Smart Cameras and Vision Sensors are indispensable in industrial image processing when it comes to automated quality control, identification tasks or measurements. Both systems combine camera, evaluation and interfaces in one compact device – but what are the differences? And when is which system the right choice?
Smart cameras are intelligent camera systems that combine image acquisition and image evaluation in a single housing. They thus form a complete image processing system in sensor format.
In contrast to simple sensor systems, the optics and illumination of smart cameras can be configured individually, making them extremely flexible. This makes them suitable for a wide range of applications – from quality inspection and position determination to complex measurement tasks.
The special thing about a Smart Camera is the interaction between intelligent hardware and powerful software.
An integrated processor processes the captured raw image data directly in the device. This enables an immediate output of results, for example in the form of a good/bad decision.
The device can be easily integrated into existing networks via an Ethernet interface, and configuration is usually carried out via an intuitive graphical user interface.
The Smart Camera therefore makes it much easier to set up image processing projects – without the effort required by a classic, PC-based vision system with a separate camera, illumination and software.
One example: The Smart Camera B60 from wenglor is equipped with auto-focus and a C mount, allowing it to be optimally adapted to different lenses and illuminations. The result is a versatile system that masters even the most demanding image processing tasks.
A vision sensor is the compact alternative to a Smart Camera. It combines optics, illumination and evaluation in a particularly small housing.
Vision sensors are usually optimized for specific tasks – such as presence checks, simple identification tasks or the recognition of colors and shapes.
Thanks to their simple operation, vision sensors can also be configured without in-depth image processing knowledge. Modern models use pre-trained neural networks that enable simple good/bad classification based on a few reference images.
One example is the B50 series vision sensor from wenglor: it offers numerous image processing functions for the automation industry – from counting and sorting to color and shape recognition and fast quality checks. It can even transmit results to the controller in real time via Industrial Ethernet.
The vision sensor works according to a simple principle: it illuminates the scene with the integrated illumination, records the image via the built-in optics and evaluates it internally.
As the hardware and software are perfectly coordinated, initial start-up is usually completed in just a few minutes. Predefined inspection tools allow users to become productive immediately – quickly, reliably and without any programming effort.
The boundaries between the two technologies are fluid – but the choice essentially depends on the complexity, flexibility and performance requirements of the application:
Criterion | Vision sensor | Smart Camera |
Task | Simple inspection and recognition tasks (e.g. presence, color, shape) | Complex applications (e.g. measurement, positioning, OCR, 3D evaluation) |
Flexibility | Fixed optics and illumination | Freely configurable optics, variable illumination |
Furnishings | Fast and intuitive, without programming knowledge | A little more complex, but customizable |
Computing power | Sufficient for simple analyses | High-performance thanks to integrated processor |
Software | Predefined tools, simple operation | Comprehensive software with in-depth functions |
Price-performance ratio | Cost-efficient for standard applications | Higher investment, but maximum flexibility |
Whether vision sensor or Smart Camera – as integrated image processing solutions in sensor format, both systems offer a simple and efficient way to solve image processing tasks directly in the machine.
If you want to carry out quick, standardized inspections, a vision sensor is the best choice.
For complex, flexible and expandable applications, on the other hand, the Smart Camera is the right choice.
With the B50 Smart Cameras and Vision Sensors and the B60 Smart Cameras, wenglor offers the right solution for every application – intelligent, powerful and easy to operate.
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