High-Accuracy Field-Of-View Inspection & Measurement Systems

VisionGauge® High-Accuracy Field-Of-View Inspection & Measurement Systems are powerful, flexible, and extremely easy to use. They can be applied to solve a wide range of applications across many different industries.

VisionGauge® High Accuracy Field-Of-View Inspection and Measurement Systems are available with either turret-based microscope type optics or with detented zoom optics. All of our industrial systems have a long working distance to provide ample clearance between the part and the lens.

All our VisionGauge® High Accuracy Field-Of-View Inspection and Measurement Systems run the VisionGauge® software package:

Powerful and easy-to-use
Includes all of VisionGauge®’s advanced patented tools & technologies (for high-accuracy automated part-to-CAD comparison, operator-independent results, etc…)
Includes a wide range of powerful inspection and sub-pixel accurate measurement tools
VisionGauge® software allows for easy data collection, statistics (with graphs & charts), reporting as well as data transmission & exchange
Supervisor-level / operator-level password protection
Robust & field-proven, with a broad installed base (over 3500 licenses in use worldwide)

These network-ready Windows™-based systems are appropriate for both the shop floor and the QC lab.

Multi-magnification turret in FOV inspection

FOV Inspection and Measurement lab station

FOV inspection system with detented zoom lens

VisionGauge® High Accuracy Field-Of-View Inspection and Measurement Systems are perfect for wide range of industrial production, quality control, and laboratory applications.

VisionGauge®’s advanced edge-detection technology produces sub-pixel accurate measurements, increases measurement repeatability, and eliminates operator-dependent measurement error. Standard configurations are available off-the-shelf and non-standard configurations can also be accommodated. We can configure a system to meet your specific requirements!

These inspection and measurement systems are built around the powerful and easy-to-use VisionGauge® software package, which means that they have a simple and intuitive Windows™ interface and include a wide range of fully-integrated tools for imaging, measurements, statistics, databasing, reporting (with charts & graphs), data transmission & exchange, and much, much more!

VisionGauge® 3D inspection & measurement systems also include a wide range of image analysis and measurement tools to allow you to successfully solve a wide range of applications. VisionGauge®’s powerful stage-based vision inspection tools include counting and sizing (blob analysis), registration and alignment, measurement, pattern matching, illumination control, color verification, defect detection, and many others.

Learn more about the various industries and applications using our VisionGauge^® inspection and measurement systems.

VisionGauge® Automation Capabilities

VisionGauge® systems are perfect for fully-automated high-accuracy inspection & measurement applications and “lights out” operation, directly on the shop floor. They can very easily be interfaced to external machinery and equipment, such as robots & cell controllers.

VisionGauge® systems can easily be dropped into an existing automated cell to provide advanced inspection and measurement capabilities, including those provided by our patented CAD Auto-Align™, CAD Auto-Pass/Fail™ and Tooth Checker™ tools.

VisionGauge’s® automation module provides extensive communication capabilities (e.g. TCP/IP over Ethernet, digital I/Os, RS232, etc…) for full 2-way handshaking (with a robot or cell controller, for example). VisionGauge® is easy to interface with a robot or other part-positioning equipment. The system’s powerful “Smart Capture” tool can even be used to wait for and detect the presence of a part to trigger an automated inspection routine.

VisionGauge® also provides extensive data collection, manipulation & exchange, statistics, charting and reporting capabilities, to give you a complete picture of production results during long automated runs.

Furthermore, VisionGauge’s® high-accuracy measurements can be used to send feedback and offsets to controllers for full-automated offset correction.

VisionGauge® systems are very widely-applicable and extremely general-purpose. They are perfect for carrying out very high-accuracy inspections and measurements in fully-automated applications.

High Accuracy VisionGauge® 3D Inspection & Measurement Systems

VisionGauge® High-Accuracy 3D Inspection & Measurement System in Half-Gantry Configuration

VisionGauge® High Accuracy 3D Inspection & Measurement Systems with built-in auto-focus and edge-detection are perfect for wide range of industrial production, quality control, and laboratory applications.

