Embedded camera modules for industrial equipment and various other applications have seen significant advancements. Along with improvements in resolution and frame rates, these modules have become more compact, cost-effective, and user-friendly. As a result, it’s increasingly common to find them integrated into robots, drones, medical devices, POS terminals, ATMs, vending machines, and inspection/measurement systems, as well as surveillance cameras for factory production lines.
Incorporating camera modules into industrial equipment opens up new possibilities for functions that were previously unattainable. For instance, equipping a vending machine with a camera module can capture images to determine the gender and age of customers, enabling the machine to tailor its beverage offerings accordingly. In essence, these modules allow for the collection of valuable marketing data. As technology continues to evolve, it’s clear that more industrial equipment will adopt embedded camera modules in the future.
Integrating a camera module into industrial equipment presents several challenges, though they are not particularly complex. The first hurdle engineers face in industrial equipment manufacturing is selecting the right camera module. Currently, there are four main types of camera modules to choose from: USB Video Class (UVC) cameras, Internet Protocol (IP) cameras, Wi-Fi cameras, and Mobile Industry Processor Interface (MIPI) cameras. Below is a brief overview of each of these four camera module options.
UVC camera modules are connected via USB cables and are commonly used in webcams for online conferencing and video streaming. One of their main advantages is ease of use—being compliant with the USB Video Class (UVC) standard, the driver software is preinstalled in the computer's operating system. This means that users can simply plug the UVC camera into their computer, and the image will display on their monitor without needing to develop custom driver software. However, UVC cameras are relatively large in size and costly, which can make them less suitable for integration into industrial equipment.
IP cameras are connected via Ethernet cables and have their own IP address, enabling them to be used simply by connecting to the internet. Often referred to as network cameras, they are commonly used for surveillance but can also be integrated into industrial equipment. Like UVC cameras, IP cameras are easy to use, with no need for custom driver software during integration. Another advantage is their long connection distance, up to 100 meters, which allows them to monitor remote locations. However, they also share the drawbacks of large external dimensions and high costs. Additionally, since video signals are compressed for transmission, there can be a delay of several frames, preventing real-time transmission.
Wi-Fi cameras are essentially wireless versions of IP cameras, offering the advantage of wireless communication between the camera module and the display monitor. With a connection range of up to 200 meters, they are highly user-friendly. However, like IP cameras, Wi-Fi cameras cannot transmit in real-time. They are also vulnerable to disconnections depending on the surrounding environment, and the connection stability may be lower, raising potential security concerns. Additionally, their large size and high cost make them less suitable for integration into industrial equipment.
MIPI cameras use the MIPI CSI-2 transmission standard, commonly found in mobile devices like smartphones. Their primary advantages include small external dimensions and low cost, as they were originally designed for mobile applications. MIPI cameras also support real-time transmission and offer a robust connection. However, there are two key disadvantages: the connection distance is limited to just 30 cm, making it challenging to apply in industrial settings where the camera and video processor are farther apart. Additionally, unlike UVC and IP cameras, MIPI cameras require custom driver software and register code to display video footage, adding complexity to their integration. However, the connection distance limitation can be mitigated with the right measures.
Selecting the best camera module depends on the specific industrial equipment and its requirements. There is no one-size-fits-all solution. Here's a brief overview of which camera is best suited for various use cases:
For rapid proof-of-concept testing, UVC cameras are ideal. Their ease of use and simple USB connection allow for quick integration and immediate video signal acquisition, making them perfect for validating new ideas.
When retrofitting industrial equipment with limited space, such as vending machines or production line inspection systems, MIPI cameras are the best option due to their compact size (around 20mm x 20mm). If the distance to the image processor is too far, combining MIPI with a V-by-One HS interface can extend the transmission range up to 15 meters.
If the video signal needs to be transmitted over distances greater than 100 meters, such as in broadcasting or underwater systems, IP cameras are the optimal choice. Their ability to handle long-distance transmission makes them the best solution for such applications.
In cases where cable routing is challenging, MIPI cameras paired with V-by-One HS provide a compact and efficient solution. Alternatively, Wi-Fi cameras eliminate the need for cables, simplifying installation.
For business equipment like POS terminals, where users may connect an optional camera, UVC cameras are the best choice. Their ease of connection allows for seamless integration of external cameras for additional functionalities, like QR code scanning.
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