Accurate, Contactless Measurement for Modern Manufacturing

In today’s highly competitive industrial world, precision engineering has become the backbone of quality assurance. Making sure every component satisfies precise design criteria is essential, regardless of whether you work in the automotive, aerospace, electronics, or tooling industries. That’s where the Optical Profile Projector, also known as a contour projector, comes into play—offering unmatched, contactless measurement for intricate parts and components.

These machines offer non-contact, high-accuracy measurement for parts with intricate profiles, threads, and geometries. From tiny screws to complex machined components, profile projectors provide a reliable, visual method of inspection that is both user-friendly and extremely efficient.

What is an Optical Profile Projector?

An Optical Profile Projector is a device that projects a magnified silhouette of a part onto a ground glass screen using an optical lens and a light source. Operators can inspect, measure, and compare features without physically touching the part, preserving the part’s quality while gaining unmatched precision.

Key Components of an Optical Profile Projector

Understanding its structure helps in leveraging its full potential:

1. Projection Lens

– Magnifies the part image at standard levels like 10X, 20X, 50X, and 100X.

– Ensures detailed visibility and accuracy in measurement.

2. Fine-Ground Glass Screen

– Projects the part’s silhouette with fine grid lines for alignment and analysis.

– Often used with overlays for profile comparison.

 3. Stage with Micrometer Control

– The part is placed on a motorized or manual XY stage.

– Digital micrometers allow micron-level stage movement.

 4. Light Source

– Halogen or LED light is used for surface and profile illumination.

– Ensures clarity and contrast for various materials and finishes.

5. Digital Readout System (DRO)

– Displays linear and angular measurements in real time.

– Reduces human error and enhances repeatability.

 How an Optical Projector Measures a Component

The measurement process is straightforward and non-invasive:

  1. Place the part on the stage with proper alignment.
  2. Illuminate the component using the adjustable light source.
  3. Project the image using a magnifying lens onto the screen.
  4. Analyze dimensions using digital readout or comparison overlays.

This method is perfect for checking radii, angles, pitches, and surface anomalies.

Application Example: Measuring a Precision Screw

A screw may appear simple, but every millimeter matters—especially in applications like electronics, automotive assembly, and medical devices. Using the PP 600VE Vertical Optical Profile Projector, the following screw features can be accurately measured:

Step-by-Step Measurement Process

  1. Secure the screw on the stage using a V-block for alignment.
  2. Illuminate the screw with halogen light to bring out the thread detail.
  3. Choose the appropriate lens (commonly 10X or 20X).
  4. Focus and align the projection on the screen.
  5. Use the DRO and overlays to begin measurements.

What Can Be Measured on a Screw:

  • Thread Pitch – Distance between thread peaks.
  • Major Diameter – The outermost diameter of threads.
  • Minor Diameter – Diameter at the root of threads.
  • Thread Angle – The angle formed by the thread flanks.
  • Lead – Axial distance the screw moves in one turn.
  • Chamfer Length and Angle – Important for starting threading.
  • Shank Diameter – For unthreaded body dimensions.
  • Overall Length – For total part specification.

This precise, non-contact approach ensures the screw’s functionality and compatibility are within tolerance, eliminating costly production errors.

Explore Our Optical Projector Models

PP300TE

  • Compact and suitable for small precision parts.
  • High-quality optics and digital interface.

PP400H (Horizontal Model)

  • Best for cylindrical or long shaft components.
  • Wide working distance and horizontal light path.

PP600VE (Vertical Model)

  •  Ideal for flat components like gaskets and circuit boards.
  •  Powerful halogen lighting and fine screen resolution.

Why Choose Optical Profile Projectors for Dimensional Inspection?

  • Non-contact measurement prevents component damage.
  • High repeatability and digital precision.
  • Real-time inspection with DRO and overlays.
  • Flexible application for different part shapes and sizes.
  • Cost-effective for quality control and R&D departments.

Frequently Asked Questions (FAQs)

Q1: What is the accuracy of an optical profile projector?

A: Most models provide precision up to ±0.001 mm, depending on the lens and DRO.

Q2: Can it measure both internal and external dimensions?

A: Yes, it can accurately measure radii, diameters, angles, and depths.

Q3: Is it suitable for small components like micro-screws?

A: Absolutely. Optical projectors like the PP 300TE are ideal for micro-components.

Q4: What’s the difference between vertical and horizontal models?

A: Vertical models suit flat parts; horizontal models are best for cylindrical or long parts.

Q5: Does it require skilled operators?

A: Basic training is sufficient. Digital systems and overlays make it easy to operate.

Conclusion: Achieve Excellence with Optical Profile Projectors

An Optical Profile Projector is your perfect solution if your business demands precision, consistency, and non-contact dimensional measurement. Whether inspecting screws, gears, or custom machined parts, these machines ensure your products meet the highest quality standards.

Ready to upgrade your inspection capabilities? Choose from our PP 300TE, PP 400H, or PP 600VE models today—and experience precision like never before.