VisionGauge^®‘s advanced edge-detection technology produces sub-pixel accurate measurements, increases measurement repeatability, and virtually eliminates operator-dependent measurement error. Standard configurations are available off-the-shelf and non-standard configurations can also be accommodated. We can configure a system to meet your specific requirements!

These 3 dimensional inspection & measurement systems are built around the powerful and easy-to-use VisionGauge^® software package, which means that they have a simple and intuitive Windows^™ interface and include a wide range of fully-integrated tools for imaging, measurements, statistics, databasing, reporting (with charts & graphs), data transmission & exchange and much, much more!

VisionGauge^® 3D inspection & measurement systems also include a wide range of image analysis and measurement tools to allow you to successfully solve a wide range of applications. VisionGauge^®‘s powerful stage-based vision inspection tools include counting and sizing (blob analysis), registration and alignment, high-accuracy positioning and measurement, pattern matching, illumination control, auto-focus, step and repeat part scanning, color verification, defect detection, and many others.

3D Inspection Power Zoom Inspection System

Configuration with Power-Zoom optics.

Also available with Microscope-grade optics

VisionGauge® 3D Measurement System Features:

Available with an open-frame stage & glass insert that allows for both transmitted and reflected illumination. Also available in half-gantry and full-gantry configurations
High-precision crossed-roller movements with built-in end-of-travel limit switches.
Encoder feedback is available with resolutions of 0.25um or 0.1um.
Stage lengths can be customized to fit part requirements, including super-extended travels.
Micro-stepping motor controller is capable of ultra-fine movements.
All axes can be controlled using either the external (3-axis, 3-speed) joystick or VisionGauge’s^® on-screen joystick. With VisionGauge’s^® intuitive “teach” mode, it is easy to create part programs. Programs can be saved to and retrieved from disk.
These systems include the complete VisionGauge® extensive measurement toolset.
Manual configurations are also available.
All illumination is LED, computer-controlled & programmable.
Available with fixed magnification or zoom optics, either manual or motorized, or high-power long-working-distance microscope optics.
A wide range of options are available to solve even the most challenging applications, such as rotary stages, adapted & specialized illumination, LASER modules, etc…

Download a pdf about our High-Accuracy 3D Measurement and Inspection Systems.

Find out more about various applications where our VisionGauge^® visual inspection and machine vision systems are being used. Also read about how our fleet of VisionGauge^® Digital Optical Comparators can solve your applications.

Portable Vision Inspection/Measurement and Smart Camera Bundles

Powerful & Easy to use Laptop-Based Mobile Visual Inspection Systems

VisionGauge® laptop-based mobile visual inspection, measurement, and data collection systems are the ideal solution for mobile, remote, and field inspection and measurement applications. These portable measurement systems produce high quality and high-resolution full color images and are compatible with almost all laptop and notebook PCs. They also support a wide range of video sources: standard video cameras, specialty video sources (borescopes, ruggedized and waterproof cameras, microcameras, flexible and rigid fiber-based scopes, handheld cameras, etc…) and even VCRs and camcorders. These general-purpose mobile systems can solve a wide range of industrial, military, and R&D applications, such as:

General mobile testing, image & data collection, and reporting,
Remote viewing, imaging, & non-contact measurement,
Flaw detection & wear assessment,
General Non Destructive Testing (NDT) and remote visual inspection,
Field surveillance,
Difficult remote applications,
Field inspection of tanks, vessels, tubes, pipes…
Internal inspection of die castings, turbine housings…
Etc…

These portable video inspection systems are very competitively priced and can be supplied either as a complete turnkey solution or as a board level and software product. The basic system includes our powerful and easy to use VisionGauge® machine vision software package with its familiar Windows™ interface, a high-resolution megapixel digital color camera, a lens, and a compatible notebook computer. This is a complete, ready-to-run solution!

Download a pdf about our Laptop-based visual inspection systems.

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Smart Camera Bundles

The VisionGauge® / Smart Camera Bundles are complete, all-in-one solutions for both imaging and machine vision applications. They include either the VisionGauge® or VisionGauge® OnLine software package as well as a Sony Smart Camera, a self-contained unit that includes a camera and PC that runs the Windows™ XPe operating system.

