High Speed Infrared Imaging Cameras

What is high speed imaging?

High speed imaging is taking pictures at a high frame rate using a short exposure time. High speed imaging in the visible spectrum covers many applications. For example in automotive crash test analysis or studies of supersonic motion of flying bullets.

Typical high speed imaging applications often require SWIR or MWIR imaging. We offer cameras that generate more than 300 (MWIR) or 1700 (SWIR) frames per second at a resolution of 640x512. Even higher frame rates are possible when using a small region-of-interest within the full frame of 640x512 pixels.

What is high speed imaging used for?

Xenics MWIR cameras are used as high speed radiometric and thermal cameras. For example in thermal signature detection, tracking or analysis of aircrafts, missiles or rockets. Thermal tracking of fast moving objects, like missiles, benefits from the addition of a high speed SWIR camera. Thermal cameras detect hot gasses and thermal plumes easily, but SWIR cameras offer more detail and resolution when imaging the (cooler) metal body or debris.

High speed Xenics SWIR cameras find application in free-space optical communication systems. These systems are based on Nd-YAG 1.06 µm or eye-safe 1.55 µm lasers. High speed SWIR cameras are used to track communicating transceivers to maintain optical links, or as a wavefront sensor in satellite communication systems. These wavefront sensors are part of an adaptive optics system. They take the larger optical link distances in free space communication into account by correcting for atmospheric distortions.

What features are needed?

• High Frame Rate - We offer frame rates up to 1730 Hz in SWIR and 460 Hz in MWIR. Our    cameras can even be faster when you reduce your region of interest.
• Short Exposure Time - A short exposure time is necessary in high speed imaging to reduce image blur.
• High Thermal Sensitivity - Thermal cameras need to have a high sensitivity level (low NETD) to detect the smallest temperature differences.
• Large Dynamic Range - An IR camera with a large dynamic range covers a large temperature area
• Low Read Noise - Low read noise results in high sensitivity for low light signals.
• Digital High Speed Interface - A digital interface like CameraLink, GigE or CoaXPress is necessary to assure reliable and fast data transfer.
• Trigger Interface with Low Jitter - A trigger interface with low jitter is a necessity for high speed applications to synchronize the camera.

What do Xenics Infrared Cameras offer?

High speed infrared cameras need to have high sensitivity levels as the exposure times will be small. Next to this, they need to have the highest possible frame rates and the ability to go to small regions-of-interest (ROIs) to increase frame rates even further. Synchronization via an external trigger connector can also play an important role.
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A Future-Proof Assembly Concept for High-End Philips Razors

APPLICATION SUMMARY

Application:	Assembly
Industry:	Consumer Goods
Products used:	Adept Cobra SCARA Robots Adept Viper 6-Axis Robots Adept AnyFeeder flexible feeder Adept SmartController CX motion controller ACE AdeptSight vision guidance
Customer:	Philips
Integrator:	Bremer Werk für Montagesysteme GmbH

COMPANY 

 Production of shavers is under an immense cost pressure and the trade offer for the devices is quite large. In combination with factors like quality and design, the purchase decision is also affected by the price. To remain competitive under these conditions, Philips’ shaver production operates out of two production sites: one in China and the other in Drachten. Today, the China facility produces 20 million shavers with two shaving heads annually and the Drachten plant’s 1,500 employees produce close to eight million devices with three shaving heads per year. The Philips center for research and development also resides in Drachten, which means that all new Philips shavers, ranging from the standard model to the high-tech shaver, are developed out of this facility.


PROBLEM

Philips required an automation solution that delivered quality, supported their profitability, and had the flexibility to adapt to any future product changes. Philips had the added challenge of requiring a production process that could assemble an enormous model variety of high-end razors - and the type of razor being assembled could change every day.

SOLUTION

Bremer Werk für Montagesysteme GmbH or "BWM" selected Adept as their single source for robotics for the Philips project. BWM built a future-proof fully-flexible automation solution using Adept components like the Cobra SCARA and AnyFeeder. More than 120 robots and 40 AnyFeeder systems provide a frictionless assembly system for razors. The robots impress with their precision, speed, and availability to perform the tasks with the highest level of accuracy.A key element to the success of the line is the AnyFeeder flexible feeding system. The inherent flexibility of the system affected a number of areas throughout the assembly automation process: wherever efficient assembly with a high-degree of individualization mattered.

The solution consists of:

• Adept Viper 6-axis s650 and s850 robots

• Adept Cobra SCARA s350, s600, and s800 robots

• AdeptSight vision guidance and inspection systems

• Adept AnyFeeder flexible feeding systems

IMPACT

The groundbreaking automation solution guarantees an economic and efficient assembly of high-end razors. In connection with the innovative components from Adept, the sophisticated assembly concept assures an unrivaled level of sustainability and the Philips plant is one of the most innovative production lines for high-end consumer goods.


