In the growing market of Surface Vision / Machine Vision solutions, image quality, resolution and ease of integration are becoming more and more important success factors. Automating previously manual quality controls opens up a large potential for cost reduction. In addition, the area of detection, selection and positioning provides a wide area of application for optical solutions.
For several decades, Mitsubishi Electric has been the worldwide leading supplier of CMOS chip-based Contact Image Sensors (CIS) for professional image capture. These sensors, marketed under the name Mitsubishi Electric - Line Scan Bar, feature not only high image quality, resolution and line rate, but also a very compact design ideal for integration in machines or mechanical devices.
Through consistent and continuous further development of the CIS technology, Mitsubishi Electric offers the sensors in increasingly higher resolutions and larger widths. The Line Scan Bar is therefore a real alternative to well-known line scan cameras, but it also offers a whole series of additional benefits.
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The Mitsubishi Electric - Line Scan Bar is a CMOS-based sensor for optical image capture. The image is captured line-by-line, and this data is then composited into a complete image by a frame grabber card. The light reflected by an object through a lens is recorded in the Line Scan Bar and directed to a photodiode. This converts the incoming light into an electrical signal whose strength is proportional to the light intensity. In an analogue to digital converter, the signal is finally converted into an 8- or 10-bit value. An essential part of the Line Scan Bar is the ‘Grin lens’ - a gradient-index lens, allowing distortion-free 1:1 representation of the object on the sensor surface, thereby crucially contributing to the high image recording quality. The sensor is also a trilinear sensor, i.e. it has a separate sensitive area for red, green and blue light. It is therefore a colour sensor that records true-colour images. For simple applications, the sensor is also available in a monochrome version that only detects gray values.
|Mitsubishi Line Scan Bar CX|
|Scan width||367 mm||587 mm||807 mm|
|Number of pixels||8,640||13,824||19,008|
|Possible resolutions||600/300/200/150 dpi|
|Line frequency at 600 dpi||55 KHz|
|Line frequency at 300 dpi||91.8 KHz|
|Line frequency at 200 dpi||110 KHz|
|Line frequency at 150 dpi||110 KHz|
|Dimensions in mm (w x h x d)||433.2 x 98.3 x 62||653.1 x 98.3 x 62||873.1 x 98.3 x 62|
|Mitsubishi Line Scan Bar AX|
|Scan width||309 mm||619 mm||926 mm|
|Number of pixels||7,296||14,592||21,888|
|Line frequency at 600 dpi||23 KHz|
|Power supply||24V / 5V|
|Dimensions in mm (w x h x d)||377 x 71 x 62||688 x 71 x 62||1,040 x 71 x 62|
A highly intensive and homogeneous LED illumination is integrated directly in the frame of the sensor housing. The illumination is therefore always optimally aligned on the sensor. Cumbersome calibration and alignment of external light sources is unnecessary. Another advantage is that an additional power supply can be omitted.
For inspection tasks in transmitted light or in special lighting specifications, our sensors are also optionally available without integrated LED illumination.
In conventional line scan cameras, the image is distorted towards the edge by the lens used. The Line Scan Bar, however, guarantees a distortion-free 1:1 copy of the object. This is achieved by means of a specially designed array of rod lenses, GRIN lenses, with a defined working distance that produce the necessary telecentric captured radiation. This is an optimal prerequisite for the quality inspection of problematic surfaces. Furthermore, it also eliminates the need for time-consuming alignment or focus during the commissioning.
The Mitsubishi Electric - Line Scan Bar uses CMOS high-end chips for high-speed image acquisition, a defined pixel size of 0.042 mm and real trilinear CMOS chips with RGB filters.
For applications in which no colour image is necessary, a monochrome CIS sensor is also available.
Due to its very compact design, the sensor only requires a fraction of the space that a system still based on line scan cameras would need. This allows system integrators and machine manufacturers more installation options when integrating the sensors in machines or systems - and important cost savings.
The Line Scan Bar is mounted to the side of the machine wall by just four screws at a working distance of 12 mm from the protective glass surface. Then the power cable and the data cable are simply plugged in, and assembly is completed. Time-consuming calibration, alignment or other settings are no longer necessary. The Line Scan Bar is pre-calibrated at the factory with a white/black correction. Compared with the assembly of a normal line camera system, a time-saving of up to two days assembly time can be achieved with the Line Scan Bar from Mitsubishi Electric.
Thanks to its easy installation, any replacement of the Line Scan Bar that is required can be done by the in-house technicians. There are no costs for deployment of service staff. Here also, there is an enormous savings potential for the end-user and the system integrator or machine manufacturer.
Sophisticated surface check
Ambitious quality monitoring
Inspection of optical security features
Robot and machine vision