Industrial Vision Inspection System

The vision system supports a wide range of camera sensors through its flexible MIPI CSI-2 interface. Compatible sensors include: Omnivision OV5640 (5MP), OV9281 (1MP global shutter), Sony IMX290/IMX327 (starlight cameras for low-light applications), and ON Semiconductor AR series. The system can accommodate sensors with 1-4 MIPI lanes and data rates up to 1.5 Gbps per lane. For high-speed applications, global shutter sensors are recommended to avoid motion blur. When selecting a sensor, consider resolution requirements, frame rate, light sensitivity, and cost. Our FAE team can help evaluate specific sensors for your application and provide interface timing analysis.

Contact our FAE team with your specific camera requirements for sensor recommendations and compatibility verification. We can provide reference designs for popular sensor options.

Measurement accuracy depends on multiple factors including camera resolution, optics, lighting, and calibration. With a 5MP camera (2592x1944) and appropriate optics, the system can achieve sub-pixel measurement accuracy of ±0.05mm over a 100mm field of view. For higher precision requirements, higher resolution cameras or telecentric lenses can be used. The FPGA-based processing enables real-time sub-pixel edge detection algorithms that improve accuracy beyond the native pixel resolution. Calibration using precision gauge blocks is essential for achieving specified accuracy. The system includes calibration routines and can compensate for lens distortion and perspective effects. For critical measurements, we recommend conducting a gauge R&R study to validate system capability.

Define your measurement accuracy requirements and field of view. Contact us for optical design consultation and accuracy validation procedures.

Yes, the vision system is designed for seamless factory integration with multiple industrial communication options. Standard interfaces include: Gigabit Ethernet with Modbus TCP/IP for PLC communication, RS-485 for legacy equipment, and discrete I/O for trigger and pass/fail signals. The system supports common industrial protocols and can be configured to match your existing infrastructure. For MES integration, inspection results and images can be transmitted via Ethernet to factory databases. The FPGA implementation ensures deterministic response times for real-time control applications. We provide configuration tools and documentation for common PLCs including Siemens, Allen-Bradley, and Mitsubishi. Custom protocol implementations are possible using the FPGA's programmable logic.

Document your existing automation architecture and communication requirements. Contact us for integration planning and protocol configuration support.

Development timeline varies based on application complexity, but typical phases include: 1) Requirements analysis and feasibility study (1-2 weeks) - define inspection criteria and validate technical approach. 2) Proof of concept (2-4 weeks) - develop algorithms on Tang Nano 9K development board. 3) Hardware design (4-6 weeks) - design custom PCB with appropriate interfaces. 4) Software development (4-8 weeks) - implement and optimize processing algorithms. 5) System integration and testing (2-4 weeks) - integrate with production line and validate performance. 6) Deployment and training (1-2 weeks) - install system and train operators. Total timeline typically ranges from 3-6 months for a complete custom solution. Using standard hardware platforms and IP cores can reduce this timeline significantly. We offer development services to accelerate your project.

Contact us early in your project to discuss requirements and development approach. We can provide phased development options to reduce time-to-market.

FPGA-based vision systems offer unique advantages compared to alternatives: Compared to smart cameras, FPGAs provide greater processing flexibility and can handle multiple cameras or complex algorithms that exceed smart camera capabilities. FPGA systems also offer lower per-channel cost for multi-camera applications. Compared to PC-based systems, FPGAs provide deterministic real-time performance with consistent latency, better reliability (no OS to crash), lower power consumption, and smaller form factor. However, PC systems may be preferable for very complex algorithms that are easier to implement in software. The Gowin FPGA solution specifically offers excellent cost-performance ratio, making it competitive with both smart cameras and PC systems while providing the benefits of both approaches. For applications requiring real-time response, multiple cameras, or custom algorithms, FPGA is often the optimal choice.

Evaluate your requirements for latency determinism, processing complexity, camera count, and cost. Contact us for a detailed comparison based on your specific application.