Industrial 3D Cameras: Rugged 3D Vision Camera for Automation – FRAMOS D435e with GigE & IP66 

3D cameras for industrial applications have to operate in harsh production environments and reliably detect moving objects at speed, e.g. when the camera is mounted on a robot arm. Stable and latency-free data transmission over extended distances is essential – using GigE Vision, for example – as is straightforward integration. FRAMOS – a global partner for vision technologies – has developed an industrial version of the Intel® RealSense™ camera that offers gigabit Ethernet connectivity and an IP66-rated dustproof and water-resistant enclosure. The camera features advanced sensor technology, ensuring reliable performance and high-resolution imaging in demanding industrial environments. So now there is an easy way to integrate 3D vision into harsh environments. The plug-and-play solution enables real-time positioning, orientation and tracking for robots, navigation for automated guided vehicles (AGVs), and many other “smart” machines, e.g. in medical engineering.

In recent years, industrial image processing (machine vision) has secured a permanent place in automation, especially in established fields such as production and quality control. Now the next step is 3D vision, a technology that has the potential to change entire industries. The future will belong to intelligent, “seeing” devices. Robotics, automated guided vehicles (AGVs) and medical devices can benefit from the new machine vision solutions, especially with the arrival of industrial camera systems that can reliably detect even fast-moving objects in harsh environments. Their real-time depth data provides the basis for fully automated processes in production lines, logistics, and industrial applications where intelligent devices make autonomous decisions. Additionally, the camera offers wide field of view options, allowing users to capture more area in industrial applications for enhanced situational awareness.

Depth cameras began their rise to prominence in the consumer sector, and are now making inroads into industrial environments. This “career path” has certainly brought advantages: large volumes mean prices are affordable, for example, while short product life cycles and development cycles have allowed the technology to make rapid progress. Technical support is available to assist with integrating the camera into various projects, ensuring smooth deployment and operation. “Off-the-shelf” technology makes handling easier, too. The camera’s versatility also allows for integration into other devices such as tablets and portable scanners, expanding its use cases for 3D modeling and scanning. Significantly, this also speeds up the whole vision development process. The camera’s technological advancements make it suitable for mixed reality applications in industrial and robotics settings, enabling immersive and augmented experiences. RealSense™ cameras from Intel® are a technologically advanced yet relatively inexpensive example of this technology. This technology can enhance a wide range of projects by providing robust 3D vision capabilities for diverse applications.

Introduction to 3D Vision

3D vision is revolutionizing the way machines perceive and interact with their environment. By enabling vision systems to capture and process depth information, 3D vision technology brings a new level of intelligence to industrial automation, factory automation, and robotics. These advanced systems can perform complex tasks with greater efficiency and accuracy, from object detection and tracking to navigation and quality inspection. By adding depth to traditional image processing, 3D vision systems empower machines to understand the shape, position, and movement of objects within their environment, making them indispensable in a wide range of industries. As automation continues to evolve, the integration of 3D vision at the edge is unlocking new possibilities for smarter, more adaptive manufacturing and industrial operations.

3D Vision Technology

At the core of modern vision systems is 3D vision technology, which combines multiple cameras, sensors, and sophisticated software to capture and analyze three-dimensional data. This technology enables the creation of detailed digital models of objects and environments, allowing machines to interpret and respond to their surroundings with high accuracy. Intel RealSense technology is a leading solution in this field, offering robust stereo vision and advanced depth sensing capabilities for a variety of industrial applications. By utilizing techniques such as stereo vision, structured light, and time-of-flight, 3D vision systems can precisely measure the shape, size, and spatial position of objects. This makes them ideal for demanding tasks like inspection, assembly, and quality control, where accuracy and reliability are paramount. The flexibility and scalability of these systems allow them to be deployed across a broad range of environments and industries, supporting the next generation of intelligent automation.

Depth Cameras and 3D Modeling

Depth cameras are essential components in 3D vision systems, providing accurate measurements of the distance between the camera and objects in its field of view. By integrating data from multiple depth cameras, it is possible to construct detailed 3D models of both objects and entire environments. This capability is particularly valuable in industrial automation, logistics, and robotics, where understanding the precise location and dimensions of objects is critical for efficient operations. Intel RealSense depth cameras are widely recognized for their high accuracy and reliability, making them a popular choice for a variety of industrial and automation tasks. These cameras enable advanced applications such as object recognition, real-time tracking, and autonomous navigation, helping to streamline processes and improve productivity across a wide range of environments.

Fit for industrial use 

Industrial automation has different requirements than the consumer segment. 3D cameras for industrial use have to operate in harsh production environments and reliably detect moving objects at speed, e.g. when the camera is mounted on a robot arm. Stable and latency-free data transmission over extended distances is essential – using GigE Vision, for example – as is straightforward integration. With its D435e 3D camera (see fig. 1), FRAMOS – a global partner for vision technologies – has set standards in this field that will accelerate the development of innovative vision applications in a wide range of industries.

