How do industrial cameras achieve high-precision imaging in micron-level inspection?

In the field of high-end manufacturing and precision machining, the requirements for detection accuracy are becoming more and more stringent, and micron-level defects may have a fatal impact on product quality. Traditional manual detection methods are not only inefficient and susceptible to subjective judgment, but also difficult to meet the dual requirements of micron-level measurement for accuracy and stability. Therefore, more and more companies are beginning to seek to build high-precision machine vision inspection systems with the help of industrial cameras to achieve automated, standardized, and traceable quality control processes.

Core challenges faced by customers

In actual production, we have come into contact with customers from 3C electronics, semiconductors, precision machinery, medical devices and other industries, who generally face the following major challenges:

Subtle defects are difficult to identify: Traditional cameras have insufficient resolution and cannot identify micron-level defects such as scratches, bubbles, and foreign objects;

Dimensional measurement is unstable: Problems such as image distortion, light interference or lens distortion lead to large fluctuations in measurement results;

Speed and accuracy are difficult to balance: In a high-beat production environment, the acquisition speed is fast but the clarity is not enough, which affects the detection results;

System integration is difficult: The compatibility between different modules is poor, resulting in a long system debugging cycle and high maintenance costs.

Solution: High-resolution industrial camera + high-performance imaging system

To address the above pain points, Zhixiang Shijue provides customers with a complete one-stop machine vision system from image acquisition → light source control → image processing → data output. Among them, industrial cameras play a core role as "eyes". We recommend using products with the following characteristics:

1. High-resolution sensor

The use of CMOS chips and more than 5 million pixels, coupled with a small pixel size (such as 2.4μm), can accurately restore details and achieve micron-level imaging. Taking the USB3.0 interface industrial camera we provide as an example, with a high-resolution lens, it can easily distinguish 0.01mm solder joint deviation on the PCB board.

2. Low noise & high dynamic range

The high signal-to-noise ratio design effectively suppresses background interference and improves the ability to restore dark details. It is especially suitable for production lines with large lighting changes, such as laser welding, glass inspection, etc.

3. Use telecentric lenses with uniform light sources

The main advantage of telecentric lenses is that within a certain working distance, the image magnification remains basically unchanged. Even if the distance between the object and the lens changes, there will be no perspective distortion and image position error. This makes telecentric lenses very suitable for use with coaxial light sources or annular shadowless light sources, which can obtain a more uniform and stable lighting environment, improve edge contour recognition capabilities, and be suitable for high-precision measurement and detection applications.

4. High-speed acquisition and real-time output

Support high frame rate acquisition and image caching technology to ensure that image data can still be output in real time in high-speed production lines, ensuring that system detection efficiency and accuracy are synchronized.

Practical case sharing: Glass cover edge defect detection

A customer supplies glass cover plates for a well-known domestic mobile phone manufacturer. Its edges are prone to tiny edge collapse and cracks. Manual detection is time-consuming and labor-intensive, and the consistency is poor. Zhixiang Shijue's technical specialist deployed a set of detection solutions based on 50 million pixel industrial cameras, combined with telecentric lenses and ring-shaped high-brightness light sources, to achieve:

Defect recognition accuracy reaches "±2μm"

The detection time for each piece of glass is shortened to 0.8 seconds

The defect detection rate is increased to more than 99.7%

After the system was launched, the product yield was greatly improved, and customer feedback showed that the rework rate and labor costs were significantly reduced.

As the manufacturing industry continues to upgrade to intelligence and precision, the application of machine vision in the field of micron-level detection will become more and more extensive. Choosing the right industrial camera and system integration solution can effectively solve the problems of errors, instability, and low efficiency in traditional detection, and help enterprises move towards higher-quality intelligent manufacturing.

If your production line is also facing the problem of high-precision detection, please contact us, Zhixiang Shijue will provide you with a customized and implementable machine vision overall solution.