As designers rethink existing vision systems or plan new industrial applications, staying ahead of technological advancements is crucial. This article explores our perspective on where image sensor technology—and its supporting components—are heading next. We’ll cover trends in sensors, optics, interfaces, and processing to provide a clear roadmap for the evolving landscape of industrial vision.

1. Trend #1: The Shift from CCD to CMOS Dominance

This year has solidified CMOS as the leading image sensor technology for both current and future applications. Sony’s decision to discontinue CCD production in favor of investing more heavily in CMOS underscores this shift, as such a move reflects clear technological advantages. CMOS sensors now combine the best features of previous technologies: higher speeds, superior integration capabilities, lower power consumption (enabling smaller cameras), and increasingly competitive image quality.

Modern CMOS sensors outperform CCDs across key metrics like dark current, uniformity, and read noise—areas where CCDs once held an edge. However, it’s worth noting that not all CMOS sensors surpass every CCD sensor. The highest-end CMOS models, equipped with cutting-edge processing (including advanced global shutters), deliver superior performance in terms of lower noise and higher dynamic range.

While CCD technology remains relevant for specific use cases—such as those requiring the exceptional sensitivity of EMCCD—it relies on mature production methods. For less demanding applications involving large sensor arrays, CCDs may still offer cost advantages.

2. Trend #2: Shrinking Pixel Sizes for Higher Resolution

The consumer market’s relentless drive toward miniaturization has fueled a trend of decreasing pixel sizes in industrial sensors. Smaller pixels allow manufacturers to pack more resolution into compact optical formats without sacrificing system layout, enabling higher resolutions while maintaining the same physical dimensions. This is particularly beneficial for inspecting finer details and intricate patterns in quality control processes.

Current industrial sensor pixel sizes range from 4.5 to 5.5 micrometers—already significantly smaller than consumer or mobile device sensors. In just two to three years, this will shrink further to approximately 3 to 3.5 micrometers. We believe this represents the end of a significant race in pixel miniaturization. As performance improvements stabilize, developers can focus on enhancing functionality through innovations like improved global shutters and advanced processing algorithms.

3. Trend #3: Increased On-Camera Processing

As image sensor quality improves, manufacturers are redirecting development efforts from basic defect correction toward sophisticated image processing. This allows cameras to incorporate additional features—such as color enhancement, digital zoom, aberration reduction, or intelligent analysis functions—without requiring external hardware (e.g., frame grabbers or specialized software modules). Compact CMOS sensors with advanced capabilities provide more flexibility in designing optical systems optimized for performance metrics like Modulation Transfer Function (MTF) optimization.

Modern cameras can now achieve higher resolutions while maintaining a balance between lens aberrations and diffraction effects by leveraging tools like Neutral Density (ND) filters. This frees designers to optimize other aspects, including optimizing the Modulation Transfer Function (MTF), which enhances image clarity.

This approach offers several benefits: reduced reliance on mechanical components ensures greater reliability with increased Mean Time Between Failures (MTBF). The latter eliminates moving parts traditionally used for light control, significantly boosting reliability and reducing failure rates typically associated with traditional optics.

4. Trend #5: USB3 Vision and CoaXPress Gain Market Share

Even as Camera Link continues to serve existing legacy systems, newer standards like GigE Vision are facing challenges due to bandwidth limitations. USB3 Vision is set to gain significant market share because it avoids the need for frame grabber cards in applications where cable length or speed constraints aren’t critical. CoaXPress has gained traction in high-end industrial and defense applications thanks to its robust performance, extended cable lengths, and rugged design.

4. Trend #4: Redefining Optics Design

Recent advancements in CMOS sensors grant designers more flexibility when selecting lens parameters. For instance, fixed aperture optimization allows lenses with improved image uniformity due to optimized contrast—especially radial falloff. This approach offers several advantages:

  • Reduced Cost: Fixed apertures and a rugged design eliminate the need for iris diaphragms or variable Neutral Density (ND) filters.
  • Enhanced Reliability: Fewer moving parts translate to improved Mean Time Between Failure (MTBF), matching typical electronic equipment reliability levels.
  • Optimized Performance: Radically simplified lens designs enhance uniformity, resolution, and repeatability through digital implementation.
  • Miniaturization Benefits: Digitized functions contribute to more compact lenses while improving power efficiency.

5. Trend #5: USB3 Vision and CoaXPress

While Camera Link may persist in legacy systems, newer applications increasingly favor modern standards like USB3 Vision or GigE Vision. USB3 Vision continues gaining traction due to its speed and simplicity, particularly with planned speed upgrades. Meanwhile, CoaXPress is expanding into high-end industrial sectors—especially defense—thanks to superior data rates, extended cable lengths, rugged connectors, and ease of integration.

Future standards must balance the need for more integrated and compact solutions by reducing bulkier components like frame grabbers or bulky connectors.

Final Thoughts: Where Do You See Industrial Vision Heading?

Last Updated: 2025-09-04 20:41:22