Triple Lens Sensor Measuring Accuracy of 0.012 in (0.3 mm) for Semi-Transparent Objects

Related Vendor

FAULHABER Drive Systems

The triple-lens system with proprietary AI from Kyocera improves close-range measurement by a factor of three. The measurement results are significantly more precise, especially for semi-transparent, thin and fine linear objects.

Distance sensors perform tasks such as quality control of SMD assembly, geometry inspection of printed circuit boards and automated inspection of miniaturized components. The non-contact measurement technology enables the precise detection of distances, heights and surface geometries without mechanical wear and with the required speed for industrial production lines. Laser triangulation sensors achieve repeat accuracies in the micrometer range and are integrated as standard in pick-and-place machines, AOI systems (Automated Optical Inspection) and SPI systems (Solder Paste Inspection).

The Development of A Triple-Lens Sensor

Kyocera Corporation has increased the measurement accuracy of its AI-based distance sensors for close-up photography by a factor of three, from 0.039 in to 0.012 in. The new triple-lens sensor solves critical detection problems for semi-transparent, thin and fine line-shaped objects that were previously difficult to detect with conventional stereo cameras and the human eye.

The Technical Operating Principle

The system uses three lenses to simultaneously capture parallax information in the combinations "left-center", "center-right" and "left-right" at a working distance of 4 in. The proprietary AI technology combines these multiple parallax data sets and thus virtually eliminates incorrect adaptations. At the same time, blind spots are reduced, which significantly improves measurement accuracy.

The triple lens configuration enables precise distance and size measurements of thin, linear objects whose alignment is parallel to the left and right lens. This includes ultra-fine wires with a diameter of 0.012 in. A measurement that enables the new system to accurately determine the distance of previously problematic object types.

Object Detection for Critical Materials

The sensor reliably characterizes objects that were difficult to detect with conventional single-lens systems:

• Thin, irregularly shaped linear objects such as cable harnesses or ultra-fine wires,
• reflective objects such as metal surfaces,
• translucent objects such as plastic components,
• Objects with repetitive patterns without clear surface features and
• Partially reflective metals and other low-texture surfaces.

The new system builds on Kyocera's AI-based dual-lens distance sensor introduced in 2024, which already enabled high-precision distance measurements with 100-µm resolution in a 4 in range. This predecessor could measure tiny objects of around one millimeter in size, even with reflective or semi-transparent properties. This was difficult with conventional stereo cameras.

However, dual-lens technology reached its limits with objects with unspecific surface features or in environments with partially obscured objects, which prevented complete detection. The triple sensor was developed to overcome these specific challenges.

Examples of Industrial Fields of Application

Manufacturing inspection: In inspection processes with objects that have frequently repeating patterns, such as electronic circuit boards or textiles, dual-lens stereo cameras are prone to misadaptation. The triple configuration uses multiple parallax combinations and significantly increases measurement accuracy and reliability. This enables precise analysis of depth and surface shape without misinterpretation.

Surgical robotics: Thin, highly reflective surgical instruments such as needles and sutures are often difficult to see against their background and can be partially obscured. The triple lens configuration with three cameras at different angles enables precise position detection by combining information from multiple viewing angles and increases the accuracy and reliability of identifying these instruments.

Agricultural robotics: When harvesting in complex environments where fruit and leaves obscure each other, the triple camera enables more accurate detection and more precise position measurement with minimal blind spots. (heh)

Future-Proof Authentication with Universal RFID Readers

Universal RFID Readers: One Solution for All Credentials