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REWRITING THE BOOK ON

DIMENSIONAL MEASUREMENTS

Dimensional Measurement
Time-Saving Dictionary

Image Dimension Measurement System

Offering a solution to any dimensional measurement problem

Conventional Dimensional Measurement


Conventional models
Dimensional Measurement System

Optical comparator, measuring microscope, vernier caliper, micrometer, 3D measuring instrument

Vernier caliper

Optical comparator

Measuring microscope

Micrometer

3D measuring instrument

Conventional measurement systems are plagued by a variety of challenges.

Time-consuming
Measurements such as position and point of origin of a target takes time.
Measurement time increases proportionally with the number of items and number of
points being measured.

Prone to user-caused errors


Measurement results vary depending on what is in focus.
Edge analysis changes with the direction and intensity of lighting.

Measuring requires skill


Learning how to operate a measurement system takes time.
Measurements, including those with virtual lines and virtual points, can be
time-consuming.

The New Standard


With the emergence of image dimension measurement systems, previously
faced problems can be solved with just one measurement system.
The IM Series Image Dimension Measurement System uses captured
images to provide measurement at multiple specified locations in just a few
seconds, all by simply placing the target on the stage and pressing the
measure button.
This booklet will look at some of the problems posed by various
measurement targets and how the IM Series solves these problems.
Image Dimension
Measurement System

Table of Contents

B
Boot

L
P. 04

Linear guide

Charpy specimen

P. 04

Clip

P. 05

Connector terminal

P. 05

CVT element

P. 06

Motor core

D
P. 06

P. 07

Rubber band

P. 07

P. 11

P. 08

Screw

P. 11

Spool valve

P. 12

T
Torsion spring

I
Inscribed gear

P. 10

H
Heat sink

Polygon mirror

G
Gear

P. 10

F
Flange

P. 09

O
O-ring

Designer goods (glasses)

P. 09

P. 08

P. 13

W
Weatherstripping

P. 13

Examples of Improvement

Boot
Conventional models
Dimensional Measurement System Optical comparator, vernier caliper
Problems and Issues

The soft rubber material of boots makes it difficult to maintain a stable dimension when pressure is
applied using vernier calipers. Moreover, because the boot shape is complicated, aligning shadows
using an optical comparator can be difficult and may lead to variations in the measurement results.

IM Series Image Dimension Measurement System


Contact-free accurate dimension measurements are
possible just by placing the target and pressing
a button.
Complex dimension measurements can also be easily
configured for such aspects as radius dimensions and
maximum and minimum points.

Charpy specimen
Conventional models
Dimensional Measurement System Optical comparator, measuring microscope
Problems and Issues

There are a large number of measurement locations associated with Charpy specimens, including overall
length, notch angle, notch height, and notch bottom radius measurements. These measurements can
take a lot of time when done with an optical comparator. Moreover, user-caused measurement errors are
common, making it difficult to determine whether the specimen adheres to standards.

IM Series Image Dimension Measurement System


Measurements necessary for Charpy specimens can be
obtained in just 3 seconds at the push of a button.
Elimination of user-caused measurement errors means
testing can be performed with confidence.

Dimensional Measurement
Time-Saving Dictionary

Clip
Conventional models
Dimensional Measurement System Optical comparator, measuring microscope
Problems and Issues

Measurements that employ virtual lines and virtual points are often performed on clips used for securing
interior and exterior automobile components and tubing. However, due to the large number of clip types,
measurements can be time-consuming.

IM Series Image Dimension Measurement System


Measurement is instantaneous, even for complex
appearances, significantly reducing measurement time.
Virtual line and virtual point extraction is also automatic,
eliminating measurement result variations caused by
users.

Connector terminal
Conventional models
Dimensional Measurement System Optical comparator, measuring microscope, Optical CMM
Problems and Issues

Many time-consuming measurements need to be performed for connector terminals that have been subjected
to complex bendingincluding the magnitude of the bending radius and the position of the radius. Moreover,
it is often necessary to manage bending shape appearances, which opens the door to appearance alignment
errors. Appearance data also needs to be managed in order to compare initial press contact and final press
contact. These are just a few of the many issues that come into play.

