Basics
Estimate camera resolution from FOV and smallest feature, then check optics, motion blur, lighting contrast and tolerance margin.
Direct answer
Resolution should be estimated from the smallest feature inside the required FOV, then checked against lens quality, motion blur, lighting contrast and tolerance margin. Pixel count alone does not guarantee inspection stability.
Resolution should be estimated from the smallest feature that must be detected inside the required field of view, then checked against lens quality, motion blur, lighting contrast and tolerance margin.
A higher-resolution sensor can still fail if the lens cannot resolve the feature, the exposure creates blur, the lighting hides contrast or the tolerance needs calibration margin.
Provide FOV width and height, smallest defect or tolerance, required pixels across the feature, working distance, line speed and sample images.
The same 5MP camera gives different inspection detail at 30 mm FOV and 300 mm FOV. Pixel size on the part is the number that matters.
If a 120 mm FOV must prove a 0.2 mm feature at 5 pixels across, the image needs about 3,000 pixels across before extra tolerance, lens and algorithm margin.
A higher-resolution sensor can still fail if the lens cannot resolve the feature, lighting does not create contrast or exposure creates motion blur.
How to test before buying
After the first pixel estimate, use the interactive tool on the Tools page and then test the lens, light and exposure on real parts. Confirm that the target feature remains visible at speed and within tolerance.
Decision checks
FOV divided by target pixel size equals required pixels.
Measurement usually needs more pixels than simple detection.
Check lens resolution, lighting contrast and exposure time.
Decision table
| Factor | Practical rule | RFQ impact |
|---|---|---|
| Basic formula | FOV divided by target pixel size equals required pixels. | Send FOV and smallest feature size. |
| Tolerance margin | Measurement usually needs more pixels than simple detection. | Send tolerance, not only defect name. |
| After calculation | Check lens resolution, lighting contrast and exposure time. | Avoid selecting by megapixels alone. |
Application proof
Small connector features require stable contrast, low distortion and repeatable part positioning before a pass/fail threshold can be trusted.
Wide moving material needs even illumination, encoder synchronization and enough line rate to avoid missing small defects.
Small parts need fast dimensional verification without slow manual measurement or inconsistent operator positioning.
Common mistakes
Factory handoff
The factory route review starts by checking whether the image can be made stable with lighting and fixture control. Then the camera, lens, reader or 3D sensor route is sized against speed, resolution, interface and installation constraints.
If you already have a Keyence, Cognex, Basler, OPT, LMI, Hikrobot or barcode-reader reference, include it as a reference model. Deyi Vision uses it to understand the application class; final selection still depends on real samples and production limits.
Guide to RFQ
Use the guide to frame the question, then send the details so engineering can recommend a route.
Request engineering RFQGuide FAQ
Divide the field of view by the required pixel size on the part, then check whether the sensor, lens and lighting can support that detail repeatably.
No. More megapixels can help detail, but they may increase bandwidth, processing load and exposure needs without fixing lighting or lens limits.
Provide FOV, smallest feature, tolerance, working distance, line speed, sensor preference, lens space and sample images.
