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Lighting systems for industrial image processing

Industrial image processing is mainly used for the visual monitoring of production processes in industry. This allows individual parts and steps in the manufacture of products to be inspected automatically. The image processing chain comprises the following areas:

  • Illumination
  • Optical imaging
  • Storage
  • Transmission
  • Digitisation
  • Evaluation

planistar is specialised in the field of lighting and can draw on a wealth of experience. Since 1990, we have not only been a producer. We provide our customers with comprehensive advice on their applications in automation and image processing in the field of light.

Just ask for advice: sales@no-spam.planistar.de or Tel. +49 (0) 9364 8060-0

Various types of lighting systems for industrial image processing

As a manufacturer of lighting systems for industrial image processing, we cover the entire product spectrum of LED luminaires. So you get all automation solutions from a single source, directly from the manufacturer:

  • Surface illumination for transmitted light applications / backlight applications
  • Surface illumination for diffuse incident light applications
  • Directed and diffuse bar luminaires
  • Strip luminaires
  • Light tunnels
  • Spotlights
  • Ring luminaires

With panel lights, dark-field luminaires, light hoods, our special lightsabres and coaxial luminaires, we complete the range and offer everything for ideal illumination in industrial image processing. In addition to individual components and accessories, we also offer complete systems.

LED lighting used sensibly

We primarily work with LED lighting. In addition, we draw on our experience with fluorescent lamp and glass fibre technology. In industrial image processing, however, LEDs have the following advantages: They are very durable and robust, have low light fall-off over the entire service life and can be switched quickly and often. In addition, any housing shape is possible.

All these points apply when the LED is handled correctly. The primary hurdle is heat generation on the LED chip. With planistar luminaires, the entire housing serves as a heat sink. The LEDs are controlled segment by segment and not centrally with a current controller. During flash, the pulse/pause ratio is monitored. Many years of experience and tests flow into the development of our systems. The result for our customers:

High-quality LED lighting for all the tasks relating to industrial image processing!

Customised solutions

It is often necessary to adapt our LED lighting systems from our standard range to the image processing tasks and specific conditions of our customers. Furthermore, we can incorporate the design of the cameras, lenses, sensors and other components into the lighting solution. Since we manufacture the individual main components in-house at planistar, we have designed our production to produce customer-specific solutions quickly and cost-effectively.

All luminaires are documented. In this way, we can reconstruct and re-manufacture your luminaires even after a longer period of time.

Tasks of image processing

Image processing solutions are fast and non-contact. They are used in inspection technology and assembly monitoring and increasingly for process control. Position determination, measurement and inspection of circumference and surface, completeness check, bar code and matrix code recognition, character recognition etc. are classic applications. Industrial image processing, for example, has become indispensable in the automotive and pharmaceutical industries. Typical applications of industrial image processing and image processing systems are:

  • Deformation detection
  • Optical character recognition
  • Surface inspection
  • Robot vision
  • Weld inspection
  • Track and trace
  • Presence check

Our lighting solutions are compatible with many camera manufacturers including Keyence, Cognex, IDS and Basler.

Selecting the right illumination for industrial image processing

When designing an image processing system, the choice of the right illumination is often underestimated. The contribution of illumination to image quality is just as important as the choice of sensor, camera and optics. The fact that this choice is not necessarily easy is due to the enormous differences in the objects to be inspected which can be encountered in the context of industrial image processing and automation.

The subject should be regarded similarly as in photography. The photographer sets the decisive accents only through the right lighting to obtain a meaningful picture.

The same applies to industrial image processing. Only that not the eye, but a camera, which can only evaluate grey scales, looks at the image. This makes it even more complex.

Since planistar originally started in the field of photography (production of light boxes), this experience helps us in consultation for the tasks of industrial image processing.

We base our selection on the following questions:

How can the object be illuminated in such a way that the critical features stand out from the image with the highest possible contrast? This requires an understanding of how the light passes from the source to the object, how it is scattered or reflected by the source, and how this light is captured by the lens and imaged on the sensor.

This depends on a number of factors:

Size of the measuring field and distance of the camera

What is the distance to the camera and how large is the measuring field?
The camera’s viewing angle and field of view can thus be incorporated into the solution for industrial image processing.

Photometric ambient conditions

What are the ambient lighting conditions like during image processing? What extraneous light could influence industrial image processing, and how can this be prevented?

Mechanical ambient conditions

What are the mechanical ambient conditions like? An image processing solution is often integrated into an existing or already planned line. Mechanical limitations, moving parts (feeders, grippers, robots) and operator stations must be considered. These limitations are particularly important when choosing the optimum LED illumination for industrial image processing.

Speed of the test object

At what speed does the test object move? The brightness and operating mode of the luminaire are set here to prevent motion blur.

Surface and shape of the test object

An important aspect is the surface and shape of the test piece (degree of gloss, straight or curved viewing surface, required depth of focus). Here, trials are often necessary to identify the possible lighting systems.

Colour and material of the test object

The colour and material of the object are also important. Not the entire spectrum of the light is reflected by the test piece. In the meantime, the light colour white with a good light spectrum is usually chosen in order to cover a large area. Sometimes it is better to only apply a certain monochrome spectrum to the test piece in order to be able to detect errors in industrial image processing more easily.

Influence on people

One aspect that has recently become increasingly important is the influence on people (occupational health and safety, working conditions). Since the lighting systems in industrial image processing are becoming brighter and brighter (up to risk class 2), the employee must also be considered. The LED lighting must not endanger (photobiological safety, DIN EN 62471) or negatively influence (interfere with) the work of the user. Therefore, excessive light or flash must be avoided or screened off. An unnatural light can also have a negative effect on the employee. We recommend a light colour of approx. 5000–6000 K, as this is similar to natural sunlight.

Since planistar operates its in-house test laboratory for industrial image processing and visual inspection, we receive test pieces from our customers to carry out tests. We are also happy to invite our customers to our facilities in order to identify suitable lighting arrangements together. If the on-site conditions are difficult, however, we travel to our customers to discuss the situation in the plant and the task of industrial image processing.

Once a possible solution has been worked out, we make PDF drawings or STEP files available to our customers. This allows our customers to plan the LED lighting into the image processing system in advance.

For standard luminaires, these are already available as downloads on the Internet and in the catalogue. In the case of customer-specific solutions for lighting systems in industrial image processing, we draw these up on request.

Any questions?

We will be happy to advise you which type or size is required for your application. In order to meet your needs, our offering of LED lighting systems for industrial image processing extends far beyond the standard product range.

More information and points of contact:

+49 (0) 9364 8060-0sales@no-spam.planistar.deComplete catalogue

We will be happy to develop tailor-made solutions for you. Fast, inexpensive and individual.

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