One of the most well-known providers of machine vision components, VA Imaging, reports that advancements in camera technology have significantly impacted warehouse and logistics automation. In addition to improving safety monitoring, cameras now play a vital role in optimising operations, tracking inventory, and increasing efficiency. By leveraging machine vision systems, warehouse operators can automate tasks such as inventory recording, counting, and tracking, enabling real-time visibility and minimising the risks of stock-outs or shortages.
Applications of computer vision in warehousing and logistics
1. Inventory management
Industrial cameras automate inventory processes like barcode scanning, item recognition, and tracking. Real-time visibility into stock levels enhances accuracy and reduces human error. Modern distribution centers increasingly rely on computer vision, robots, and automation tools to maintain efficiency in global supply chains. Industrial cameras, specialised lenses, machine vision lighting, and software form the core of these automation solutions, replacing manual labor in tasks that previously involved warehouse employees. These technologies improve process speed and reduce errors significantly.
2. Quality control
Cameras also serve as essential tools for quality control, detecting product defects, damaged goods, and ensuring compliance with quality standards. Machine vision systems outperform manual inspections by identifying anomalies with greater precision and efficiency.
3. Process optimisation
Computer vision software and image processing algorithms optimise workflows by analyzing footage of warehouse operations. These systems identify bottlenecks, streamline picking and packing processes, and improve overall efficiency.
4. Remote monitoring and management
Warehouse managers benefit from remote monitoring capabilities enabled by computer vision. Live camera feeds and analytics dashboards provide real-time data, allowing operators to monitor operations, detect issues, and make informed decisions from any location.
Industrial camera solutions for warehouse logistics
A customer application described by VA Imaging involves a scanning tunnel where parcels of varying sizes are transported on a conveyor belt. The task is to read barcodes on the parcels to assign them to storage locations and update the warehouse software. The barcodes can appear on any of five sides of a package—top, front, back, left, or right—but not the bottom. To ensure reliable barcode reading, the conveyor pauses briefly for image capture.
For this application, selecting the appropriate industrial camera was critical. A resolution of at least 17.5MP (5000×3500 pixels) was required to capture the thinnest barcode line (0.2mm) with two pixels per line. The ‘MER2-2000-19U3M’ camera, featuring a 20MP Sony IMX183 sensor, was chosen for its capability to meet these demands. Since barcodes are monochromatic, a black-and-white camera sufficed. To cover all possible barcode orientations, the customer deployed five cameras, one for each viewable side of the parcels.
Although simplifying the process by requiring parcels to be placed in a defined position was considered, the potential for conveyor line interruptions made a multi-camera setup more practical. This approach ensured continuous operation without disruptions due to misaligned parcels.
Lens selection for the IMX183 sensor
Using VA Imaging’s lens calculator, the appropriate lens for the MER2-2000 camera was determined. The camera’s 1″ sensor with 5496×3672 pixels and 2.4µm pixel size required a 16mm focal length lens (‘LCM-20MP-16MM-F2.8-1.1-ND1’) to achieve a 547x366mm field of view (FOV) at a working distance of 680mm. This setup ensured accurate barcode capture within the scanning tunnel.
Machine vision lighting and protective housing
Uniform, homogeneous lighting is essential for effective barcode scanning. VA Imaging recommends bar lights customised to specific dimensions and colors for optimal illumination. To safeguard the camera setup against external factors, IP67-rated metal protective housings were employed. These housings’ modular design allows for lens flexibility and adaptability to future application changes, such as altered FOV or working distances.
Supporting warehouse logistics with computer vision
Computer vision technology provides powerful solutions for automating warehouse processes and optimising logistics. By integrating cameras with machine vision software, facilities can achieve real-time inventory management, enhance quality control, streamline operations, and enable remote monitoring. The scanning tunnel example highlights the importance of selecting the right cameras, lenses, and lighting for successful implementation.
With proper planning and the right components, VA Imaging emphasises that computer vision can transform efficiency and accuracy in warehouse logistics. Organisations interested in implementing similar systems can contact VA Imaging for expert support in selecting components customised to their automation needs.
