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Imaging Setup Fundamentals

Imaging Setup Fundamentals

This page explains the core principles and technical foundations behind achieving optimal image quality for AI-based inspection with the OV80i camera system.

Image Acquisition Theory​

Sony IMX334 Sensor Architecture​

The OV80i utilizes a Sony IMX334 sensor specifically selected for industrial vision applications.

Sensor Characteristics:

  • Resolution: 8 MP optimized for inspection detail and processing speed
  • Frame Rate: 30 fps capability for high-speed production lines
  • Shutter Type: Rolling shutter for high-quality image capture
  • Pixel Quality: High-quality pixels for consistent AI model performance

Rolling Shutter Benefits:

  • High-Resolution: Captures detailed images suitable for AI analysis
  • Low Noise: Produces cleaner images in various lighting conditions
  • Cost-Effective: Provides excellent performance for the cost

Lens System Integration Theory​

C-Mount Compatibility: The OV80i uses standard C-mount lens threading, allowing compatibility with any C-mount lens.

Available Focal Length Options: The lens focal length can be adjusted using the lens. The software has built-in lens distortion correction algorithms that eliminate the fish eye effect of each lens, making the image more geometrically accurate and square.

Common C-Mount Focal Lengths:

  • 6mm - Wide field of view, close working distances, larger parts
  • 8mm - Balanced field of view with moderate working distance
  • 12mm - Standard lens, optimal balance for most applications
  • 16mm - Narrower field of view, longer working distances
  • 25mm - Telephoto option for detailed inspection of smaller areas

C-Mount Lens Flexibility:

  • Universal Compatibility - Any C-mount lens can be physically mounted
  • Recommended Options - Listed focal lengths are optimized for typical industrial vision tasks
  • Custom Applications - Other C-mount focal lengths available for specialized requirements
  • Easy Replacement - Standard threading enables quick lens changes

Optical Considerations:

  • Working Distance - Relationship between focal length and mounting height
  • Field of View - 4:3 aspect ratio, multiply width by 0.75 for height calculation
  • Depth of Field - Focus range acceptable for consistent part inspection
  • Motorized Focus - Precision focus adjustment for optimal sharpness

Illumination System Design Principles​

8 Programmable PWM LED Architecture​

LED System Specifications:

  • LED Count: 8 programmable white LEDs
  • Control Method: PWM (Pulse Width Modulation) for precise intensity control
  • Spectral Output: White LED for color-neutral illumination
  • Power Management: Integrated thermal and power efficiency optimization

PWM Control Benefits:

  • Precise Intensity - Exact brightness control for consistent lighting
  • Repeatability - Digital control ensures consistent illumination across captures
  • Power Efficiency - PWM reduces heat generation and power consumption
  • Integration Ready - Coordinated with camera exposure for optimal timing

Lighting Strategy for AI Inspection​

Illumination Fundamentals:

  • Contrast Enhancement - Proper lighting increases feature visibility for AI models
  • Shadow Minimization - Even illumination reduces false edge detection
  • Surface Texture Revelation - Appropriate angle and intensity reveals defects
  • Consistency Requirements - Stable lighting ensures reliable AI model performance

Lighting Configuration Principles:

  • Direct Illumination - High contrast for edge detection and dimensional inspection
  • Diffused Illumination - Reduced glare for surface finish inspection
  • Angle Optimization - Lighting angle selection based on defect type and surface
  • Intensity Balancing - Uniform field illumination without overexposure

Camera Settings Optimization Theory​

Exposure Control Fundamentals​

Exposure.gif

Exposure Time Management: Max exposure time is now up to 500ms, from 150ms previously, with further extension to 1 second in newer versions.

