ProCam® – Active Alignment
ProCam® Align Smart product video
ProCam® Testing of camera modules for various applications
ProCam® – Testing of camera modules for automotive applications
ProCam®
Active alignment, assembly and testing of camera modules and LiDAR systems
With the measurement and production equipment of the ProCam® series, we offer the latest solutions for the challenge of active alignment and series production of high-precision optical sensor systems. Active Alignment technology has a key function in optimizing the image quality of camera modules and LiDAR components. By providing optimal image quality across the entire field of view, active alignment is an established and efficient manufacturing process to produce high-end camera applications and LiDAR systems.
What is active alignment? Aligning an image sensor to a lens while actively reading image data from the sensor.
High performance
Shortest cycle times of less than 10 seconds by ProCam®: More than 360 camera modules per hour with highest product quality. Repeatability of up to 0.5µm (during) in the alignment process.
Flexibility
Our systems are not only fast, but also very flexible: Product changeover in less than 1 min. Various customizing set-ups of collimators and test charts.
Proven technology
Trusted and proven processes: Electronic integration of more than 80 different cameras realized. More than 12 years of experience in Active Alignment.
Active alignment & assembly of ADAS cameras
Advanced Driver Assistance System (ADAS) technologies for vehicles require highly reliable image processing systems and optical sensors to ensure safe and trouble-free operation on the road. Lives depend on it. These requirements are met by TRIOPTICS optical measurement and manufacturing systems. We integrate these high-precision metrology modules into mass production and provide solutions for the lens quality check, active alignment and end-of-line test for fully automated camera production lines.
Applications
The demand for high-quality machine vision systems and optical sensors for a wide range of applications in many different industries is steadily increasing, and imaging systems that enable better optical performance are required. In this context, the reduction in pixel size and increase in pixel density of modern image sensors pose a challenge to the precise optical alignment of lenses and sensors. TRIOPTICS strives to ensure the necessary performance of camera systems with reliable measurement and control algorithms. The ProCam® and CamTest product lines have proven to meet availability and yield requirements with low cycle times. Solutions range from products for semi-automated production to system integration for fully automated production lines that meet the requirements of the automotive industry.
Automotive
ADAS (Visible camera, 3D camera, Night vision camera, LiDAR)
Interior observation, DMS, Head up Displays, Touchless Control
Mirror replacement
Heavy duty, special and military trucks
Industrial
Bar code reader
Navigation, Geospatial
Heavy duty, Farming equipment
Borescope
Security, Healthcare & Consumer electronics
Surveillance
Video conferencing
Medical cameras
Endoscopes
Product Overview
ProCam® Prototyping
Consulting and engineering services for camera and LiDAR alignment
Our service to develop the best possible camera module according to your requirements. The service includes ongoing in-house manufacturing of prototypes and small series.
Design optimization for the best possible active alignment process
The alignment is done in the sub-micrometer range in all 6 axes (tilt, shift, focus, rotation) to achieve the optimum image quality
Support for choosing the best manufacturing strategy based on your demands e.g. batch size and cycle time
Our services at a glance:
Joint optimization of your camera sample for the active alignment process
Initial inspection of the lens with the ImageMaster® HR
Active Alignment including UV curing with ProCam®
Oven curing
Final quality control and detailed analysis by CamTest
Finding the best configuration for your series production by using ProCam® and CamTest
We are happy to assist you with the choice of the adhesive. You will also receive the evaluations and measurement results for traceability and analysis.
ProCam® Lab
Entry-level system for active alignment of camera modules
With the new ProCam® Lab, we offer the ideal solution for customers who want to master the critical challenge of active alignment and assembly of high-precision camera modules with a small number of pieces. Customers can easily get started in the camera business and optimize their prototypes for later series production.
In addition to the purchase of our active alignment system ProCam® Lab Basic, we also offer a full package to set up a complete assembly line. The full package includes, among others:
Object generator, Dispense module, UV curing module
Thermal curing oven and freezer for glue storage
Sample specific workpiece carrier and lens gripper
ProCam® Align Smart
Assembly station for cameras and LiDAR systems for small series production
The ProCam® Align Smart is a premium solution for optimizing the optical performance of camera modules through active alignment.
Automatic glue dispensing
Alignment of the optics to the sensor or vice versa
Precise adjustments for translation, tilt, focus and rotation to allow for optimal image quality
Process ends with automatic UV-curing
Active alignment within sub-micron/sub-arcmin precision
Up to 6 degrees of freedom
Real-time MTF characterization and final MTF test
Active alignment of wide-angle optics up to FOV 140° (FOV up to 170° possible after individual clarification
Innovative target projection for infinite-finite and finite-finite conjugated samples
Dual-/Stereo- and Triple-Camera alignment as well as LiDAR alignment on request
Easy change-over procedure using kinematic mount
Basic machine including control system, hardware and software, operating elements and displays
Customized instrument options: dispenser (application-specific), object generator (camera-specific), workpiece carrier, UV, gripper, camera connection incl. frame grabber (camera-specific)
ProCam® TT
Assembly station for cameras and LiDAR systems for high-volume production
ProCam® TT is a highly automated, high performance system for active alignment and assembly of cameras and LiDAR systems with a very small footprint.
