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Technology of Machine Vision Cameras

Machine vision cameras play a critical role in vision applications, especially in automated quality control. In combination with machine vision controllers and 2D image processing software, the high-resolution image data is analyzed, and errors as well as irregularities in production processes are identified.

What Is a Machine Vision Camera?

A machine vision camera, also known as an industrial camera, is a key part of a 2D image processing system. Its main function is to capture images, which are then processed by a combination of hardware and software. The information obtained is prepared for various applications.

A typical example of an image processing application in a manufacturing system is quality control, presence control and completeness control. This involves analyzing a specific feature of a part that is produced on an assembly line. In this way, it can be checked whether the part meets the quality criteria or, if necessary, must be sorted out.

The camera is part of the image processing system. This consists of the following components:

Main Components of 2D Image Processing Systems

Selection Guide for the Right Lens

Find the right lens for your industrial camera easily and automatically using the Vision Calculator:

The Difference Between Machine Vision Cameras and Smart Cameras

Machine Vision Cameras

  • Image evaluation takes place via the machine vision controller and the image processing software

  • Multiple cameras can be connected to a single machine vision controller

  • Faster process times thanks to high computing power of the machine vision controller

  • Suitable for very high resolution inspection tasks

  • Compact camera design



 

Smart Cameras

  • Image capture and evaluation takes place in the smart camera

  • Data output via integrated interfaces

  • Optionally integrated illumination technology

  • No additional controller required



 

Applications of Machine Vision Cameras

Position Check

Robot Positioning

Parts Measurement

Quality Control

Presence Check

Process Monitoring

Code Reading

Reliable Solution for Cross-Industry Applications

Automotive Industry

  • Quality inspection of car interior doors

  • Quality inspection of engine blocks

  • Position detection for automated tightening

Electronics Industry

  • Position check of PCBs

  • Checking the alignment of components

  • Inspection of plug connectors and cables

Packaging Industry

  • Check packages for damage, contamination or missing labels

  • Label inspection of packaging

  • Minimum shelf life test on PET bottles

Food Industry

  • Orientation of beverage cans 

  • Label check on packaging

  • Tethered cap inspection

This Is the Difference Between Surface and Line Cameras

The following table summarizes the main differences between surface and line cameras:

Surface cameras

Image capture of complete 2D surfaces (with one capture)
High image quality
Ideal for stationary objects
Suitable for general image processing



Line Cameras

Image capture takes place line by line (movement is necessary to capture the object)
Image quality dependent on motion and time of image capture
Ideal for applications with moving objects and endless materials 
High speed

Operating Orinciple of CMOS Sensors with Global or Rolling Shutter

CMOS image sensors have two exposure methods that control how an image is captured and read. These procedures determine the exposure time and thus the amount of light that is converted into electrons as a value in the camera sensor. A distinction is made between global shutter and rolling shutter:

Global Shutter

Entire image area is exposed simultaneously 
Suitable for static as well as dynamic applications
No image distortion on moving objects

Rolling Shutter

Lines are exposed with a time offset
For static applications
Image distortions due to fast object movements (rolling shutter effect)
Capturing still images 

The Rolling Shutter Effect

With the rolling shutter, the exposure time is the same for all pixels of the sensor, but the exposure of the individual lines takes place one after the other with a time delay. The rolling shutter effect occurs when an object moves faster than the exposure and read time, causing the image to be distorted due to exposure.

Left: Global shutter, Right: Rolling shutter

Monochrome or Color Camera? Which Do I Use When?

Actual Image

使用单色相机拍摄图像

单色相机能够将物体与背景区分开来。

使用彩色相机拍摄图像

彩色相机能够将物体彼此区分开来,并与背景区分开来。

在工业图像处理中,需要区分单色相机和彩色相机。单色相机可捕捉灰度,并聚焦于图像中的亮度差异。因此它们特别适用于需要精细对比度和细节的应用,例如表面检测或物体测量。

相反,彩色相机可以捕捉颜色信息,使其能够更精确地捕捉表面。它们可以分析整个色谱,并由此提供更详细、更多样化的图像再现。这使其非常适合颜色发挥重要作用的应用场景,例如产品质量控制,其中颜色差异可能表明材料存在缺陷。

安装机器视觉照相机时的注意事项

为了确保图像的可靠拍摄,在调整工业摄像机时要注意以下提示。
除了摄像头的最佳对准之外,照明系统的定位也很重要。要检测的物体的形状对于光线到达摄像机的方式至关重要,决定着能否产生尽量高的对比度。例如,必须注意角度和由此产生的反射。 

机器视觉照相机的接口

工业摄像机的以太网接口可以通过网络传输图像数据。该接口通常用于工业图像处理,以将摄像机连接到机器视觉控制器或其他设备。

千兆以太网 (GigE)

Gigabit Ethernet (GigE) is an Ethernet technology that enables data transfer rates of up to 1 Gigabit per second (1 Gbit/s). The main features of Gigabit Ethernet in connection with industrial cameras are:
 
  • Fast transfer of large amounts of image data

  • Easy integration thanks to protocol standard

  • Multiple cameras can be operated in a network


It is also possible to connect the machine vision camera via a cable using PoE (Power over Ethernet), which means that both power supply and data transfer take place via a single connection.


分辨率

传感器的分辨率表示像素数:分辨率越高,则像素大小越小,可识别的细节就越精细。由于像素大小不同,相同尺寸的传感器可能具有不同分辨率。 

帧频

帧频表示摄像机每秒拍摄的完整帧数。更高的帧频可用于在快速处理应用中拍摄大量图像。

曝光时间

曝光时间决定了照射到 CMOS 传感器上的光线量,从而影响拍摄图像的亮度。较长的曝光时间会生成更明亮的图像,但也可能会因此而导致运动模糊和图像噪点增大。较短的曝光时间可实现快速应用,并减少与之相关的运动模糊。 

为每种应用提供适当的分辨率

分辨率精度例如
1.6 MP不需要极高分辨率的应用光学字符识别、装配检查、存在性检查
5 MP需要中等细节精度的应用检查包装
12 MP需要高精度的应用精细机械部件的检测
24 MP需要极高分辨率和细节精度的应用检查印刷线路板元件是否有缺陷
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