KOMPASS brings outer diameter measurement and bore checks to every round part as it passes the station. Calibrated cameras capture each edge around the circumference, fit the diameter and compare it with your limits, so oversize, undersize and oval parts are held before assembly.
A diameter checked at one angle can pass while the part is oval, or while the bore has a burr at its entry. Round parts need many edge readings, not one measurement.
Our AI Product Inspection system, KOMPASS™, pairs calibrated vision hardware with trained models for outer diameter measurement and bore checks around each round feature. The result reaches the line controls with an image of the part.
Outer diameter measurement depends on a sharp, undistorted view of the round edge. KOMPASS combines that view with edge models trained on your parts and a direct link to the line response.
Flat parts sit on a backlit stage, while shafts are viewed side-on. The view is calibrated with a reference target so pixels convert to millimetres.
The model locates the edge around each round feature despite chamfers and burrs, then fits the diameter and reports out-of-round.
Each diameter is checked against its limit. Failing parts are held or rejected, and every reading is stored with its image.
Send us your drawing, the diameter limits and a few good and out-of-limit parts. We will assess the optics and presentation the check needs.
Get In TouchPlug gauges, offline metrology and inline outer diameter measurement each have a role. The difference is how many parts, and how much of each circle, gets measured.
Outer diameter measurement with vision captures the round edge as a sharp contrast boundary, usually with silhouette imaging where the light sits behind the part. The software finds hundreds of edge points around the circumference and fits a best-fit circle through them. Its diameter is compared with your limit. Because many points are used, a single burr or speck has little effect on the result. Each stored image shows the fitted circle, so a reviewer can confirm the edge was read correctly.
Yes, for through-holes and openings the camera can see clearly. Inner diameter measurement works best when light passes through the bore or when the bore entry is well lit against a darker face. Deep blind bores, internal grooves and features far inside the part are better suited to bore probes or other sensors, so their feasibility is checked during scoping. The station also confirms that the hole is present and open, which catches missed drilling or blocked bores.
It can report ovality alongside diameter, because the measurement covers the whole circumference. The difference between the largest and smallest measured widths shows whether the part is out of round. That matters for rings, bushings and seals, where a part can pass across one axis and still fail fit. Full roundness analysis to formal standards remains a task for the metrology room.
A standard lens makes closer edges appear larger, so a slight change in part height changes the reading. A telecentric lens keeps magnification constant across its working depth, which is why it is common for precision round parts. It also avoids viewing the inside wall of a bore at an angle, which can make the opening look smaller than it really is. The trade-off is a smaller field of view, so the lens is chosen around your largest part.
Chamfered bores show two edges, the chamfer and the true bore wall, so the station must know which one your drawing specifies. KOMPASS is trained on examples that include normal chamfers and burrs, and the measurement plan states which edge to use. Without that instruction, a bore diameter measurement can report the chamfer instead of the functional size.
A bore gauge or air gauge gives very precise readings on the parts someone checks, and remains the reference for audits and calibration. Inline vision adds coverage: every part measured at line speed, with each result stored. Many plants keep their gauges for first-article and periodic checks while the vision station screens every part made in between those checks. That combination keeps the precision of the reference gauge and adds the coverage only an inline check can give.
Often, yes. Washers, rings, bushings and flanged parts can present OD and ID in one view, so both are measured from the same image. Shafts and parts with features on different planes may need a second camera or a side-on view. The measurement plan defines every diameter on the part, its limit and the edge it is taken from. Where a feature cannot be seen from one direction, the plan records which camera measures it.
Send the drawing with each diameter and limit, the part variants, the line speed and how parts are presented. Good parts plus known oversize, undersize and oval examples help us test optics quickly. With that, we recommend the camera layout, lighting and reject point for outer diameter measurement and bore checks on your line. Known oval parts are especially useful, because they show how the station reports out-of-round.
Share your drawing, diameter limits, part variants and line speed. We will assess the optics every round feature needs and give you a clear plan with timing and cost. Deployment usually takes 6 to 8 weeks.
