Optical Comparator (Profile Projector)
Unique Types of Camera-Based Dimensional Measurement Tools
Key Takeaways
- Camera‑based CMMs (XM Series/WM Series) enable fast 3D/GD&T measurements on the shop floor.
- Automated optical comparators (IM-X1000 Series) deliver high‑speed, non‑contact 2D dimensional checks.
- IM-X1000's multisensor capabilities add laser, probe, and rotary for limited 3D capture and the high multi‑point throughput.
- IM-X1000's high-accuracy LM camera head suits tight tolerances; IM camera head excels at rapid multi‑part, multi‑feature inspection.
- Vision systems reduce setup and operator skill needs, enabling automated reporting and traceability.
Dimensional measurement tools are devices that measure 2D elements, like distances and circumferences, as well as 3D and GD&T features. Historically, these have been manual tools that require repeated processes with long measuring times and a lot of calculation. However, new technology has entered the metrology market to help automate and evolve the traditional dimensional measurement tools.
This dimensional measurement equipment is supplied with cameras, software, and technology that technicians can trust to produce the same measurements. Compared to the new tools, handheld tools like micrometers, calipers, and rulers are showing their weaknesses.
In this blog, we’ll dive into unique types of dimensional measuring equipment that are sure to leave manual dimensional instruments in the dust.
Coordinate Measuring Machine
The first type of dimensional measurement equipment is a coordinate measuring machine, also called a CMM. A coordinate measuring machine measures traditional measurements like diameter and distances, as well as 3D/GD&T features like spheres, cone angle, flatness, perpendicularity, and hole position.
There are different types, like bridge, cantilever, gantry, horizontal, or portable. They each use a probe to collect coordinate data points. The probe touches the part and records the measurements. CMMs work well with sturdy parts that won’t be affected by probe contact, so they’re useful on substances like metals and hard plastics. CMM usage is commonly found in the automotive, aerospace, and medical industries.
KEYENCE’s CMMs
KEYENCE offers CMMs that are easy for anyone to use, anywhere in the facility including the shop floor. The systems enable accurate 3D, GD&T and CAD comparison with automated reporting capabilities. The two coordinate measuring machines that KEYENCE has are the XM-5000 Series Handheld Probe and the WM-6000 Series Wide Area Coordinate Measuring Machine.
CMM measurement applications include:
- Machined parts
- Molds
- Stamping
- Die casting
- Welding distortion
XM Series vs. WM Series
The XM Series and WM Series are handheld CMMs with seven probe markers for the controller camera to capture. Although these tools are handheld, their wireless capabilities give users almost limitless degrees of measurement freedom and a wide range of motion for easy measurement. To get a measurement, simply touch the probe to the part!
Both CMMs use quartz glass and lenses that reduce temperature influence, so they conquer any shop floor. However, the difference between these two CMMs lies in their applications.
The WM reaches a wider area than the XM at 25m (82 ft), compared to the XM’s 2m (6 ft). Because of these differences, the WM is ideal for large components that cannot be moved, so the measurement device must go to them, while the XM can support small parts with its stage and up to 6ft parts in general. In this case, one does not necessarily outperform the other; it is solely up to the size measurement needed.
Optical Comparator
Optical comparators are long-used dimensional instruments that utilize a stage, lens, and light to create a shadow on the stage for measurement. These dimensional instruments measure 2D features, like length, width, radius, diameter, and angles. Typical optical comparators measure X and Y axes simultaneously in 2D.
Optical comparators are widely used on smaller parts where it may be hard to use conventional tools to take a measurement and/or fragile parts because there is no contact in the measurement. Industries like aerospace, automotive, semiconductor, medical, and defense use optical comparators for small components.
KEYENCE’s Automated Optical Comparator
KEYENCE’s automated optical comparator, the IM-X1000 Series, is an automatic optical inspection system that uses vision technology. These dimensional instruments can measure in 2D and collect data in seconds by detecting location orientation and finding millions of data points.
KEYENCE's latest IM-X Series is a modular system with three stage sizes and two different main camera head types - the wide-field IM head and the high-accuracy LM head - with various multisensory capabilities including probe, laser, and rotary. Regardless of set up, these tools guarantee easy and accurate measuring and programming.
There are only two steps to measure with any of the optical comparators: place the part(s) on the stage and press the measure button. All models are supplied with technology to auto-adjust and detect edges with a 20-megapixel monochrome CMOS sensor and telecentric lens. Each model has measurement reporting technology that organizes the measurement data. This being said, let’s dive into the differences between the options that make each unique.
Wide-Field IM Head
In addition to all the standard features the optical comparators have, the IM-X1000 Series' IM camera head is a master of 2D non-contact measurements. When the IM-X measures, it can collect up to 5,000 dimensions on 1,000 parts in as little as one second. The IM-X's IM head is designed for quick and accurate measurement where inspection efficiency is a priority, ideal technicians who typically use optical comparators, calipers, or micrometers.
High-Accuracy LM Head
The IM-X1000 Series' LM camera head is the high-accuracy version of the IM. With an optical zoom of up to 50x, even the smallest details can be expanded and accurately measured. It has a very high +/-0.7μm accuracy and 0.1 μm repeatability within the field of view, suitable for situations where inspection precision is a priority. This model is supplied with features that combat typical measuring difficulties.
Multisensor Capabilities
Both the IM and LM camera head additional measurement capabilility options beyond high-precision optics and multi-color illumination for measurement. For technicians currently using measuring microscopes or optical CMMs, the IM-X1000 enables upgraded probing, laser, and rotary capabilities that the other automated optical comparators don’t possess. Probing allows for accurate contact measurement of top, side, and angled surfaces, without the need for fixturing. The multi-color laser lets users get instant height and depth mesurement of an shape or material. Lastly, the rotary's automated indexing allows for 360° measurement to perform rotational GD&T measurements including circularity and runout.
Use KEYENCE’s Dimensional Measuring Equipment
At KEYENCE, we specialize in vision technology. We offer over 10 dimensional measurement equipment choices within the six types in this list of measuring devices. Our sensors, comparators, profilers, profilometers, micrometers, and CMMs are used in aerospace, construction, automotive, semiconductor, medical devices, and more industries!
Our knowledgeable team is trained to help you pick the best dimensional measuring equipment for your application. Contact us today to start incorporating laser technology into your measuring process!
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