The VisionGauge® / Smart Camera Bundles come with everything fully installed and configured and are ready to run right away. They include all of VisionGauge®’s powerful software tools. And because of VisionGauge®’s simple and intuitive interface, they are extremely easy to setup and use.

These Smart Cameras now can also interface to our custom-designed VisionGauge Camera Interface Module and Illumination Controller. This module supplies power to the camera, allows compact illumination control, and breaks out all of the camera’s I/O and serial signals.

Smart Camera Interface Module and Illumination Controller

VisionGauge® camera illumination controller

The VisionGauge® Camera Interface Module and Illumination Controller can be used either in conjunction with any of the Sony Smart Cameras or as a “stand alone” illumination controller.

When used in conjunction with any of the Sony Smart Cameras, the VisionGauge® Camera Interface Module and Illumination Controller:

Powers the camera
Breaks out all of the camera’s I/O and Serial signals
Controls the illumination

When used as a “stand alone” illumination controller, the VisionGauge® Camera Interface Module and Illumination Controller can be used to:

Manually control the illumination intensity (using a trim pot)
Control the illumination intensity via a computer’s output (0-5V).

The VisionGauge® Camera Interface Module and Illumination Controller is compatible with 24V continuous LED illuminators and uses an industry-standard 9-pin “D” connector (i.e. “DB-9 female” on the controller).

The VisionGauge® Camera Interface Module and Illumination Controller includes the required 24V power supply and is available as either an enclosed or a board-level product.

Download a pdf with information about the VisionGauge Smart Camera Interface Module.

Request a Quote

The VisionGauge® / Smart Camera System Bundles are perfectly suited for a wide range of applications including industrial, imaging, microscopy, image analysis, machine vision inspection, and quality control.

Product Overview pdf

The VisionGauge® / Smart Camera Bundles include either the VisionGauge® or VisionGauge® OnLine software package. Please follow the links below for more information about these machine vision software packages:

Information about the VisionGauge® software package (pdf)

Information about the VisionGauge® OnLine software package (pdf)

Multi-Camera/Multi-View Vision Systems

VisionGauge^® Online multi-camera vision systems are perfect for applications requiring different views of a part or inspection of multiple lanes. VisionGauge^® OnLine machine vision software allows the user to create inspection programs that can switch quickly between cameras and process numerous images on-the-fly. These vision systems are able to be configured with multiple high-resolution digital cameras and repeatable illumination with several light sources controlled by the software. Our multiple camera vision systems can fit directly into a process line or are available as a stand-alone system.

These multi-camera vision systems are able to be customized and feature VisionGauge^® OnLine machine vision software which includes many tools to produce an inspection program that yields reliable results:

Object Counting and Sizing / Blob Analysis
Part Identification
Defect / Flaw Detection
Presence / Absence Detection
Image Processing and Analysis
Automated Measurements
Optical Character Recognition and Verification
Pattern Matching and Part Location
Alignment and Registration
Color Verification
and more…

Learn more about applications where our VisionGauge® visual inspection and machine vision systems are currently being used. Contact us to find out how VisionGauge® systems can solve your application.

High-Resolution, Wide Field-of-View Measurement Systems

The VisionGauge^® Wide Field-of-View, High-Resolution Measurement Systems use specialized long-working-distance telecentric optics to produce extremely crisp & clear imagery with ultra-low distortion. Different configurations are available with field-of-views as wide as 4.5″ (approx. 115 mm). These inspection and measurement systems also include a high-resolution digital color camera and are capable of resolutions as fine as 0.001″ (approx. 25 um).

Wide Field-of-View Optical Measurement System

VisionGauge^® high-resolution, wide field of view measurement systems come with both transmitted & reflected illumination and, as an option, can also include adapted X-Y-Theta positioning mechanisms for quick and easy part alignment. Multiple illumination options are also available to make parts truly stand out for inspection.

These field of view measurement systems are built around the industry-standard VisionGauge^® machine vision software package. As such, they support all of the tools and functionality of the Standard Edition of the VisionGauge^® software package and provide all of the benefits, power and ease-of-use of VisionGauge^®.

These high-accuracy systems are ideal for high-resolution volume inspection, measurement and documentation of parts measuring a few inches.

