High-Resolution Line Scan Cameras for High-Speed Imaging

A line scan camera must deliver high-speed imaging without sacrificing resolution. KEYENCE systems are engineered for that. Their sensors operate at line rates up to 142,800 lines per second. When paired with resolutions of up to 8192 pixels per line, these systems generate detailed, stitched images quickly enough to keep pace with demanding production schedules.

Standard lighting won’t cut it at this speed. To address this, KEYENCE integrates structured lighting through its LumiTrax™ technology. Each inspection produces multiple image types: specular, diffuse, gloss ratio, and shape maps. It helps expose surface conditions like fine scratches, dents, and contamination that would otherwise go unnoticed. Motion control is another key factor. If the line accelerates, the capture rate adjusts to track changes closely.

Unlike systems that rely on external PCs, KEYENCE packs processing power into the controller itself. Vision tools run directly on the platform. This speeds up inspection cycles and cuts down on integration complexity. In tight spaces, every millimeter matters. That’s why sensor designs have shifted to smaller pixel sizes, down to 3.5 µm, enabling 4K and beyond in a compact footprint.

This type of inspection works best when a full view of the product isn’t possible in one shot or when the product is in continuous motion.

Battery production lines use line scan systems to monitor foil edges and spot wrinkles in real time. In labeling operations, the system "unwraps" the surface of curved bottles and checks graphics, barcodes, and alignment. For wide-format materials, such as solar panels or door skins, the camera captures a full-width image with uniform resolution without slowing the line.

Products with reflective or textured surfaces benefit too. Where a standard area scan might show glare or shadow, line scanner systems keep the lighting consistent from edge to edge. That means fewer missed defects and more reliable outputs across inspection shifts.

The KEYENCE XG-X Series supports high-speed line scan vision inspection and advanced logic control. The platform handles capture speeds over 165,000 lines per second and runs inspections using embedded processors. There’s no need to transfer data to a separate PC or server.

One system, multiple jobs. Defect detection, dimensional checks, label verification, and OCR all run in parallel. The system adapts based on inspection criteria. Engineers can set up logic to trigger based on encoder feedback, ensuring each line is captured at the right moment.

LumiTrax™ integration means the system doesn’t rely on a single lighting profile. Instead, it captures five distinct image sets for every pass. This increases contrast on subtle defects without requiring manual reconfiguration of lighting. Whether inspecting metal sheets or transparent film, the system isolates surface irregularities with precision.

For teams working in complex environments, the XG-X platform reduces the number of components needed. Lighting, camera, controller, and encoder input are unified. That saves setup time and lowers the barrier to full production deployment.

Automotive suppliers use KEYENCE line scan vision inspection systems to inspect steel door panels before paint application. The goal is to catch dents and waviness early, before they affect finish quality. In packaging, lines use the technology to inspect labels on curved bottles as they spin to maintain alignment, clarity, and legibility.

Battery manufacturers use line scan camera setups to review electrode coatings, flagging foil contamination or uneven layers. Food processors inspect dough sheets before baking to catch dimensional shifts or tearing. In electronics, narrow solder tracks are checked for uniformity and bridging defects, all without stopping the line.

A line scan sensor captures more surface detail than a frame-based setup, resulting in fewer false rejects and improved process feedback.

Speed isn’t sacrificed for resolution, and whether inspecting 360° surfaces or sheets running 100 meters per minute, the system keeps pace.

Encoder synchronization makes sure that even as conveyor speeds change, image data remains clean. This matters for maintaining traceability, especially in industries such as EV, pharma, and semiconductor, where every unit must undergo a full-surface inspection.

The platform is compact and integrates into lines with limited space. There’s also no need for an external PC. The same hardware that captures the image also analyzes it and triggers downstream actions.

KEYENCE offers a whole ecosystem of vision systems tailored to demanding inspection environments.

• Browse our machine vision lineup
• See how the VS and XG-X systems support advanced applications

This technology is used wherever speed and surface fidelity intersect:

• Battery manufacturing: foil and tab inspection
• Flexible packaging: label and seam verification
• Food & beverage: high-speed label and seal inspection
• Metalworking: continuous defect detection on wide coils
• Logistics: in-line code verification on curved or rotated packages