IM Series Image Dimension Measurement System


Up to 99 locations can be measured instantly even for
complex measurements such as virtual lines and radius
center positions.
Comparisons with ideal bending shapes stored in
CAD data and bending appearances stored from initial
contact can be easily performed.

Examples of Improvement

CVT element
Conventional models
Dimensional Measurement System Optical comparator
Problems and Issues

Every CVT uses hundreds of parts, so the number of required measurement samples is large. The
accuracy requirements are also strict, such as tolerances for portions that sandwich the laminated rings.
CVTs are important safety parts, so accurate measurements are essential.

IM Series Image Dimension Measurement System


Measurements that would otherwise take time
with an optical comparator, such as finding the
distance between points at a position 1 mm
below a reference line, can be performed just by
placing the target and pressing a button.
User-caused variations in the measurement
results are also eliminated, allowing accurate
measurements to be obtained.

Designer goods (glasses)


Conventional models
Dimensional Measurement System Visual inspection, optical comparator
Problems and Issues

When it comes to designer goods inspections, the similarity between a product and the submitted
prototype product is more important than dimensional measurement management. Conventionally, this
could only be done through visual inspection and contour alignment using optical comparators. Not only
did this take time, but also quantification of inspections was not possible.

IM Series Image Dimension Measurement System


The contour of an acceptable product can be captured
directly, allowing for appearance comparisons between
an actual accepted product and a mass-produced
product.

Dimensional Measurement
Time-Saving Dictionary

Flange
Conventional models
Dimensional Measurement System Optical comparator, measuring microscope, 3D measuring instrument
Problems and Issues

With flanges, measurements that use virtual lines and hole center positions are common, meaning
measurements take time. User-caused measurement errors are also common, making measurements
that much more difficult.

IM Series Image Dimension Measurement System


Measurementsincluding hole pitch, pitch circle, and
geometric tolerances such as concentricitycan be
performed just by placing the target and pressing a
button.

Gear
Conventional models
Dimensional Measurement System Optical comparator, gear thickness meter
Problems and Issues

Inspection measurements of dimensions, inner diameters, and concentricity, as well as base tangent
length measurement, are done during the production process. Performing these measurements
with an optical comparator takes time and opens the door to errors. Moreover, base tangent length
measurements are done with a different measurement system, which can also be time-consuming.
In the end, inspection delays can lead to late deliveries.

IM Series Image Dimension Measurement System


Measurements necessary for gears can be obtained
in just 3 seconds at the push of a button, allowing for
an even higher number of measurement targets to be
handled.
Also, the elimination of user-caused measurement errors
improves quality.

Examples of Improvement

Heat sink
Conventional models
Dimensional Measurement System Vernier caliper, 3D measuring instrument
Problems and Issues

With a heat sink, the number of measurement points is extensive, including plate thickness and pitch.
This means measurements take time. In addition, the measurement points can be small, making
measurement with vernier calipers or 3D measurement systems difficult.

IM Series Image Dimension Measurement System


Measurements such as pitch and thickness can be done
instantly at the press of a button for up to 99 locations.
In addition, measurement is non-contact, so even
fine-point measurements can be performed with no
dimensional errors.

Inscribed gear
Conventional models
Dimensional Measurement System Optical comparator, measuring microscope
Problems and Issues

With inscribed gears, measurement is not performed while the gear is fixed. This makes measurement
impossible when using contact-type measurement systems such as vernier calipers and thickness
gauges. Measurements can only be done using an optical comparator or a measuring microscope.
However, the gear may shift if the XY stage is moved quickly, so measurements need to be done
carefully, which takes time.

IM Series Image Dimension Measurement System


Non-contact measurement can be performed instantly
at the press of a button and without movement of
the XY stage.

Dimensional Measurement
Time-Saving Dictionary

Linear guide
Conventional models
Dimensional Measurement System Measuring microscope, 3D measuring instrument
Problems and Issues

Bearing guide measurements include distances from imaginary points of intersection and measurements
of the positional relationships for a hole. Performing these measurements using a movable stage
measurement system takes an extremely long time. The product variety is also diverse, so users are
interested in finishing each measurement as quickly as possible.

IM Series Image Dimension Measurement System


Hole position measurements can be performed for all
points at the push of a button just by setting the XY
direction and references. Distances from virtual lines can
also be measured accurately. If measurements of targets
with similar shapes are being performed, the enlargement
ratio for a created program can be changed and the
program saved under a different name in order to eliminate
the need to recreate the settings for each product.