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Thermal imaging cameras monitor ­overhead lines in Delhi metro railways

Every day millions of commuters use the metros of Delhi. The Delhi Metro Rail Corporation (DMRC) sees to it that they are all arriving timely on their destination. Being service oriented and caring about their customers: that is what DMRC is all about. In order to keep the metro network up and running at all times, DMRC is using FLIR thermal imaging cameras.

The Delhi Metro is a rapid transit system serving Delhi, Gurgaon, Noida and Ghaziabad in the National Capital Region of India. The network consists of six lines with a total length of 189.63 kilometers with 142 stations of which 35 are underground. It has a combination of elevated, at-grade and underground lines and uses both broad gauge and standard gauge rolling stock. The Delhi Metro is built and operated by the Delhi Metro Rail Corporation Limited (DMRC). The metro has an average daily ridership of 1.8 million commuters and the DMRC operates around 2,700 trips daily between 6:00 and 23:00 running with an interval of 2 minutes 30 seconds between trains at peak frequency.

Predictive maintenance using thermal imaging

This large and intensely used network needs to be maintained well, to prevent the network to be worn due to the intense use, causing mayhem for millions of commuters. That is why the maintenance crews were already using thermal imaging cameras as part of the predictive maintenance program. Generally speaking all electronic equipment and components heat up before they break down. These potential problems will be clearly shown in a thermal image. By detecting this rise in temperature in an early stage using FLIR thermal imaging cameras, the maintenance crews can plan repairs and prevent costly failures and downtime. To that end all components of the railway network are regularly inspected by maintenance crews using a FLIR E50 thermal imaging camera. These periodic inspections play a crucial part in the DMRC’s preventive maintenance program.

Installation of a thermal imaging camera

When recently problems occurred in the metro railway network, which caused huge delays, DMRC suspected the problem was caused by the section insulators. The DMRC maintenance crew therefore installed one of their FLIR E50 thermal imaging cameras in an IP66 rated protective enclosure with Germanium infrared window to monitor the problematic section for an entire work day. Protected from adverse weather conditions by the protective enclosure the FLIR E50 thermal imaging camera was able to safely record the infrared radiation emitted by the section insulators and provide thermal images with each pixel corresponding to a non-contact temperature measurement.

The Composite Video Out of the FLIR E50 thermal imaging camera was linked to a Digital Video Recorder (DVR) with capacity of one Terabyte in order to record the data. After monitoring the section insulators for an hour the system writes a video file. These hourly video files were used to correlate temporary rises in temperature with the time of day, network load and other factors to determine the cause of the problem.

Causes found in thermal data

The installation of the protective enclosure with thermal imaging camera and DVR was done by FLIR products distributor M/s NNK International and DMRC staff. They performed the installation during the night to prevent hindrance to the metro users.
Tests were conducted at sites where the problems were severe and the results were recorded during the instances when the pantograph passes the section insulators. It was observed that factors like system load and environmental conditions played a big role in the deterioration of the section insulators. To further attribute the problem the thermal imaging camera was used to monitor the instances when the temperature of the section insulators went above a previously set threshold.
Careful analysis of the thermal data has allowed the DMRC to take the appropriate action. This thermal information has also helped DMRC to check the redundancy of its system during different weather and loading conditions for ensuring better services to its commuters.

What is a section insulator?

Section insulators are used on the overhead lines system (catenary structure) of railways to electrically isolate and separate sections for maintenance without having to turn off the entire system. The overhead line system is broken into electrically separated portions known as sections. Section insulators are also used extensively on change overs and can be used in conjunction to isolate sections in separate phases being fed by different feeder substations.


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Vision Sensors Eliminate Rejection of Good Parts in Inspecting Wheel Fasteners

One of Maclean Vehicle Systems’ (MVS’s) many automotive fastener products is stainless steel capped wheel nuts. The nuts are assembled on an index machine that processes two parts simultaneously at each station. The fasteners must be inspected to verify the nuts are properly threaded. MVS previously performed this fastener inspection with an eddy current sensor whose accuracy was less than desired, at times resulting in expensive over-sort.

