This is an example of how TOYOTEC’s RDL Lens solved 3D recognition and picking issues in factory automation.

Problems in Robotic Picking Systems

■Needs to measure shape / size along object detection

■Lack of processing speed / accuracy

■Making original-design lens / lens unit is too costly

Robot picking in factory automation is the main and highly competitive area of robot application, and severe specification and processing speed are required for lens units.

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Based on past cases solved by TOYOTEC, we will explain the key points in camera lenses for human recognition and human monitoring systems.

Issues in human recognition / monitoring systems

■Environment changes drastically based on time, location, etc.

■The objectives are “humans” who continuously move

■Market LED lighting have inconsistent illuminance distribution

For human recognition / monitoring systems, the ability to operate stably without being affected by changes in the surroundings is a must . The acquired information must be free of noise and  have all required information. The information needed will decide the lens specification. When designing these devices, optical design and lens design knowledge are required.

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A lens with a focal length close to the human viewing angle is called a “standard lens,” while a lens with a focal length closer than that of a standard lens is called a “wide-angle lens”. Wide-angle lenses are used in all kinds of optical systems, including cameras, because they can capture a wider range of images than standard lenses.

On the other hand, one of the requirements for wide-angle lenses is “low distortion”. Distortion and volume deformation are typical distortions in wide-angle lenses. This is a result of wide-angle lenses being convex lenses. When you use a wide-angle lens to obtain information over a wide area, distortion is an issue that is bound to occur, no matter how small or large the level.

Here are some tips on how to eliminate this distortion.

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RDL Lens: The RDL (Real Distortion-Less) lens unit

RDL lens is a revolutionary new lens unit that has succeeded in minimizing distortion through TOYOTEC’s unique optical design technology.

3 features of RDL Lens

• 1. High Resolution – By removing distortion using optical design instead of image processing software, drop in pixel rate is prevented.
• 2. Drastic Distortion Reduction – Distortion reduced down to below 2% by TOYOTEC’s original optical design.
• 3. Horizontal Field of view 120°

TOYOTEC also offers custom prototyping of the RDL Lens. We can design and manufacture plastic and glass lenses as well as entire lens units, so we are able to propose performance improvements for the unit from the design stage. Please feel free to contact TOYOTEC if you have any questions about lens and lens systems design.

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「120°Wide Angle, Ultra-Low Distortion, and High Quality」 

This document introduces the features of RDL Lens, including actual examples, because of its ultra-low distortion at the wide-angle end, which is characteristic of wide-angle lenses.

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