Motor core
Conventional models
Dimensional Measurement System Optical comparator, Optical CMM, 3D measuring instrument
Problems and Issues

There are many measurements required with motor cores, including radius size and the position and
angle of radius and circle center positions. These measurements can be time-consuming. In addition,
the required accuracy for each core is extremely high because this influences accuracy after lamination .
User-caused errors can be life-threatening.

IM Series Image Dimension Measurement System


Up to 99 locations can be measured instantly even for
complex measurements such as virtual lines and radius
center positions.
Comparisons with ideal bending shapes stored in
CAD data and bending appearances stored from initial
contact can be easily performed.

Examples of Improvement

O-ring
Conventional models
Dimensional Measurement System Vernier caliper, tape measure
Problems and Issues

Contact from the vernier calipers can cause the O-ring to become distorted, giving rise to measurement
errors. In addition, if measurement is performed while the shape of the O-ring is distorted, values for
a given measurement point may change and prevent accurate measurements from being obtained.

IM Series Image Dimension Measurement System


Measurement is non-contact, so measured values are
not affected by contact pressure.
The ability to measure the O-rings inner circumference
makes it possible to determine the diameter and inner
diameter.

Polygon mirror
Conventional models
Dimensional Measurement System Measuring microscope
Problems and Issues

With polygon mirrors, angular dimensions are very strict, which prevents measurement from being
possible unless using current dedicated measurement equipment (such as an auto-collimator).
The current drive is to make angle and external dimension measurements more efficient.

IM Series Image Dimension Measurement System


Just placing the target and pressing a button makes
it possible to obtain accurate product angle and
dimension measurements.
Measurements are displayed on top of the product
image, so results are visible at a glance.

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Dimensional Measurement
Time-Saving Dictionary

Rubber band
Conventional models
Dimensional Measurement System Vernier caliper, optical comparator
Problems and Issues

Measuring a rubber band includes measuring the outer and inner diameters, but because the shape
is unstable, accurate measurements are difficult. Measurements also vary from person to person, and
obtaining an average measurement for multiple locations takes a very long time.

IM Series Image Dimension Measurement System


Measuring the perimeter makes it possible to obtain the outer and inner
diameters instantaneously through calculation, and because there are
no user-caused errors, its possible to ensure stable quality.

Screw
Conventional models
Dimensional Measurement System Vernier caliper, optical comparator, thread gauge
Problems and Issues

Measuring with optical comparators and measuring microscopes takes time and is prone to usercaused errors. Measuring with vernier calipers and micrometers is also prone to errors. With a thread
gauge, measurement is time-consuming, the gauge can become worn, and only a pass/fail judgment
can be performed.

IM Series Image Dimension Measurement System


Inside diameter, outer diameter, and effective diameter measurement
can be done in just 3 seconds at the press of a button and with no usercaused errors to worry about.
In addition to acceptance judgment, values can also be managed,
which can lead to precise process improvements. This allows precise
instructions to be given to customers for incoming inspections.

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Examples of Improvement

Spool valve
Conventional models
Dimensional Measurement System Optical comparator, GD&T and profile measurement system, micrometer
Problems and Issues

The use of measurement systems varies according to aspects such as outer diameter, L size, groove
diameter and position, corner radius, and measurement locations. The necessity of initial, mid-way, and
final measurements, as well as the large variety of types, calls for a system that includes 10 full-time
measurement inspectors.

IM Series Image Dimension Measurement System


Measurements generally done with multiple
measurement systems can be done with a single
IM Series device.
This leads to increased sampling measurement and
improved quality.

Torsion spring
Conventional models
Dimensional Measurement System Optical comparator
Problems and Issues

Initial product inspections such as the distance and angle from the reference circle to the bending
portion can be done using an optical comparator, but center line measurements need to be displayed as
figures, requiring at least 10 minutes for one spring. With dozens of types being manufactured in a single
day, the time spent waiting for inspections hinder any possible increases in productivity.

IM Series Image Dimension Measurement System


Virtual line measurements for one spring can be done
in 3 seconds.
Thanks to dramatically reduced inspection times for
initial products, productivity can be improved by 50%.

