JAI Prism Cameras Extended insight – crisper and spectral inspection with prism technology

Jari Löytömäki JAI Finland

May, 2014 GLOBAL REACH… worldwide operational and commercial presence with distribution to more than 40 countries RESEARCH & DEVELOPMENT a unique blend of technologies & competencies

• Area scan and line scan camera technology.

• Analogue-to-digital circuit design.

• Software engineering.

• Image pre-processing techniques.

• High-speed interfaces.

• Optical knowledge.

• Imager and multi-imager technology.

CCD/ 2CCD 3CCD 3CMOS 4CCD 4CMOS CMOS WHY PRISM BASED CAMERAS? Superior and spectral imaging

Multi-imager cameras provide better color fidelity and spatial precision than single-imager color cameras with BAYER filter

4 CUSTOMERS IN A RANGE OF APPLICATIONS Proven track record

Tile inspection Bed sheets inspection Sports – finish line PCB inspection

Film scanning Wood inspection Print inspection Food inspection

Textile inspection Pharma inspection Raw cotton inspection Parts inspection

5 PRISM BASED CAMERAS Superior color and spatial precision

3-CCD RGB image 1-CCD Bayer image

3-CCD resolution equals 3-4 times single imager resolution: • A 3-CCD VGA camera resolution equals a 1 megapixel BAYER resolution

3-CCD RGB image – 0.8 megapixels Bayer CCD – 0.8 megapixels Kowa 3-CCD lens 50mm F1.8 Kowa 3-CCD lens 50mm F1.8 6 PRISM BASED CAMERAS Superior color and spatial precision

3-CCD RGB image 1-CCD Bayer image

3-CCD RGB image – 2.0 megapixels Bayer CCD – 5.0 megapixels

7 PRISM BASED CAMERAS Superior color and spatial precision

3-CCD RGB image 1-CCD Bayer image

3-CCD RGB image – 2.0 megapixels Bayer CCD – 5.0 megapixels

8 THE 3-IMAGER CONCEPT Line scan prism

R Sensor - color channel

Optics G

Sensor - color channel

JAI’s prism-based cameras detect even the most subtle color variations and details. Sensor - color channel B 9 THE 3-IMAGER CONCEPT Area scan prism

10 APEX SERIES Superior color and spatial precision APEX

AT-030MCL Large pixels Fast inspection 7.40 µm pixels 120 frames/s 3-CCD 3 x 1/3” 0.3 megapixels 640 x 480 120 frames/s 7.4 µm pixels Key features: • Speed: The world’s fastest 3-CCD area scan camera. • Sensitivity: 7.4 µm pixels and ƒ1.2 prism enable camera to operate at high speeds with less illumination • Linear matrix circuit: Adobe RGB or sRGB presets simplify calibration with printers, monitors, and other systems • Automatic functions: shading compensation, auto exposure, noise reduction RGB Color circuit and auto white balance • Suitable for a range of applications (pharmaceutical, print inspection, web inspection, LED inspection etc.)

11 PRISM CAMERA AT-030 and binning

Pixel

H

Xsg1 Vertical CCD Register

Normal full scanning

H

2 line Vertical Binning Video Out

Horizontal CCD Register Reset S/H

Horizontal Setting Effective/total Frame rate Frequency Off (No V Binning)) 494/511 61.571 KHz 120.49 frames/sec. 2:1 V Binning 247/257 49.828 KHz 193.89 frames /sec. 12 PRISM CONTRA BAYER Two 120 fps cameras

. 3-CCD – 3x Sony ICX424AL (VGA) • 120 fps • 7.4 µ x 7.4 µ • 3 x 1/3” CCD, size 4.88 (h) x 3.66 (v) mm2 • = 53 mm2 (imager area)

. Single imager – 1x TrueSense imaging KAI-1050 (1MP) • 120 fps • 5.5 µ x 5.5 µ • ½” CCD, size 5.65 (h) x 5.65 (v) mm2 • = 32 mm2 (imager area)

13 THE 3-IMAGER CONCEPT (area scan) Bayer technology vs. prism-based technology

Bayer pattern Gb B Gb B

R Gr R Gr Interpolated ”True Interpolated green” Gb B Gb B red blue R Gr R Gr

3-CCD true colors R R R R G G G G B B B B

R R R R G G G G B B B B True True True R R R R G G G G B B B B red green blue R R R R G G G G B B B B 14 CCD 1 CCD 2 CCD 3 THE 3-IMAGER CONCEPT (area scan) Bayer technology vs. prism-based technology

G G B B

R R G G Interpolated ”True Interpolated G G B B red green” blue R R G G

3-CCD true colors R R R R G G G G B B B B

R R R R G G G G B B B B True True True R R R R G G G G B B B B red green blue R R R R G G G G B B B B 15 MTF Modulation Transfer Function and color reproduction

