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ProCam® Align Smart product video
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ProCam® Testing of camera modules for various applications
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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 instruments of the ProCam® series we offer solutions for the critical challenge of active alignment and series production of high-precision optical sensor systems. Due to a controlled, automated manufacturing process, our systems ensure accurate, repeatable and fast alignment and assembly of camera modules. The optimization of the image quality by using the active alignment technology leads to a decrease of production rejects. The increasing yield and high image quality make active alignment an efficient manufacturing method for high-end camera applications.
Proven technology
Active alignment in the submicron range in up to six degrees of freedom. It is also suitable for wide-angle optics with a FOV of up to 180°
Flexibility
We realize both: alignment of the lens to the sensor board or alignment of the sensor board to the lens for double, stereo or triple cameras as well as for LiDAR systems
High performance
Our system for mass production is designed for shortest cycle times of less than 12 seconds: up to 300 camera modules per hour with highest product quality
Product Overview
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 system for active alignment and assembly of cameras and LiDAR systems in mass production.
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
ProCam® Prototyping
Consulting and engineering services for camera and LiDAR alignment
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 optimum image quality and the best possible active alignment process
Determining optimal alignment strategy and degrees of freedom (up to 6) based on your accuracy requirements
Providing support in terms of glue selection
Support for choosing the best manufacturing strategy based on your demands e.g. batch size and cycle time
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® 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
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
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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…