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Dimensional Measurement
Time-Saving Dictionary

Weatherstripping
Conventional models
Dimensional Measurement System Optical comparator
Problems and Issues

Deviation can be measured by overlapping enlarged shapes using an optical comparator, but usercaused errors may occur, and deviation amounts cannot be provided as values. In addition to being
time-consuming, the data cannot be saved.

IM Series Image Dimension Measurement System


CAD data overlay comparisons can be performed
instantly, allowing for deviation measurement.
Because user-caused measurement errors can be
eliminated, exact measurements can be obtained.

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Dimension Measurement System Benefits


Significant reductions in measurement time
The steps required for measurement constitute simply placing the
measurement target on the stage and pressing a button to begin
measurement. These two steps are all it takes to obtain measurements
for up to 99 locations in just a few seconds. For example, lets assume
that conventional measurement methods require 10 minutes for one
target. Conducting 50 measurements a day would amount to about
2000 hours per year. With the IM Series Image Dimension Measurement
System, one measurement can be done in seconds, reducing the hours
to just about 40 per year.

Elimination of user-caused measurement errors


Conventional measurement systems require the user to decide the
measurement point, where target edges should align, where the focus
should be, and a host of other aspects that can lead to variations in
measurement results depending on the habits and skills of the user.
With an image dimension measurement system, positioning and
orientation adjustment for a target are performed automatically, and
measurement is performed for a set point. Manual operations that
previously played a role in measurement errors, including measurement
point specification, edge alignment, and focus adjustment, are no
longer an issue.

[Hours Spent on Measurement per Year]

2000 hours

Measuring microscope/
Optical comparator
40 hours

1960 hours of labor reduced!


Image Dimension
Measurement System
IM Series

? mm

Measurement results vary


from person to person

Operator A

Operator B

Operator C

78.4 mm

78.6 mm

78.8 mm

No user-caused measurement errors!

Operator A

Operator B

Operator C

78.6 mm

78.6 mm

78.6 mm

Simple and convenient saving, searching, and statistical processing of measurement results
All measurement results are automatically saved to the built-in hard
disk drive. Critical statistical values required for inspection reports,
including maximum/minimum values, averages, , 3, and CPK values,
are calculated and displayed automatically just by selecting the
measurement data. Inspection reports and analysis reports can also
be created at the push of a single button.

Inspection reports or analysis reports can be


created easily.

The histogram settings can be changed as desired.

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Trend graph shows the trend of products at a glance.

Dimensional Measurement
Time-Saving Dictionary

More than just outline measurement from waveform images!

Image Dimension Measurement System IM Series


3 new functions

Accurate measurement even for locations


where outlines are hard to obtain

Profile extraction illumination function

Just place and press for height and depth measurement

Automatic height gauge function

Automatic determination of measurement points just by selecting


the measurement items

Fully automatic measurement

When measuring with a measuring microscope, how


the lighting hits the target can change how the edges
appear, which has an effect on measurement results.
The lighting unit in the IM Series is capable of storing
such information as the type and properties of lighting
for a particular target. In addition, difficult-to-measure
surfaces such as curved surfaces are always
illuminated under the same conditions, so outlines are
accurately extracted for stable measurement.

Introducing a 3D height/depth measurement model


to the conventionally 2D IM Series of dimensional
measurement systems. Measurement with the new
model is still as easy as Place, Press. Process.
During measurement, moving to a measurement
point is automatic. Eliminating the need to separate
tasks between multiple measurement systems
not only allows for improved work efficiency but
also eliminates person-to-person variations in
measurement results even for height and depth
measurements.

With the IM Series, theres no need to set


measurement points. The appropriate measurement
locations are determined automatically from the
image just by selecting the measurement items,
such as the width or holes. This fully automatic
measurement function helps make measurements
such as single-item measurements more efficient.

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KA11-1066

The information in this publication is based on KEYENCEs internal research/evaluation at the time of release and is subject to change without notice. Company and product names mentioned in this catalog are trademarks or registered trademarks of their respective companies.
The specifications are expressed in metric units. The English units have been converted from the original metric units.
Copyright (c) 2016 KEYENCE CORPORATION. All rights reserved.
IMReducingMeasurmentTime-KA-EN-US 1046-1 E 611C14