Other Field-of-View inspection and measurement systems are also available with various customizations to fit your application, including boom stand configurations and extended travel for tall parts, “ruggedized” stand with coarse / fine focusing mechanism, zoom lens optics, detented optics, both transmitted and reflected illumination, etc…

Long Travel Field-of-View Measurement Systems

Read more about various applications where our VisionGauge^® visual inspection and machine vision systems are being used.

Learn about how VisionGauge^® Digital Optical Comparators can improve your inspection and measurement processes.

Download this information in .pdf format.

Cartesian Measurement and Vision Inspection Systems

VisionGauge Cartesian Measurement and Inspection Systems are designed for fast and accurate positioning followed by vision inspection and high-accuracy field-of-view measurements.

These systems feature fully programmable 3D motion for fast and repeatable motion over long distances, making them ideal for dynamic inspection applications with high duty-cycles. Our Cartesian Inspection systems are used in a wide range of industrial production and quality control applications. They are also appropriate for part scanning, using VisionGauge’s® “scan mode” over a user-defined area.

Full-Gantry high-power VisionGauge cartesian system

Our VisionGauge Cartesian Measurement and Vision Inspection Systems are built around the powerful and easy-to-use VisionGauge® machine vision software package, which means that they have a simple and intuitive interface and include a wide range of fully-integrated tools for imaging, image analysis, statistics, databasing, reporting, and much, much more!

The Cartesian measurement system can be controlled manually through an external (3-axis, 3-speed) joystick, as well as through the “on-screen” joystick. Automated inspection is also easy to program with “step-and-repeat” operation using VisionGauge’s® intuitive “teach mode”. These automated programs can be saved to disk and reloaded by operators on-demand for fast execution.

These systems are offered in both half-gantry and full gantry configurations: Half-gantry (i.e. “bridge”) configurations reduce space requirements, while full gantry configurations are recommended for ultra-long travels and heavy samples. Both open and closed-frame configurations are available, in addition to multiple mounting and support configurations for your part.

Open-frame, half-gantry cartesian measurement system

High-resolution zoom optics are available in both manual and motorized (i.e. “power zoom”) configurations. Other “custom” optical configurations are also available. These systems benefit from a variety of programmable computer-controlled illumination options for repeatable lighting and consistent measurement results. Our application experts can customize and configure our vision inspection systems to meet your specific requirements.

Read more about various applications where our VisionGauge^® visual inspection and machine vision systems are being used, and learn about how our VisionGauge^® Digital Optical Comparators can solve your application.

Download this information in .pdf format.

Automated Optical Inspection Systems (AOI systems)

VisionGauge^® OnLine Automated Optical Inspection Systems (AOI systems) are fully-automated 3D inspection and measurement systems capable of delivering high-accuracy results for various applications and industries. Many different configurations are available, depending on the requirements of the application.

High-Accuracy, High-Speed Automated Optical Inspection Systems

VisionGauge^® Online High-Speed Automated Optical Inspection systems are the ideal solution for demanding high-throughput, high-resolution applications. These systems are suitable for a wide range of applications requiring automated defect detection and high-accuracy measurements, including MicroElectroMechanical systems (for MEMS inspection or MEMS measurement), semiconductor and discrete device inspection and measurement, and much more.

VisionGauge® High-Speed, High-Accuracy AOI System inspection area

VisionGauge® Online High-Speed AOI machines are multi-processor based automated inspection systems that support concurrent image analysis and stage motion. It is a complete, fully-contained, self-standing unit in a full gantry configuration (i.e. the camera moves over the parts; the parts themselves do not move).

These systems are available with a resolution as fine as 0.1 micron. Multiple customizations are possible to meet application-specific requirements including modifications to the camera, optics, illumination module, fixtures, and more. An optional LASER module for automated laser profiling can also be integrated. We provide a wide range of travels, short and long, and a high-speed 240 VAC servomotor motion system for rapid, accurate positioning.

VisionGauge® Online High-Speed Automated Optical Inspection machines are powerful, but easy to use and easy to program. Fully-automated inspection and measurement programs (i.e. “recipes”) are created and modified using VisionGauge®’s intuitive Graphical User Interface. Programs can be saved to disk and read-in later on, allowing the possibility to manage different inspection routines for different parts.

