Profile Projector vs Automatic Optical Measurement System

Whether you're replacing an old profile projector or buying your first measuring instrument, this comparison comes up every time you purchase an optical measuring instrument.

But let's look a little deeper.

Profile projectors primarily require technical metrology knowledge. All operators will need some training and expertise to perform the measurement consistently and accurately.

Automated optical devices may be useful in this situation. It is true that knowledge and experience are required to program the meter. However, once the program is saved it will be available for all future measurements. The initially programmed measurements will be made available to other operators with a simple click of a button.

Performing measurements with a single button, without the need for part positioning, not only saves you incredible time, but also eliminates the need for personnel training and the possibility of misunderstanding the measurement system.

The projector may seem like a better choice in a small workshop where the same engineer measures different parts with little fluctuation. Optical solutions are the best option when parts change or multiple operators use the same machine to take measurements. Because you may have witnessed that different operators give different measurement results for the same part in traditional profile projector measurements.

How tight are your tolerances; Is there a decimal, percent or thousandth tolerance?

Either system can work if your tolerances are at decimal level.

But what if your parts have tolerances at the hundredth level? The limitations of the profile projector will now begin to become apparent. Measurement deviations will be clearly detected by various operators. The operator may become tired, misinterpret data or enter incorrect numbers. With so many variables that can cause errors, there is no guarantee that faulty products will be caught.

In contrast, an optical measuring device will eliminate subjectivity while also providing more accurate measurements.

It is widely accepted that optical devices cannot be used in the production area.

This has always been true historically. Optical equipment has been developed over the last five years to operate in harsh workshop conditions without compromising accuracy.

Automatic optical measuring machine is more expensive than projector!

A great projector will be cheaper than a system that does the same job automatically. But your company's reputation is valuable.

Here we return to step 1

The projector will take 10 minutes to measure a part, as with any optical measuring device. However, the optical measuring machine will convert 10 minutes after the program is recorded into 10 seconds if there is a large batch of the same part.

Let's think about something else: the profile projector is used for the first batch inspection after the start of a new project or to confirm the accuracy of machines in the workshop after recalibration.

In this example, an automated optical equipment only needs 30 seconds to complete the inspection, while the projector needs 30 minutes to complete the inspection. During this period, production is stopped.

How much do you think a stopped production line costs per hour?

Automated optical measurement systems provide real-time data, allowing you to intervene immediately if parts are out of tolerance and prevent costly production errors.

Not only does this significantly reduce delivery times, but it also ensures you don't lose money on scrap material and provide your customers with the error-free product you've always promised.

Have you ever heard of Industry 4.0?

Finally, the optical measuring machine collects digital data.

Statistics software and production execution system (MES) and generate excellent and comprehensive reports.

When fully integrated, the optical measuring device can automatically correct tooling on your production machines.

Conclusion

Let's finish by noting that the projector is still a suitable tool when consistent measurement by the same person, low frequencies, and flexible tolerance are acceptable.

Automated optical measuring equipment excels in high-volume environments where customers demand traceability, CNC machines are used, batches are constantly changing, and work is concentrated on small and medium-sized production batches.

Is there a solution everyone can accept?

There is no room for error when meeting sensitive consumer needs in today's industry.

Time and precision are of the essence; To attract new business and retain existing customers, you must consistently source exact parts and demonstrate full capabilities, which can only be done with automatic optical measurement.