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DIMENSIONAL MEASUREMENTS
Dimensional Measurement
Time-Saving Dictionary
Vernier caliper
Optical comparator
Measuring microscope
Micrometer
3D measuring instrument
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.
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
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
10
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.
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.
11
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.
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.
12
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.
13
2000 hours
Measuring microscope/
Optical comparator
40 hours
? mm
Operator A
Operator B
Operator C
78.4 mm
78.6 mm
78.8 mm
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.
14
Dimensional Measurement
Time-Saving Dictionary
15
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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