VisionGauge® OnLine Software Inspection and Measurement Tools

Defect detection
Color verification
Pattern matching
High-accuracy measurements
Object counting & sizing

Assembly verification
Image analysis
Blob analysis
Presence/absence detection
Optical character recognition / verification
and much more…

Sample videos:

Head-on view

Oblique view

Download a pdf with more information about the VisionGauge^® High-Speed, High-Accuracy (AOI) Automated Optical Inspection System.

High-Accuracy AOI Systems for 3D Inspection and Measurement

Our VisionGauge® High-Accuracy AOI Systems are the AOI solution you need. They are fully-automated, full-color systems capable of high-accuracy measurements, automated defect detection, color verification, optical character recognition, and much more.

Automated Optical Inspection (AOI) system

Our automated optical inspection equipment features high-precision, crossed-roller movements with 0.1 micron encoder feedback and micro-stepping motor controller capable of ultra-fine movements. All axes can be automated and are controlled using an external multi-axis, 3-speed joystick or on-screen joystick controls.

The built-in “Auto-Focus” provides fast, accurate, and repeatable re-focusing. With VisionGauge® OnLine’s intuitive ‘teach’ mode, it is easy to create part programs, then let the system perform automated measurements. Programs can be automatically loaded, saved, and read-in from disk so they are ready to operate as soon as the part is in place. VisionGauge® OnLine’s extensive set of measurement tools and “Auto-Scan” feature with advanced detection capabilities are perfect for applications requiring automatic defect detection.

An open-frame stage with a glass insert allows for both transmitted and reflected illumination. Half- and full-bridge configurations are also available – for example, if your application requires heavy loads and long travels. Standard configurations are available ‘off the shelf’ and non-standard configurations can also be easily accommodated: We have a great deal of experience with customization and can configure a system to meet your specific requirements.

Small Automated Optical Inspection System (AOI System) for Analog Video

An small model AOI System with an analog camera

Download a pdf with more information about the VisionGauge^® High-Accuracy (AOI) Automated Optical Inspection System.

Automated Optical Inspection Built Around VisionGauge® OnLine Software

Part Groups Interface in the VisionGauge OnLine software

Using the VisionGauge® OnLine software package, these AOI machines have a simple and intuitive Windows™ interface and include a wide range of fully-integrated tools for imaging, automated optical inspection (AOI) and automated measurements, qualitative Pass/Fail inspection, pattern matching, optical character recognition and optical character verification (OCR & OCV), statistics, databasing, signal processing, reporting and much, much more!

These automated inspection systems are very easy to program. Everything is done using the mouse & joystick, through VisionGauge’s® intuitive graphical user interface making it quick and easy to review results, view images of “pass” or “fail” parts, export data to Excel or any other application, activate built-in SPC (with graphs as well as numerical & pass/fail statistics), etc…

Advanced software tools include:

robust and accurate Auto-Focus,
wide range of advanced edge-detection based sub-pixel-accurate measurement tools,
automatic registration tools,
powerful, rotation independent pattern matching tools,
color verification tools,
“Counting & Sizing” (blob analysis) tools,
power zoom,
programmable computer-controlled illumination,
and more… the software is continuously being updated and improved with new features and inspection tools.

Our automated optical inspection systems are widely-applicable and include a vast range of analysis and measurement tools to allow you to successfully solve countless inspection and measurement machine vision applications. See how automated visual inspection can help your business.

View more information about applications our AOI systems have been used to solve in various industries. Also, learn about our powerful and adaptable VisionGauge^® Digital Optical Comparators and how they can solve your application.

Optical Character Recognition & Verification Systems (OCR / OCV Systems)

Our VisionGauge^® OnLine Optical Character Recognition Systems / Optical Character Verification Systems for industrial applications are equipped with advanced scanning software able to automatically locate and read text. They also have a complex recognition process that can verify that the text matches the expected character string. Additionally, our systems can compute results statistics, export & exchange results, produce reports, execute operations conditional on Pass/Fail results, and more.

