Digital Optical Comparator, with the optional supplemental rotary stage, can be used to measure run out:

Here is a “product overview” presentation, from September 2011:

Here’s a video of the fully-automated inspection of an aircraft engine turbine blade:

Here’s a short video of an application involving the fully-automated inspection of an aircraft engine impeller:

Below is a video showing how the system can be used to create a part’s CAD file (for example: for reverse engineering):

Here’s a video showing how the system can be used to carry out fast, easy & accurate fully-automated measurements:

Using the VisionGauge® Digital Optical Comparator to easily and accurately measure features that are larger than the system’s field-of-view:

Using the VisionGauge® Digital Optical Comparator Z-axis LASER Measurement Module to easily and accurately measure the depth & height of features on your part:

YouTube-logoView our entire Youtube channel for more VisionGauge® Digital Optical Comparator Videos.

VisionGauge® Digital Optical Comparator Videos

Large Travel Systems

VisionGauge® Digital Optical Comparators are also available in large travel configurations to accommodate parts with larger dimensions.

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.

500 Series VisionGauge® Digital Optical Comparator - Super-Extended Travel Configuration
The super-extended travel configuration 500 Series VisionGauge® Digital Optical Comparator for inspection of large and heavy parts.

Super-Extended 36″ travel system in 500-series horizontal configuration:

Super-Extended 36" travel horizontal digital optical comparator

24″ x 24″ travel system in 500-series vertical configuration:

24" x 24" travel system in vertical configuration VisionGauge Digital Optical Comparator

Please contact us for more information. We can configure a system to meet your requirements!

VisionGauge® Digital Optical Comparator Customizable Options

Many other options are available with the VisionGauge® Digital Optical Comparator, including:

  • Adapted NIST-traceable stage micrometer with certificate of calibration (this will allow you to carry out the yearly re-calibration yourselves)
  • Upgrade of the X and Y axis encoders from 0.5 um resolution to 0.1 um resolution.
  • Extended (i.e. 24″) X-axis travel stage upgrade (from the standard 12″ travel) for Horizontal configuration VisionGauge® Digital Optical Comparator
  • Extended (i.e. 12″) Y-axis travel column upgrade (from the standard 6″ travel) for Horizontal configuration VisionGauge® Digital Optical Comparator
  • Extended (i.e. 24″ x 24″) X-axis and Y-axis travel stage upgrade (from the standard 12″ x 12″ travel) for the Vertical configuration VisionGauge® Digital Optical Comparator
  • Extended (i.e. 12″) Z-axis travel. Applicable for either the horizontal or vertical configuration of the VisionGauge® Digital Optical Comparator
  • “Additional monitor option” to automatically load and display inspection instructions & criteria or other related documents when the work order barcode is scanned to automatically load the appropriate CAD file
  • On-axis reflected LED illumination module (programmable and computer-controlled) fully integrated with VisionGauge® Digital Optical Comparator. This reflected (i.e. “front”) illumination module produces a very different type of front illumination that is very “flat” (i.e. “shadow free” and low glare) that is more appropriate for certain types of parts. This illumination module is mounted on a “swing arm” to allow the operator to easily put it in position & retract it when it is not needed.
  • Supplementary rotary encoded motorized axes (i.e. to rotate the part), including:
    • All required motion control hardware for the supplementary motorized axis (for part rotation). This motion control hardware is completely and seamlessly integrated with the system’s existing motion control hardware
    • Motorized encoded high-accuracy rotary stage
    • Fixture to mount the stage to the system’s dovetail grooves
    • All required cables & power supplies
  • LASER module for Z-axis measurements, including:
    • High-accuracy structured LASER module
    • LASER controller hardware (to completely control the LASER’s operation from within the software)
    • Adapted fixture to mount the LASER module onto the Z axis stage
    • Software upgrade
    • All required cables & power supplies
  • Optional standalone “desktop” software license (to allow you to remotely view your CAD files, setup tolerances, create automated inspection and measurement programs, etc…)
  • VisionGauge® Annual Support and Update Program Membership Renewal (which provides users with unlimited technical support and free software updates for a full 1-year period). Note that unlimited technical support and free software updates are included for the 1st year with every VisionGauge® Digital Optical Comparator (Patent Pending) system.
  • Replacement air filter (this is the only “consumable” part in the entire system!)

 

Other accessories, system configurations, fixturing (etc…) are also available…

An optional supplementary monitor to automatically display related files, reports and information on the VisionGauge® Digital Optical Comparator
An optional supplementary monitor to automatically display related files, reports and information.
Optional adapted diffuse on-axis illumination module on VisionGauge® Digital Optical Comparator
Optional adapted diffuse on-axis illumination module. This specialized illumination module produces a very different type of front illumination that is very "flat" (i.e. "shadow free" and low glare) that is more appropriate for certain types of parts. It is module is mounted on a "swing arm" to allow the operator to easily put it in position & retract it when it is not needed.

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

VisionGauge® Digital Optical Comparator Customizable Options

Z-axis Laser Measurements

Z-Axis LASER Measurement Module

VisionGauge® Digital Optical Comparators are available with an optional Z-Axis LASER Measurement Modules.

In the application below, for example, the VisionGauge® Digital Optical Comparator is used to measure the depth of slots in aircraft engine turbine blades. Without the Z-Axis LASER Measurement Module (i.e. the image on the left below), it is only possible to measure XY dimensions on the part (for example: the slot width).

However, with the Z-Axis LASER Measurement Module (i.e. the image on the right below), the part’s z-axis depth & height variations can all be measured, easily & accurately.

Image obtained with standard front (reflected illumination) on VisionGauge® Digital Optical Comparator
Image obtained with standard front (reflected illumination).
Z-axis laser measurements for depth and height of parts on VisionGauge® Digital Optical Comparator
The LASER shows all of the depth & height variations in the part.

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

VisionGauge® Digital Optical Comparators – Z-axis Laser Measurements

Rotary Stages / Rotary Axes

VisionGauge® Digital Optical Comparators are available with supplementary rotary axes. Our rotary stages are extremely flat and of the highest quality. They produce very repeatable movement and rotate the part about the stage’s true center.

Rotary stages can be mounted in different planes to accommodate the specific requirements of your application.

Multiple rotary stages can also be used (to provide “Pan & Tilt” capability, for example).

VisionGauge® Digital Optical Comparator rotary stage/axis
VisionGauge® Digital Optical Comparator rotary stage/axis
An aircraft engine impeller mounted on a VisionGauge® Digital Optical Comparator rotary stage/axis
An aircraft engine impeller mounted on a VisionGauge® Digital Optical Comparator rotary stage/axis
Rotary stage mounted normal to the optical axis on VisionGauge® Digital Optical Comparator
Rotary stage mounted normal to the optical axis
Rotary stage mounted with the axis of rotation aligned horizontally with a 5C Collet chuck on VisionGauge® Digital Optical Comparator
Rotary stage mounted with the axis of rotation aligned horizontally (and with a custom fixture that includes a 5C Collet chuck)
Rotary stage and workholding for turnkey runout measurement application
Rotary stage and workholding for turnkey runout measurement application

The above video shows a VisionGauge® tool for Automatic Part Alignment that is often used in conjunction with rotary stages.

Overall Outline of Rotary Stage included in "VGDOC-30-RS" (different dimensions and configurations are available) on VisionGauge® Digital Optical Comparator
Overall Outline of Rotary Stage included in "VGDOC-30-RS" (different dimensions and configurations are available)

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

VisionGauge® Digital Optical Comparator – Rotary Stages / Rotary Axes