“We looked at a number of different vision sensors,” said TJ Konieczke, Manufacturing Controls Engineer for MVS. “Some were sensitive, intimidating and had a high learning curve like the vision systems that we have used in the past. We selected Cognex Checker® vision sensors because they are very easy to program and operate. We simply put them in place, connect a PC to the USB port, train them on the part to be inspected, and pick tools off a menu that inspect the critical features of the part.”
Konieczke mounted two Cognex Checker 101 vision sensors looking down at a 45 degree angle about five inches from the two parts in the inspection station of the assembly machine. The parts are presented to the inspection station in a fixture and held in position by a spring-loaded keeper, so there is some variability in the height at which they are positioned. Konieczke set up the vision sensor by dragging inspection tools and dropping them onto the features that he wanted to inspect. First, he addressed the variable placement of the part by using an edge finder tool to locate the edge of the part. Then he picked a brightness tool to look for the light reflecting off the threads.
He then set up the vision sensor to interface with the programmable logic controller (PLC) that operates the assembly machine. The PLC provides a static output that indicates when a fixture is in position with two new parts. When the vision sensor receives this signal it captures an image and inspects the part. The vision sensor then sends an output to the PLC indicating that the part is either good or bad. Based on the inspection results, the PLC determines whether to send the part to the pass or fail bin.

Most recently, MVS has standardized new applications on the Cognex Checker 232 vision sensor that provides high resolution and a wide field of view to inspect small features up to 1,600 parts per minute.

The ability of the vision sensor to determine the position of the part and evaluate the brightness of the entire opening of the nut as opposed to an individual point evaluated by a traditional sensor has eliminated incorrect pass/fail decisions. The elimination of sorting costs quickly paid for the new vision sensor. The vision sensor has also increased confidence that not a single bad part will be shipped to the customer. “The latest generation of vision sensors is much more reliable and accurate while being just as easy to set up and operate and not much more expensive than traditional sensors,” Konieczke concluded.
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Souce - www.cognex.com

High-Speed Industrial Cameras for Pharmaceuticals

Automation Machine System is used in various Industries in Mumbai, India. Automation or automatic control, is the use of various control systems for operating equipment such as machinery, processes in factories, boilers and heat treating ovens. This Automated Systems are also used to reduced human intervention. Some processes have been completely automated.

High-speed digital cameras today are generally thought of as expensive, cumbersome and difficult to operate. Now, Many Companies offers cameras with outstanding image quality at frame rates up to 16,000 per second in compact, point-and-shoot packages. Priced to fit demanding budgets, these high-speed cameras save time and money on the production line and simplify slow-motion research... right out of the box.

The pharmaceutical industry is continually being pushed to improve their overall processes through initiatives like GAMP, the Good Automated Manufacturing Process of the ISPE. Validation compliance and traceability are critical to success. Pharma’s many different products are manufactured and packaged in a variety of containers using automated packaging machines and lines. These high-speed cameras are used throughout the pharma industry for research and production.

The production of pharmaceuticals is subject to highest quality and safety requirements. In addition, various legal regulations make an immaculate production process indispensable.

Processes can be monitored, analyzed and optimized consistently with the help of high-speed cameras. By doing so, the high quality maintained in pharmaceutical industry can be assured and the efficiency of the production processes is increased.

In the packaging industry, there are various permanently growing requirements with respect to efficiency of processes. Fast and reliable process chains are essential critical factors for success. The use of high-speed cameras enables targeted monitoring and thus a steady enhancement of the whole production chain. Less errors result in a higher efficiency and return on investment. So, these High Speed Cameras are also used for Packing Pharmaceutical Products. 

The design of the high-speed cameras is ideally suited for the pharmaceutics and packaging industry.  Even under extreme conditions (e.g. varying temperatures, vibrations, difficult lighting situations, spatial limitations), they reliably provide significant pictures.

Owing to their excellent image quality, high speed and photo sensitivity, the high-speed cameras comply with the highest requirements.

In the pharmaceutical and packaging industry often long time recording is necessary in order to completely capture long-term processes and unexpected events or very fast successive single events. For these applications, the use of long time recording systems may be advisable. In continuous process control the pictures are transferred directly to a ring store hard disk system in real time. That way, interruptions that usually occur due to the time-consuming read out of data from the camera are omitted.

We have several of High Speed Cameras Brands and Products with us in Mumbai, India

If you want to know more about high-speed cameras and high-speed recording systems in connection with your application, please do not hesitate to give us a call. We will gladly give you advice

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JAI's Industrial Cameras for Automation Industry

JAI's industrial CCD/CMOS cameras are used for a wide range of industrial machine vision, medical, transportation and global security applications, helping to improve quality, safety and productivity.

The automotive industry is a quality critical industry. Vision technology is applied not only by car manufacturers directly on the assembly line, but also by car component sub-suppliers specializing in quality production of e.g. brake systems, gearboxes, catalytic converters, tires, airbags and other critical car components.

