Choosing Cameras, Lenses and Lighting for Factory AI Inspection

Size the view around the task

Specify the smallest defect or character and the full region that must be visible. Estimate pixels across that feature, then validate with real samples rather than assuming a universal pixel threshold. Record working distance and mounting restrictions. Include variation in product height so focus is checked across the actual depth range.

Freeze the required motion

Choose exposure and triggering around product motion. Longer exposure gathers more light but can blur moving features; increasing gain does not restore lost detail. Check shutter behaviour with the actual movement and illumination. Test worst-case line speed and verify that image transfer and processing can keep pace without accumulating delay.

Use lighting to reveal the feature

Compare backlighting for silhouettes, diffuse light for reflective surfaces and directional light for surface texture. These are starting points, not universal prescriptions. Trial the arrangement with acceptable and defective samples. Shield uncontrolled ambient light where practical and specify how lenses and light covers will be cleaned.

Document and lock the validated setup

Record lens, focus, aperture, exposure, trigger timing, light position and camera pose. Use stable mounting and suitable protection for the environment. Recheck performance after replacement or adjustment. A commissioning image set and setup photographs make later troubleshooting more effective than a model file without capture documentation.

FAQ

Technical References

• Basler: Optimizing Image Quality