Exposure Configuration:

  • Automatic Exposure - Camera adjusts based on scene brightness
  • Manual Exposure - Fixed exposure time for consistent lighting conditions
  • Exposure Range - Up to 1 second maximum for low-light applications
  • Motion Considerations - Shorter exposures prevent motion blur in dynamic environments

Exposure Optimization Strategy:

  • Lighting Coordination - Balance exposure time with LED intensity
  • Noise Management - Optimal exposure reduces sensor noise
  • Dynamic Range - Proper exposure utilizes full sensor capability
  • Consistency - Fixed exposure ensures repeatable image characteristics

Focus and Optical Optimization​

Focus Control Methods:

  • Manual Focus - Fixed focus setting for consistent working distances

  • Focus Validation - Sharpness assessment for optimal image quality

  • Depth of Field - Focus range management for part variation tolerance

    Focus.gif

Lens Distortion Correction Mode: Enhance the imaging accuracy by correcting for lens distortion during the Imaging Setup process. All lenses have some degree of distortion, and the distortion is more apparent the shorter the focal length of the lens. Correcting for lens distortion can enhance the accuracy of alignment and model prediction, by ensuring parts are dimensionally accurate no matter where in the frame it is.

Distortion Correction Benefits:

  • Dimensional Accuracy - Consistent measurements across entire field of view

  • Alignment Enhancement - Improved template matching accuracy

  • AI Model Performance - Better feature consistency for training and inference

  • Edge Quality - Reduced geometric distortion improves edge detection

    Lens Correction.gif

Image Quality for AI Models​

Resolution and Pixel Utilization​

Resolution Optimization:

  • 8 MP Effective - Balanced between detail capture and processing speed
  • Pixel-to-Real-World Scaling - Accurate dimensional measurements
  • ROI Optimization - Maximize resolution utilization within inspection areas
  • Processing Efficiency - Resolution matched to AI model requirements

Image Quality Metrics:

  • Sharpness - Edge definition critical for feature detection
  • Contrast - Sufficient dynamic range for AI model discrimination
  • Noise Level - Clean images improve AI model reliability
  • Consistency - Repeatable image characteristics across production

Consistency Requirements for AI​

AI Model Stability Factors:

  • Focus Consistency - Stable focus across production runs
  • Exposure Stability - Fixed exposure settings for consistent feature detection
  • Color Balance - Neutral color representation for accurate analysis

Image Standardization:

  • Reference Standards - Consistent imaging conditions for training and inference
  • Calibration Procedures - Regular validation of imaging system performance
  • Environmental Compensation - Adjustment for changing production conditions
  • Quality Validation - Image quality assessment before AI processing

Industrial Environment Considerations​

Environmental Adaptation​

Operating Environment:

  • Temperature Range - Stable operation across industrial temperature variations
  • Thermal Management - Heat dissipation for consistent performance
  • Vibration Resistance - Mechanical stability in production environments
  • Contamination Protection - IP40 rating for dust and moisture resistance

Mounting and Installation:

  • Mechanical Stability - Secure mounting for consistent imaging geometry
  • Thermal Considerations - Front mounting points for high-temperature environments
  • Accessibility - Maintenance access for cleaning and adjustment
  • Integration - Compatibility with existing production equipment

Production Integration Theory​

System Integration Requirements:

  • Timing Synchronization - Coordinate imaging with production line speed
  • Environmental Lighting - Account for ambient lighting variations
  • Maintenance Planning - Regular cleaning and calibration procedures
  • Long-term Stability - Consistent performance over extended operation

Performance Optimization:

  • Line Speed Compatibility - Imaging speed matched to production requirements
  • Quality Consistency - Maintain image quality throughout production runs
  • Predictive Maintenance - Monitor imaging system performance trends
  • Calibration Schedules - Regular validation of optical and illumination systems

Configuration Best Practices​

Imaging Setup Workflow​

Setup Sequence:

  1. Lens Selection - Choose appropriate focal length for application
  2. Focus Optimization - Achieve optimal sharpness for part features
  3. Lighting Configuration - Set LED intensity and uniformity
  4. Exposure Setting - Balance exposure time with lighting for optimal image quality
  5. Distortion Correction - Enable if dimensional accuracy is critical

Performance Validation​

Image Quality Assessment:

  • Focus Validation - Verify edge sharpness across field of view
  • Lighting Uniformity - Check even illumination distribution
  • Exposure Optimization - Validate proper dynamic range utilization
  • Consistency Testing - Verify repeatable imaging performance

🔗 See Also​