Leakage Inspection in Limited Spaces with Board-level Vision Cameras
Max Reijngoudt
Hydraulic leak detection is essential to make sure performance is maximized, downtime is minimal, and potentially expensive repairs are avoided. By developing a hydraulic leak detection system with machine vision cameras, engineers can minimize the time it will take to notice any faults in a machine and gain reassurance in the system's reliability. One recent application required a compact machine vision setup that could be used to check a hydraulic system for leaks within an extremely tight space. In common limited-space applications, we recommend using a board-level camera (VA Imaging’s VEN cameras series) together with application-identified lenses. In the following article, we will explain how these two components, along with the Daheng Imaging SDK, made up an effective solution used for a hydraulic leak detection project and which could be used for applications with similar demands.
Table of contents
Machine Vision Camera Selection
For effective leak detection, an industrial camera is needed which provides compact dimensions and a fast frame rate. Based on the researcher's requirements, we advised the ‘VEN-161-61U3C’, a 1.61-megapixel global shutter camera, utilizing the Sony IMX296 sensor. The sensor provides the capability for the camera to achieve a resolution of 1440x1080 pixels with a frame rate of 61 FPS, allowing fast image capture for leak monitoring in real time.
Furthermore, the VEN-161-61U3C board-level camera is particularly fitted for constrained environments. The dimensions of the camera are 35x35x20.8mm, which fits into very small places and hence is ideal for compact installations in hydraulic systems. The recommended version of the camera to the customer was the C-mount housing option, which is a combination of a C-mount with a 5mm extension ring. The camera can also be ordered with just a CS-mount, an M12 mount and even without a mount for projects with extra tight space limitations. Also, it was important for the customer to have a color camera, in order to notice and identify any possible irregularities in the color of the leakage.
Moreover, with the VEN-161-61U3C camera, the customer was able to see within a Field of View (FOV) of about 300x200mm, the smallest detail of around 1mm. Thus, this camera was a fit for detecting minor hydraulic leaks that could grow into larger problems.
Lens selection for Sony IMX296 sensor
Selection of the proper lens is paramount for bringing out the optimal performance of the camera in regard to leak detection. In this application, the VA-LCM-5MP-04MM F2.0-018 lens was used. The mentioned C-mount lens features an image circle of 1/1.8", along with having a 4mm focal length. Therefore, this matched well with the VEN-161-61U3C camera and proved suitable for capturing high-precision images.
By using the ‘VEN-161-61U3C’ along with the ‘VA-LCM-5MP-04MM-F2.0-018’ lens, at a working distance of around 245.5mm, the customer was able to achieve an actual FOV of around 305x228.7mm. A configuration like this ensures that the needed area coverage is achieved with finer detail capture, hence ensuring appropriate leak detection in the given region.
Software for Leakage Inspection
For this Leak detection system, the client required a development kit to create software for image processing, highlighting possible leaks, and issuing an alert. Therefore, the Daheng Imaging Software Development Kit (SDK) was suggested. It was used to aid the client in building a custom tool that would serve to identify leak events within the hydraulic system. In this situation, the Daheng Imaging SDK was installed on the Windows operating system, but it also supports systems like Linux and Android. Furthermore, the SDK has a demo program, which includes a user interface to provide customers with an easy way of setting parameters like the exposure time of a camera. If needed, it also includes various programming examples.
Leakage Inspection Applications
The board-level camera ‘VEN-161-61U3C’, together with the 04mm C mount lens ‘VA-LCM-5MP-04MM-F2.0 018 lens’, is a good composition for precise leak detection in cramped industrial conditions. Due to its compact form factor, high resolution, and efficiency of the frame rate, this camera is quite reliable not just for hydraulic system leak detections, but also for other similar applications. Additionally, flexibility in the Daheng SDK allows developers to implement customized software in a very easy and quick way, so the whole setup will be user-friendly and easy to deploy.
Support for leakage inspection vision system
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