In the field of the Industrial Internet of Things (IIoT), the transmission and real-time monitoring of image data have become core requirements for enhancing production efficiency and ensuring equipment safety. Whether it's defect detection on intelligent manufacturing production lines or remote operation and maintenance of smart energy systems, the efficient acquisition and stable transmission of image data rely on the collaborative work of 4g modems and industrial cameras. This article will analyze how this "golden duo" creates value for enterprises through practical cases and technical principles, and explore how to select suitable solutions.
The essence of an 4g modem is a "translator" for data transmission. It converts serial data from industrial sites (such as sensor signals and PLC instructions) into network protocol data and transmits it to the cloud or monitoring center via channels like 4G/5G or Ethernet. In image data transmission scenarios, the role of the 4g modems is particularly crucial:
4g modems support mainstream protocols such as Modbus and MQTT, enabling seamless integration with industrial cameras from different brands. For example, in photovoltaic power plant inspections, the 4g modems can compress and encode 4K high-definition images captured by industrial cameras and upload them in real-time to a cloud-based AI platform via a 5G network, achieving millisecond-level defect recognition.
In industrial scenarios, 4g modems need to possess characteristics such as electromagnetic interference resistance and a wide operating temperature range (-40°C to 85°C). For instance, in blade inspections at wind farms, the 4g modems must stably transmit 4K high-definition image data under strong winds and low temperatures to ensure that the remote monitoring center can obtain equipment status in real-time.
By 2025, the application of 4g modems will further expand the boundaries of image transmission. For example, in smart factories, the combination of 4g modems and edge computing technology can achieve image transmission delays as low as 10ms, meeting the needs of high-real-time scenarios such as AGV vehicle navigation and robotic vision guidance.
Industrial cameras are the "eyes" of machine vision systems, and their performance directly determines the accuracy and reliability of image data. When selecting industrial cameras, the following parameters require special attention:
High resolution (e.g., above 2 megapixels) is suitable for precision inspection scenarios, while high frame rates (e.g., above 60 FPS) are suitable for capturing moving objects. For example, on surface mount technology (SMT) production lines, CMOS industrial cameras with high frame rates are needed to avoid detection errors caused by motion blur.
CCD cameras are still widely used in high-precision visual inspection scenarios due to their characteristics of no smearing and low noise, while CMOS cameras, with their advantages of low cost and low power consumption, are rapidly gaining popularity in areas such as intelligent warehousing and logistics sorting.
The resolution of the lens must match the camera's pixels. For example, if the lens resolution is 200 line pairs per millimeter (LP/mm), a sensor chip with 400 pixels per millimeter should be selected to fully utilize the lens's performance.
After industrial cameras acquire image data, it is transmitted to the cloud via the 4g modem's serial or network interface. For example, in drone inspections of photovoltaic power plants, images of solar panels captured by industrial cameras are transmitted in real-time to the cloud via a 4g modems. Combined with AI algorithms, this enables automatic defect recognition, increasing the efficiency of manual inspections by over 80%.
Through the 4g modem's bidirectional communication capabilities, managers can remotely adjust the parameters of industrial cameras (such as exposure time and gain value) and even remotely control their start and stop. For example, in smart water conservancy projects, the angle and focus of river monitoring cameras can be remotely adjusted via the 4g modems to achieve real-time flood warning responses.
4g modems support technologies such as AES-256 encryption and VPN tunnels to ensure the security of image data during transmission. At the same time, through protocol adaptation with MQTT, HTTP, etc., they can seamlessly integrate with existing MES and SCADA systems in enterprises.
Electromagnetic interference and network fluctuations are common challenges in industrial scenarios. It is recommended to choose 4g modems that support 5G multimode communication and have anti-interference designs, such as products that support 5G SA/NSA dual-mode and multi-link redundant transmission.
The PLCs, sensors, and other equipment in industrial sites have diverse interfaces. It is necessary to choose 4g modems that support multiple serial ports such as RS232/RS485/TTL and ensure compatibility with the trigger signals and data formats of industrial cameras.
Priority should be given to selecting 4g modems that support functions such as edge computing, local storage, and breakpoint continuation to meet data security needs in unstable network environments.
Given the complexity of industrial environments, it is essential to choose suppliers that provide 7×24-hour technical support and rapid response to ensure timely recovery in case of equipment failures.
On electronic component SMT production lines, industrial cameras capture PCB board images at a speed of 0.1 seconds per frame. The 4g modems transmits these images to a cloud-based AI platform via a 5G network, enabling real-time detection of soldering defects in SMT components with an accuracy rate of 99.9% and a false detection rate below 0.1%.
Industrial cameras are core components of machine vision systems, and their performance directly affects image quality and detection accuracy. When selecting industrial cameras, the following key parameters should be considered:
Resolution determines image details, while frame rate affects dynamic capture capabilities. For example, in the detection of high-speed moving objects, high frame rate cameras are needed to avoid motion blur.
CCD and CMOS sensors each have their advantages. CCD sensors perform more stably in imaging high-speed moving objects, while CMOS sensors, with their low power consumption and high integration, have become the preferred choice for smart cameras. Enterprises need to weigh their options based on specific scenarios.
The resolution of the lens must match the camera's pixels to avoid resource waste. For example, when the lens resolution is 200 LP/mm, a sensor chip with 400 pixels per millimeter should be selected to ensure system accuracy.
A automotive parts manufacturer adopted a solution combining a 5G 4g modem and a 4K industrial camera to achieve real-time defect detection on production lines. Through the 5G network, images captured by the industrial camera are uploaded to the cloud for image recognition and analysis, increasing the accuracy of defect detection to 99.5% and effectively recording defects in items to be inspected, providing a data analysis basis for tracing the causes of defects.
On fully automated assembly lines, industrial cameras upload captured images to the cloud in real-time via a 4g modems, combined with machine vision algorithms to achieve spatial guidance and defect detection. For example, in automotive parts production, through the combination of 5G + industrial cameras + 4G MODEMs, real-time monitoring and adjustment of processes such as automatic welding and automatic painting are achieved, reducing the product defect rate by over 30%.
Given the numerous signal interferences in industrial environments, it is necessary to choose 4g modems with anti-interference capabilities to ensure stable data transmission.
4g modems need to support multiple serial protocols (such as RS232, RS485) to adapt to industrial cameras from different brands and models.
Priority should be given to selecting 4g modems that support functions such as MQTT protocol and edge computing to reserve space for future intelligent upgrades.
Resolution: Choose based on detection accuracy requirements. For example, detecting 0.1mm-level defects requires a camera with over 2 megapixels.
Frame Rate: For detecting high-speed moving objects, a frame rate above 30 FPS is needed.
Sensor Type: CMOS cameras are suitable for low-cost, low-power scenarios, while CCD cameras are suitable for high-precision, high-stability needs.
With the popularization of 5G networks, the combination of 4g modems and industrial cameras will bring more possibilities:
5G networks will reduce transmission delays from 100ms in 4G to within 10ms, supporting high-real-time needs such as AGV navigation and robotic remote control.
By analyzing image data collected by industrial cameras through cloud-based AI, functions such as automatic defect classification and process parameter optimization can be achieved.
The collaborative application of 4g modems and industrial cameras is not just a technical combination but a key support for enterprise digital transformation. By reasonably selecting equipment and optimizing system architecture, enterprises can achieve multiple values such as increased production efficiency and reduced operation and maintenance costs. In the wave of Industry 4.0, mastering this technological combination will provide a solid guarantee for enterprises' competitiveness in the field of intelligent manufacturing.
and Industrial Cameras?