JAI’s camera technology delivers high quality images used in a wide range of applications in assembly, process verification and gauging as well as robot guidance. Typical examples include on-line inspection of critical dimensions, assembly gaps/angles, reading of data matrix codes, flaw detection, welding quality and spray finishes.

JAI camera technology is also applied in the design process of cars in connection with testing and verification of aerodynamic efficiency in wind tunnels and for strain/stress testing of body sheet metal and other vital car parts.

Some of the JAI Cameras Useful in Automation Industry are

• Area Scan Cameras

JAI provides a broad offering of single-sensor area scan cameras featuring progressive scan technology. These cameras incorporate a mixture of CCD and CMOS sensors with resolutions ranging from VGA up to 20 megapixels.

These Area Scan Cameras cameras deliver impressive combinations of high resolution, multi-tap frame rates, extended sensitivity, excellent thermal management, and advanced pre-processing features for applications where image fidelity is critical.

• Area Scan Cameras (2/3 CCD)

JAI is the foremost provider of prism-based Area Scan camera technology for industrial imaging. These advanced designs enable two, three, or more sensors (CCD or CMOS) to be precisely aligned to a single optical path to deliver unique capabilities for machine vision, medical, scientific, Automation or other applications.

Leveraging proprietary designs, patented alignment techniques, and years of hands-on assembly experience, JAI’s multi-imager, prism-based area scan cameras provide both superior image fidelity and the durability to perform in a wide range of laboratory and industrial settings.

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Baumar Sensors help to keep food High tech and hygiene

Hygienic safety and optimized production, processing, storage, filling and bottling processes: food and beverage production is a very complex matter. And with our unique and extremely wide portfolio, we are optimally prepared for this tricky process. In the long food processing chain from raw material to the retail market, Baumer sensors provide valuable support in many places.

For example, Machine Vision System By Baumer Sernsors refined the principle of frequency deviation technology for level measuring. The functional principle here exploits the fact that every material, regardless of its consistency, has a a particular permeability for electrical fields, so it is possible to distinguish media reliably and replace the vibrating fork principle which is more susceptible to errors.

The list of possible applications is long: Baumer sensors perform pressure, temperature and level measurement tasks during food processing with great precision. Baumer offers reliable aids for food packaging, filling or storage as well as for quality control.

Glitch-free brewery process despite foam and sticky media

 With Baumer's CleverLevel, the clever alternative to the vibrating fork, process stoppage is a thing of the past. Do you experience overflow issues in your excess yeast tanks due to the sensor not detecting foam? Or does foam in your CIP caustic tank cause overflow issues or even cause pumps to run dry? Baumer offers you the perfect solution with CleverLevel. Universally usable for all types of media. Installed as high and low limits throughout the complete brewing process from raw barley storage to maturation.

Baumar Sensor Application in Brewery – Food and Beverage Industry

• Foam overflow protection in the yeast tank

Baumer Sernsors - CleverLevel easily detects any sticky or adhesive foam in excess yeast tanks to avoid overflow during filling.

Dry run protection of your pumps
CleverLevel can reliably ignore any foam – light, thick, sticky, or non-sticky – and therefore prevent your pumps from running dry. - See more at: http://mvrpl.com/baumar-sensors-help-keep-food-high-tech-hygiene-article-69.html#.VhYLTm6ByKJ

Dry run protection of your pumps
CleverLevel can reliably ignore any foam – light, thick, sticky, or non-sticky – and therefore prevent your pumps from running dry. - See more at: http://mvrpl.com/baumar-sensors-help-keep-food-high-tech-hygiene-article-69.html#.VhYLTm6ByKJ

• Dry run protection of your pumps

CleverLevel can reliably ignore any foam – light, thick, sticky, or non-sticky – and therefore prevent your pumps from running dry

• Foam overflow protection in caustic CIP tanks

CleverLevel ignores or detects foam which allows for reliable filling of the caustic CIP tank. The PEEK sensor tip is resistant to all cleaning medias used during CIP and supplied with in a robust stainless steel housing resistant to high pressure cleaning.


Baumer Sernsors - CleverLevel

Always the right level detection – the vibrating fork alternative.

Since pasty materials are prone to stick to these forks, it can often cause measuring errors when vibation level switches are used. Coarse granular media such as grains can easily become lodged between the forks and also cause measuring errors. Moreover, not only are the forks difficult to clean, but liquid and powder substances even require different fork designs. With the sensors of the CleverLevel switch, no media remnants or solids are able to accumulate on the sensors. A precise and reliable level detection is thus ensured even under difficult
circumstances.



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