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What Types of Cameras Are Used in Machine Vision?

1. ‌Primary Camera Types and Technologies‌
   ‌A. Area Scan Cameras‌
   ‌Function‌: Capture 2D images in a single frame, ideal for static or slow-moving objects.
   ‌Key Specifications‌:
   ‌Resolution‌: 0.3 MP (VGA) to 150 MP (e.g., semiconductor wafer inspection).
   ‌Frame Rate‌: 30–200 FPS (standard), up to 1,000 FPS for high-speed models.
   ‌Sensor Type‌:
   ‌CMOS‌: Dominates 90% of industrial applications due to low cost, high speed, and rolling/global shutter options.
   ‌CCD‌: Preferred for low-noise imaging in astronomy or medical microscopy (dynamic range >75 dB).
   ‌Applications‌: Barcode reading, surface defect detection, and dimensional metrology.
   ‌B. Line Scan Cameras‌
   ‌Function‌: Capture images line-by-line for continuous motion (e.g., web inspection).
   ‌Key Specifications‌:
   ‌Line Rates‌: 1–140 kHz (e.g., 4k-pixel lines at 70 kHz for printing defect detection).
   ‌Pixel Width‌: 5–10 μm for high-density imaging.
   ‌Applications‌: Textile, metal strip, and print quality inspection.
   ‌C. 3D Cameras‌
   ‌Technologies‌:
   ‌Stereo Vision‌: Dual cameras for depth mapping (accuracy ±0.1 mm).
   ‌Structured Light‌: Projects patterns to measure object topography.
   ‌Time-of-Flight (ToF)‌: Measures light travel time for real-time 3D mapping (e.g., bin picking).
   ‌Applications‌: Robotics guidance, weld seam inspection, and volume measurement.
   ‌D. Specialty Cameras‌
   ‌SWIR (Short-Wave Infrared)‌: 900–1700 nm range for material penetration (e.g., solar cell inspection).
   ‌Thermal Cameras‌: Detect heat signatures (accuracy ±1°C) for electrical fault detection.
   ‌UV Cameras‌: 200–400 nm sensitivity for fluorescence or semiconductor lithography.
2. ‌Critical Selection Criteria‌
   ‌A. Resolution and Pixel Size‌
   ‌Rule of Thumb‌: Minimum resolution = (Feature Size ÷ Pixel Size)².
   Example: Detecting 0.1 mm defects requires 2 MP (1600×1200) with 5 μm pixels.
   ‌B. Frame Rate and Shutter Type‌
   ‌Global Shutter‌: Freezes fast motion without distortion (e.g., 500 FPS for bottling lines).
   ‌Rolling Shutter‌: Cost-effective for static or slow-moving objects.
   ‌C. Spectral Sensitivity‌
   ‌Monochrome vs. Color‌:
   Monochrome: Higher sensitivity (2–4×) for low-light or laser-based systems.
   Color: Essential for food grading or pharmaceutical blister pack inspection.
   ‌D. Interface Standards‌
   ‌GigE Vision‌: Up to 10 Gbps; cable lengths up to 100 m.
   ‌USB3 Vision‌: 5 Gbps; plug-and-play for portable systems.
   ‌CoaXPress‌: 12.5 Gbps/channel; long-distance data transmission.
   ‌E. Environmental Durability‌
   ‌IP Ratings‌: IP67 for washdown environments (food processing).
   ‌Temperature Range‌: -40°C to +70°C operation for automotive testing.
3. ‌Industry-Specific Applications‌
   ‌A. Automotive Manufacturing‌
   ‌Camera Type‌: 5 MP global shutter CMOS with GigE interface.
   ‌Tasks‌:
   Inspect engine components for cracks (10 μm resolution).
   Verify brake pad alignment (±0.05 mm accuracy).
   ‌B. Electronics Production‌
   ‌Camera Type‌: 25 MP area scan with 3.2 μm pixel size.
   ‌Tasks‌:
   Solder joint inspection on high-density PCBs.
   OLED display uniformity testing.
   ‌C. Pharmaceutical Packaging‌
   ‌Camera Type‌: 2 MP color camera with coaxial LED illumination.
   ‌Tasks‌:
   Verify pill count and blister seal integrity.
   Detect label misprints (Pantone color matching).
   ‌D. Agriculture and Food Processing‌
   ‌Camera Type‌: 3D ToF cameras with IP69K housing.
   ‌Tasks‌:
   Sort fruits by size and ripeness (RGB + NIR).
   Detect foreign objects in packaged goods.
4. ‌Emerging Trends‌
   ‌Embedded Vision‌: Cameras with onboard AI processors (e.g., NVIDIA Jetson) for defect classification.
   ‌Multi-Spectral Imaging‌: 6–8 channel cameras for hyperspectral material analysis.
   ‌Quantum Dot Sensors‌: Enhanced UV/IR sensitivity for semiconductor inspection.
5. ‌Comparison of Leading Camera Brands‌
   Brand Specialty Key Model Resolution Frame Rate
   Basler High-speed ace 2 Pro 20 MP 163 FPS
   FLIR Thermal imaging A700 640×512 30 Hz
   Teledyne Line scan Linea HS 8k pixels 140 kHz
   Sony Global shutter IMX540 12 MP 40 FPS