Picked the Wrong Lens? Your Detection Error Could Double – Avoid These Pitfalls!

In machine vision inspection systems, lenses are often considered just one of those "accessories," but they are a core tool in visual solutions that impacts inspection accuracy. Improper lens selection not only leads to image distortion and insufficient resolution, but can also exponentially amplify inspection errors, directly impacting production quality on the production line. So, how can we avoid common lens selection issues? Let's discuss!

Why is lens selection so important?

In machine vision systems, the lens acts like the lens in the human eye—its primary responsibility for accurately transmitting optical information to the image sensor.

Thus, lenses play a crucial role in machine vision. Here are a few key selection criteria:

Resolution matching: Insufficient lens resolution results in a loss of image detail, making it difficult for inspection algorithms to accurately identify small defects.

Distortion control: Greater distortion leads to more distorted images at edges, resulting in inaccurate measurement results.

Depth of field range: Insufficient depth of field results in blurring at different heights on the object surface, affecting the stability of inspection results.

In short, lens quality directly determines the clarity of inspection images and the accuracy of data readings.

Three Common Pitfalls in Lens Selection

1. Focusing Only on Price, Not Specifications

Many companies are easily attracted to low-priced lenses when purchasing, but overlook key specifications such as resolution, pixel size, and distortion. Low-priced lenses often significantly increase errors in high-precision inspection scenarios.

2. Ignoring Camera Compatibility

Even a high-performance camera won't perform to its full potential if the lens isn't compatible (e.g., insufficient image circle or resolution).

3. Inadequate Scene Adaptability

Different inspection scenarios have significantly different requirements for lens focal length, depth of field, and aperture. Blindly using the same lens model can easily result in partially sharp images and overall blur.

How to Choose the Right Industrial Lens?

Matching Resolution to Pixel Size: The lens resolution should be higher than the pixel resolution of the industrial camera to ensure that image clarity meets inspection requirements during use.

Pay Attention to Distortion: For high-precision inspections such as dimensional measurement, choose lenses with low distortion.

Lens Depth of Field and Aperture: A large depth of field maintains clarity across the entire inspection area. Aperture design should also consider light source brightness and image clarity. Reliable Supplier: Experienced suppliers will design the optimal matching solution based on the customer's specific inspection needs.

Real Case: Error Reduced by 70% After Lens Replacement

We received a request from an automotive parts manufacturer who was experiencing frequent misjudgments due to high inspection errors. Our technicians conducted on-site analysis and determined that the root cause was insufficient lens resolution and excessive distortion. After testing, our technicians replaced the lens with a low-distortion, high-resolution industrial lens. This improved inspection accuracy, reduced the misjudgment rate by over 70%, and significantly increased production efficiency.

Industrial lenses may be small in size, but they have a significant impact on machine vision inspection. Choosing the right lens is like equipping your inspection system with high-definition lenses. Therefore, when selecting a lens, consult with us regarding parameter matching and conduct as many field tests as possible. This will avoid the risk of rework, adjustments, and production stoppages during later production, which can impact production efficiency and time. Zhixiang Shijue specializes in customizing industrial cameras, lenses, lighting, and visual inspection solutions, providing customers with integrated services for precise imaging and stable recognition. Contact us for more scene matching test solutions.