Lighting Controller
| Cat | Products Name | Price |
|---|---|---|
| AIMRSE-RV-OS-082 | DPA2024E(B) Digital Current Controller (24V, 2A/CH) | |
| AIMRSE-RV-OS-083 | DPA2012E(B) Digital Current Controller (12V, 2A/CH) | |
| AIMRSE-RV-OS-084 | DPA2005E(B) Digital Current Controller (5V, 2A/CH) | |
| AIMRSE-RV-OS-085 | DPA6024E(C) High-Power Digital Current Controller (24V, 6A/CH) | |
| AIMRSE-RV-OS-086 | DPA20024EB Ultra-High-Power Digital Current Controller (24V, 20A/CH) | |
| AIMRSE-RV-OS-087 | DPA6024ES Line Scan Digital Current Controller (24V, 6A/CH) | |
| AIMRSE-RV-OS-088 | AP1024F Analog Voltage Controller (24V) | |
| AIMRSE-RV-OS-089 | APA6024-2 High-Power Analog Current Controller (24V, 6A/CH) | |
| AIMRSE-RV-OS-090 | DPA2024EC-4 Mini Digital Current Controller (24V, 2A/CH) | |
| AIMRSE-RV-OS-091 | APM0524B-2 Mini Analog Current Controller (24V, 1.8A/CH) |
Introduction
An Industrial Lighting Controller is the precision power management unit that regulates the intensity, timing, and synchronization of machine vision lights. By providing stable constant current or constant voltage outputs, it ensures consistent illumination levels despite fluctuations in factory power. More importantly, it enables high-speed "strobe" or "overdrive" modes, allowing LEDs to pulse at multiple times their standard brightness for microsecond intervals. This precisely timed control is essential for freezing motion in high-speed production lines and extending the overall life cycle of the lighting hardware.
Working Principle
1. Power Regulation
The controller converts standard factory DC power into a highly stable output, using high-frequency switching to prevent any flickering or ripple in the LED light.
2. Trigger Logic
Low-latency opto-isolated inputs receive signals from cameras, PLCs, or sensors, initiating the illumination sequence with microsecond precision.
3. Strobe Timing
The controller manages the pulse width (duration) of the light, often overdriving the LEDs to provide massive brightness for short exposures to eliminate motion blur.
4. Intensity Control
Digital dimming (up to 1024 steps) allows users to fine-tune the brightness of each individual channel via software or hardware dials to match the application needs.
Key Technical Specifications
-
Constant Current Drive
Ensures consistent luminance and prevents LED thermal runaway. This is the industrial standard for maintaining repeatable image contrast over long production runs. -
Overdrive Strobe Mode
Boosts brightness up to 300%-1000% of nominal levels for short durations (e.g., 10μs to 100ms), enabling high-speed capture with very short exposure times. -
Independent Multi-Channel Control
Available in 2, 4, or 8-channel configurations, allowing different lighting types (e.g., ring and backlight) to be controlled and sequenced independently. -
Sub-Microsecond Pulse Resolution
High-precision internal timers provide strobe pulse resolution down to 1μs, ensuring perfect synchronization with ultra-high-speed industrial cameras. -
Dynamic Trigger Delay
Configurable internal delays between the input signal and the light pulse, useful for compensating for sensor latency or robotic travel time. -
Safety & Protection Logic
Equipped with internal circuit protection for short-circuits, over-voltage, and thermal monitoring to protect expensive LED lighting arrays.
Fig 1. Digital Precision Controller for High-Bandwidth Machine Vision Illumination
Communication Interfaces
Ethernet (TCP/UDP) & EtherCAT
Enables remote configuration and real-time control over the factory network. Supports integration into automated Industry 4.0 environments for dynamic lighting adjustments.
RS232 / RS485 Serial
The classic industrial standard for point-to-point communication with PLCs or industrial PCs, offering reliable parameter control in high-interference settings.
Opto-Isolated Digital I/O
Hardware-level trigger ports designed to interface directly with camera "strobe" pins or sensor outputs, ensuring noise-free signal transmission.
Typical Applications
High-Speed Motion Freezing
Using overdrive strobe pulses to capture crystal-clear images of fast-moving products on conveyors without any motion blur.
Multi-Spectral Sequencing
Rapidly switching between different light colors (e.g., Red, Blue, IR) within milliseconds to capture different features in the same workstation.
Precision Metrology
Providing perfectly stable light intensity for sub-micron dimensional measurements where even slight brightness drift could affect accuracy.
Selection Guide
Selecting a controller requires matching the electrical needs of your lights with the speed of your production line. At AIMRSE, we help you optimize your illumination power:
- Drive Mode: Constant Current is preferred for LEDs to maintain color temperature and brightness stability; Constant Voltage is used for simpler indicator-type lighting.
- Peak Power Requirements: Ensuring the controller can supply sufficient instantaneous current for high-power strobe or overdrive applications.
- Control Method: Choosing between manual dials for simple setups or digital communication (Ethernet/Serial) for recipe-based automated production lines.
- Dimming Resolution: High-resolution (10-bit or higher) dimming is required for tasks involving very dark or very reflective surfaces.
Hardware & Quality Standards
Our controllers are built to industrial standards to ensure long-term stability in 24/7 operations:
- Power Stability: High-frequency PWM dimming (up to 100kHz) to prevent rolling shutter interference.
- EMC Immunity: Full compliance with CE, FCC, and RoHS standards for high electromagnetic noise environments.
- Mounting: DIN-rail or screw-mount ready for easy integration into industrial electrical cabinets.
Software & Integration Support
We provide a comprehensive software ecosystem for modern vision system configuration:
- Web-based GUI for easy configuration without installing specialized software.
- Ready-to-use SDKs for C++, C#, and Python to integrate control into your vision app.
- Pre-written function blocks for Siemens, Beckhoff, and Mitsubishi PLCs.
- Access to detailed timing diagrams for multi-camera/multi-light synchronization.
Related Products
Technical data represent typical values. As applications vary, we recommend consulting our technical team to ensure the best fit for your specific requirements.
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