Prism camera characteristics

= Electro-optical PSF Electrical MTF Lens+prism+imager Camera electronics

16 MTF Modulation Transfer Function and color reproduction

Prism camera characteristics

• Imager – No color interpolation (each RGB point in object space sees a pixel) – No low pass filter required (close to 100% fill factor for each color) • Color filters – Hard coated filters; steep slopes and tight tolerances (can be user-defined) • Electronics – No color contamination due to electrical crosstalk (individual camera per color plane) • Lens – Point Spread Function – good/bad - will not result in color crosstalk (separate color planes) 17 HARD DICHROIC PRISM COATINGS Advantages

Advantages of hard dichroic filters Steep • Precise wavelength cutoffs and steep slopes slopes provide for less color crosstalk (crisp colors). • Long-term stability and a longer product lifetime is maintained. • Tight batch-to-batch coating tolerance. Minimal color crosstalk • High transmittance results in better sensitivity.

Drawbacks of soft polymer dye used for BAYER filters and for tri-linear and dual-line designs: • Large crosstalk resulting in lower color precision. • Batch-to-batch variation in dye. • Limited long term stability. • Lower transmission.

18 4 IMAGER PRISM NIR sensitivity – RED and NIR

Spectral response

Sensor and prism. No lens.

19 LQ-200CL / LQ-050CL Simultaneous imaging of R, G, B + NIR light

The incoming light is split into 4 spectral bands (RGB + NIR) with perfect pixel- to-pixel alignment.

The Red, Green, Blue and NIR pixels see exactly the same point on the object

at all times. Visible light Near infrared light (400 – 750 nm) (750 – 1100 nm)

20 LQ-200CL /LQ-050CL Specifications

COMMON FEATURES: LQ-200CL • 4-CCD line scan camera • RGB/NIR prism with 4 2048 pixels sensors (4 channels) 14 μm x 14 μm pixel 19048 lines/s • Low-noise operation (S/N: 58 dB) providing superior image quality • 4 x 8 bits or 4 x 10 bits output Front view • One-push automatic white balance • Flat-field correction and color shading LQ-050CL compensation • Binning functions for increased sensor 512 pixels 14 μm x 14 μm pixel sensitivity 70922 lines/s • Gamma correction using LUT table • Set-up and installation aid with built-in test pattern generator Rear view

21 CHANNEL BALANCING RGB PRISM CAMERAS Individual shutter control for low noise color balancing

Level CCD output Level Gain balanced Level Shutter balanced 100 % 100 % 100 % -2dB -9dB Signal Signal Signal

Noise Noise Noise 0 % Channel 0 % Channel 0 % Channel B G R B G R B G R 9dB 0dB 2dB 282 100 126

Same exposure and same Signals normalized by using Signals normalized by using gain for all 3 channels. individual channel gain: individual channel shutter: Color balancing required ! Blue is +9 dB gain, and red Blue exposure is 282, is +2 dB. green exposure is 100, red exposure is 126. Noise increases proportionally. Gain/noise stays at minimum! 22 THE 3-CCD CONCEPT Color space calibration

• Linear color matrix circuit.

• Lets users fully manage the gamut of the color output.

• Enables calibration between camera, monitors, printers and other peripherals for applications needing precise color matching.

• Built-in presets for sRGB and Adobe RGB color spaces.

• Manual adjustment of R,G, & B also provided.

23 LINE SCAN Off-axis viewing…

Tri-linear technology Advantages of Line Scan prism technology When inspecting undulating objects, non-flat objects or if the camera is Exact color registration through precise positioned off-axis, the tri-linear sensor alignment. technology gives different magnification for the spectral bands resulting in distorted color registration. Unwanted halo effects occur!

HALOHALOHALO NO HALO

R, G and B (co-site sampling)  24 SPECTRAL IMAGING From RGB to…?

25 SPECTRAL IMAGING Customization

Band sampling

• A certain defined bandwidth for each imager • Clear separation or defined overlap between bands • Customized coatings is an option for strategic customers Hard dichroic coatings.

CCD 1 CCD 2 CCD 3 CCD 1 CCD 3 CCD 1 CCD 3 CCD 2 CCD 2

λ λ λ λ λ λ1 2 3 1 2 3 λ1 λ2 λ3 26 SPECTRAL IMAGING Customization

27 ENGINEERING & MANUFACTURING second to none quality

In-house design and alignment ensures

• Full control of the prism assembly process • Filter characteristics • Affordable customized prisms/filters

Clean room - class 1000 and 6 axis auto-alignment. THANK YOU for seeing the possibilities

Jari Löytömäki

[email protected]