The industrial version of the Intel® RealSense™ camera offers gigabit Ethernet connectivity and a sturdy IP66-rated dustproof and water-resistant aluminium housing. It operates reliably at ambient temperatures between 0 and 55 °C, and is ideally equipped in other ways too for use in harsh production conditions. The robust enclosure and weather-resistant features make it suitable for outdoor applications in industrial and agricultural environments. The screw-fastening gigabit Ethernet (M12) and power supply (M8, for 12 or 24V) connections can withstand movement and vibration, unlike USB cables. If it is necessary to work without separate power cables, a version with Power over Ethernet (PoE) is available. Four M3 mounting holes on the body make for easier installation, e.g. fastening in robotics applications. Long transmission distances are no problem, either. Image data is preprocessed in the camera and can be sent over cables up to 100m in length.

In addition to its use in harsh production conditions, the camera is capable of inspecting and handling different materials, including flexible packaging, with AI-supported 3D gripping and 3D vision systems to ensure quality and optimize manufacturing processes.

Performance in a compact package 

The powerful technology is well protected inside the highly compact camera, which measures 100 x 47 x 38mm and weighs just 250g. Its main task is to see in stereo – just like humans do. Viewing objects and things with two eyes produces true, quantified depth perception (see fig. 2). To achieve this, the camera is equipped with the Intel® D430 Depth Module (0.9MP resolution), the Intel® D4 Vision Processor for depth calculation, and an additional RGB camera module (2MP resolution). These advanced features enable accurate detection, measurement, and AI integration for improved inspection and automation tasks.

The depth module and processor allow the camera to perform detailed analysis of depth data and point clouds, supporting object shape recognition, tracking, and movement analysis for comprehensive object assessment.

The RGB camera module supports high-quality imaging, and adjusting image contrast is essential for optimal defect detection, OCR, and assembly verification.

The camera can be used with the Intel® RealSense™ SDK 2.0 and any other GigE Vision software. Its ease of operation, uncomplicated integration as a plug-and-play 3D vision solution, and affordable price make the robust camera suitable for numerous applications, as more and more industries today demand innovative 3D vision solutions. The camera is also capable of inspecting the surface of materials for dents, scratches, and inconsistencies, enhancing quality control processes.

Thanks to its compact size, the camera is ideal for use in space-constrained industrial environments, optimizing available space in logistics, warehousing, and manufacturing settings.

Depth Sensing and Object Recognition

Depth sensing is a foundational element of advanced 3D vision systems, allowing machines to accurately gauge the distance to objects and surfaces within their environment. When combined with powerful object recognition algorithms, depth sensing enables real-time identification and tracking of objects, supporting complex tasks in manufacturing, logistics, and beyond. Intel RealSense technology delivers state-of-the-art depth sensing capabilities, empowering developers to build vision systems that can adapt to diverse environments and challenging conditions. Whether deployed in indoor manufacturing facilities or expansive outdoor logistics hubs, these systems provide the precision and flexibility needed for tasks such as assembly, quality control, and inventory management. By harnessing the full potential of depth sensing and object recognition, industries can achieve new levels of automation, efficiency, and insight.

Potential applications in all kinds of industries 

There are interesting possibilities for the industrial depth camera in robotics. A “seeing” robot can recognise different parts in pick-and-place applications, for example, and set them down accordingly – on a processing station, conveyor, or driverless transport system (see fig. 3). 3D vision gives these driverless systems fully autonomous mobility, enabling them to move around in complete safety and avoid people or other systems without additional installations such as rails or markers. 3D vision is also increasingly used in mobile robots, enhancing their ability to navigate and interpret everyday environments. The camera plays a crucial role in collision avoidance, enabling obstacle detection and intelligent navigation to prevent accidents during autonomous movement. Another application is in medical engineering, where devices with camera systems can automatically ensure and maintain optimal alignment with the patient (see fig. 4). The camera’s ability enhances robotics and facial recognition systems, allowing machines to better understand, respond to, and interact with their environments. Advanced machine vision provides robots with improved sight, enabling more accurate environmental understanding. The integration of 3D vision is further supported by a robust vision system, which enables object detection, measurement, and automation in various applications. Motion analysis is also essential for object tracking and spatial awareness in robotics, supporting precise movement and tracking capabilities.

Collaborative robotics is another field that is benefiting from innovative 3D vision solutions. Technical teams benefit from these solutions in multi-disciplinary projects, such as robotics, AI, and immersive technology development. “Seeing” cobots are much better at interacting with people, which means they can do more and be deployed more flexibly. Gesture control is a promising area of research in this context, and even the retail sector can benefit from 3D vision. If retailers can see how their customers move about in-store, or when and where they stand still, that already tells them a lot. Intelligent retail analytics tools can then supply more insightful findings. The user’s imagination is practically the only limit on the innovative possibilities that 3D vision opens up, and there is an exciting journey ahead.