These Optical Character Recognition and Verification systems include adapted, low distortion optics and programmable, computer-controlled illumination, for maximum repeatability of results. They also include the entire VisionGauge^® OnLine toolset. All of VisionGauge^® OnLine’s image processing and analysis tools are thus available to automatically “cleanup” the image before carrying out the character recognition operation. This can dramatically improve results in the cases where there is contamination, background noise, difficult to read characters, etc.

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VisionGauge^® OnLine’s automated OCR / OCV tool is very robust in the presence of print defects and includes an advanced, proprietary “character splitting” algorithm to deal with print imperfections, smears, and other defects. VisionGauge^® OnLine’s OCR / OCV tool is “user-trainable” and supports user-supplied character and symbol libraries.

Below you can view sample videos of a customized Optical Character Recognition / Optical Character Verification System. This is a motorized system that was adapted to process 272 parts at a time, on two trays. The system sits on a regular workbench.

Many different configurations of our VisionGauge^® OnLine Optical Character Recognition / Optical Character Verification Systems are available. If you’re in need of a custom OCR system we can configure a system to meet your specific requirements! Contact us for more information.

View more information about the various industries and applications our VisionGauge^® visual inspection and machine vision systems have assisted. Our ground-breaking VisionGauge^® Digital Optical Comparators also feature optical character recognition and verification software tools. You can learn more about those systems here.

Wire/Cable Cross-Section, Connectors, and Wire Bond Inspection Applications

High-Resolution Cable Cross-Section Inspection and Measurement

VisionGauge^® high-resolution cable cross-section inspection and measurement systems are designed to carry out high-accuracy automatic measurements of multi-strand cables. Measurements include:

Cable Measurement Systems

Insulator thickness over every outer strand
Minimum insulator thickness
Cable outer diameter
Inner diameter (i.e. best fit through the point of minimum insulator thickness on each outer strand)
ID / OD concentricity
Insulator area

All of these results are obtained within seconds by pressing a single button. Furthermore, the measurements are completely operator independent.

These cable measurement systems can accommodate cables with any number of strands. These systems also include X-Y-Theta positioning mechanisms for quick & easy part alignment.

The VisionGauge^® software that runs these systems has a simple and intuitive interface. You can use it to quickly and easily compute statistics, plot graphs and charts, and send measurement data to other software and database applications across your network. All of the measurement tools and functionality of the Standard Edition of the VisionGauge^® software package are supported.

These cable and wire measurement systems are very rugged and well designed. They can be used on either the production floor or in the quality-control area and they require virtually no maintenance. They use specialized long-working-distance telecentric optics to produce very crisp & clear high-resolution imagery with extremely low distortion.

Standard configurations can accommodate cables and wires up 1.7″ in diameter and produce measurements with a resolution of 0.0001″ (i.e. 2.5 um). Non-standard configurations are also available.

Insulator Thickness

ID, OD, Concentricity

Insulator Area

Wire Bond Measurement and Inspection

Wire bonding is the most common method used for interconnection inside many integrated circuits and microchips. It is a delicate process that requires high accuracy. VisionGauge® Online Automated Optical Inspection Systems (AOI Systems) can reliably verify bond and wire presence in integrated circuit board wire bonding applications, inspect wire bond connections, and perform high-accuracy measurements on them.

Our AOI systems can be configured with auto-focus and high magnification optics, and they reliably provide measurements in micron range, making it a perfect system for microchip inspection or wire bond inspection. Additionally, our systems are fully capable of producing repeatable motions in three dimensions which allows you to measure objects that extend outside of the camera’s Field-of-View and position your parts accurately. VisionGauge® Online contains a versatile toolset for measuring loop height, wire length, and many other features.

These inspection systems are fully programmable with the aid of our easy-to-use VisionGauge® Online machine vision software. There are numerous features in the software to enhance and automate your inspection, and with our custom inspection systems you can be sure our product will work for your applications.

These highly customizable systems that can learn how to perform an inspection for you, control input and output signals, and create user-defined reports, the VisionGauge® Online Automated Optical Inspection Systems (AOI Systems) are an ideal solution for wire bond inspection and measurement.

Information is also available about more recent applications solved with VisionGauge® Digital Optical Comparators.

Tag: optical measuring systems