How to ensure the stability of visual equipment in complex environments?

With the rapid development of industrial automation and intelligent manufacturing, visual equipment has become an indispensable "eye" of the production line. However, the application environment in reality is often much more harsh than that in the laboratory: high temperature, high humidity, dust, oil pollution, vibration and shock, etc., all of these factors are a test of the stability and reliability of visual equipment. So, how can we ensure that the visual system can still operate stably and efficiently in these complex environments?

The following will analyze the key factors for the stable operation of visual equipment in complex environments from multiple aspects such as structural design, protection level, environmental adaptability, and system anti-interference ability.

1. Structural protection design: the "first line of defense" for stability

The stable operation of visual equipment depends first on the reliability of the equipment structure design. Industrial cameras have high-strength metal shells, integrated sealing structures, and visual equipment interface protective caps, which can effectively resist dust, water vapor, and fog during use. In particular, camera products with IP67 protection level can maintain stable sealing for a long time in production lines with high humidity, high dust or splashing liquids, such as in food packaging, lithium battery manufacturing, and metal processing, to avoid failures caused by contamination or short circuits of internal components.

2. Temperature and humidity adaptability: "internal cultivation" that is not afraid of changes in temperature

In industrial sites, different working environments may experience frequent temperature changes or long-term high-temperature operation. Excellent visual equipment needs to have:

Operating temperature range: -20℃—60℃

Built-in temperature control protection mechanism

Thermal stability design of materials and circuits

In addition, when visual equipment is operated in a high-temperature environment for a long time, it can automatically reduce the frequency to ensure the life of the equipment and the quality of image output.

3. Anti-vibration and anti-shock: Facing the "moving world"

In application scenarios such as automation equipment, robotic arms, and conveyor lines, the equipment is often in a state of vibration or high-speed movement during operation. In order to ensure stable imaging, the visual system needs to improve the anti-interference ability by upgrading the equipment performance:

Reinforced housing and bracket design

Anti-loosening lock thread interface (such as M12 connector)

Internal components adopt anti-vibration structure layout

High-speed cache mechanism prevents screen interruption

Industrial cameras have been verified by vibration/shock tests of the IEC 60068 standard, which can more effectively ensure their stable output in dynamic working conditions.

4. Electromagnetic compatibility

Electromagnetic interference is a common hidden danger of visual equipment in industrial environments, especially in high-power motors, welding equipment, etc. High-quality visual equipment usually needs to have the following functions:

Shielded PCB boards and cables

Grounding protection

Comply with CE/EMC and other electromagnetic compatibility standards

These can effectively reduce communication anomalies, data frame loss, image distortion and other problems caused by EMI.

5. Software debugging and remote monitoring: intelligent and stable guarantee

Stable operation is not only a hardware matter, but the software system also plays an increasingly critical role. Advanced visual systems can support: real-time status monitoring (temperature, voltage, connection status)

Remote debugging and firmware upgrades

Automatic abnormal alarm and log recording

This type of "visualized" system health management tool not only makes the equipment more "smart", but also makes maintenance more efficient.

VI. Application Cases: Stable Performance in Lithium Battery Manufacturing

Intelligent Vision has recently launched a number of industrial cameras. In the test of the customer's lithium battery production line:

Facing the production line environment filled with dust and oil mist, the equipment has been running continuously for more than 100 hours, and the image output is stable;

Deployed on the robot's automatic handling arm, it can resist continuous vibration and still maintain accurate recognition;

Combined with our self-developed SDK, parameter adjustment and real-time temperature monitoring are performed through the remote platform to effectively reduce the frequency of manual maintenance.

Vision equipment plays a frontline role in manufacturing production and must not be afraid of complex working conditions. This is not only a test of hardware design, but also a comprehensive reflection of software and hardware collaboration and system integration capabilities.

Choosing visual equipment that can withstand the test of the environment is the basic guarantee for enterprises to achieve continuous, efficient and intelligent production. In the future, with the evolution of technology and the improvement of standards, visual equipment will continue to break through the limits and provide more stable power for the manufacturing industry. If you want to learn more about high-stability industrial vision products, please browse our product center or contact our technical consultants.