Cycle time 12 seconds/ 300 units per hour (depending on the individual customer’s camera data)
Fast product change within the cycle time
Manually operated or integrated into an automated production line
High precision collimator target generators
Active alignment within sub-micron/sub-arcmin precision
Up to 6 degrees of freedom
High-precision adhesive dosing unit and image processing controller
Active alignment of wide-angle optics up to FOV 180° (possible after individual clarification)
Double/stereo and triple camera alignment and LiDAR alignment on request
Small footprint: 1400 mm × 1480 mm × 1875 mm
Comprehensive data interface for traceability and analysis
Connection to MES and host computer
Variable enclosure for manual loading or automatic robot loading
Various test modules can be integrated on request
Basic machine including control system, hardware and software, operating elements and displays
Customer- and application-specific device options: Controller rack, load/ unload function, dispenser, object generator, workpiece carrier, UV unit, gripper, camera connection
Software
ProCam® Software
The ProCam® software “CamAlign” consists of components for the fully-automated active alignment process:
Using high precision image analysis algorithms, all relevant parameters for the accurate alignment process such as the MTF at multiple field positions and the tilt of the image plane are automatically analyzed in real-time and used in the alignment process.
All stages of the alignment and measuring process are software-controlled by ProCam®
With the integrated scripting tool, the measurement and alignment process can easily be tailored to specific customer needs and products.
The measurement data can be saved in a database so that the process is completely traceable
Configuration files for different types of camera modules for fast product change
Technical Data
| Parameter | ProCam® TT | ProCam® Align Smart |
|---|---|---|
| Alignment axes | 5 or 6 | 5 or 6 |
| Resolution linear | 0.2 μm (X,Y) 0.08 μm (Z) | 0.2 μm (X,Y) 0.08 μm (Z) |
| Resolution rotatory | 2.5 μrad (Θx, Θy) 5 μrad (Θz) | 2.5 μrad (Θx, Θy) 5 μrad (Θz) |
| Repeatability linear | ± 0.15 μm (X,Y) ± 0.06 μm (Z) | ± 0.15 μm (X,Y) ± 0.06 μm (Z) |
| Repeatability rotatory (pitch, yaw, roll) | ± 2 μrad (Θx, Θy) ± 3 μrad (Θz) | ± 2 μrad (Θx, Θy) ± 3 μrad (Θz) |
| Typical sample alignment accuracy, linear | ± 2 μm1) | ± 2 μm1) |
| Typical sample alignment accuracy, rotatory (pitch, yaw, roll)1) | Pitch and Yaw: ± 0.6 mrad Roll: ± 0.9 mrad (Sensor to sensor) ± 1.75 mrad (Sensor to mechanical reference) | Pitch and Yaw: ± 0.6 mrad Roll: ± 0.9 mrad (Sensor to sensor) ± 1.75 mrad (Sensor to mechanical reference) |
| Sample objective lens EFL | 0.7 mm … 30 mm (1 mm … 12 mm Standard) | 0.7 mm … 30 mm (1 mm … 12 mm Standard) |
| Sample objective lens diameter | 4 mm … 30 mm (smaller or bigger diameter on request) | 4 mm … 30 mm (smaller or bigger diameter on request) |
| Field of view test chart | up to 70° (up to 100° possible after individual clarification) | up to 70° (up to 100° possible after individual clarification) |
| Field of view collimators | up to 160° mechanical set up2) up to 140° for optical measurement3) | up to 160° mechanical set up2) up to 140° for optical measurement3) |
| Test targets | Test chart or collimators Available with VIS or NIR | Test chart or collimators Available with VIS or NIR |
| Performance | 300 UPH (units per hour) calculated on following parameter: 2 seconds UV curing time, continuous images from camera @ > 30fps, < 1second camera start-up time, parts loaded as specified, tolerance for lens FFL +/-100µm, scan range <300µm, alignment process max. 2 scans, loading and unloading within cycle time | <60 sec. process time (without sample loading/unloading) Process time calculated on following parameter: sensor board initialization time <1 s, camera frames >30 fps, continuous images from camera, UV snap curing <2s with preselected lenses. |
| Dimensions (h x w x d) | 1,875 mm (1,800 mm without flowbox) x 1,470 mm x 1,550 mm; customized | 2,200 mm x 1,750 mm x 1,100 mm |
| Camera interface | MIPI, Parallel, LVDS, Analog or directly to PC via e.g. USB, FireWire, CamLink, GigE and others | MIPI, Parallel, LVDS, Analog or directly to PC via e.g. USB, FireWire, CamLink, GigE and others |
| Weight | 600 kg … 800 kg | |
| Type | stand alone or inline (integratable) | stand alone |
1) Typical accuracy reached on following sample parameter: pixel size 6μm, F# = 2.8, EFL = 4.5mm.
2) Up to 180° possible after individual clarification, depending on sample and mechanical surrounding, for bigger FoV technical investigations necessary.
3) Depending on distortion, individual clarification necessary.
Upgrades & Accessories
Robot loading
Plug & produce collimator dome
Sensor test
Knowledge Base
More knowledge for experts
Everything you need to know about image quality testing of camera modules can be found in the knowledge base of CamTest…