Barcode scanning is critical in warehouse operations, supporting embedded systems such as forklifts, autonomous mobile robots (AMRs), automated guided vehicles (AGVs), robotic arms, and conveyor systems. It ensures accurate tracking, inventory visibility, and seamless process automation.
Choosing the right camera for demanding warehouse environments, such as unpredictable lighting, continuous vibration, and varying motion speeds, can be far more complex.
It’s not about simply picking the highest-resolution camera model available.
In this blog, we cover:
- Key challenges in real-world warehouse environments
- Comparison of different resolution camera performance using real barcode images
- A structured approach to camera selection
- e-con Systems’ barcode scanning cameras for warehouses
How Cameras Ensure Effective Barcode Scanning
Cameras play an important role, enabling barcode scanning, navigation, collision avoidance, safety monitoring, and various levels of automation. However, different systems impose distinct requirements on camera performance.
For instance, vehicle-mounted systems require reliable on-the-move scanning, while fixed-mount systems, such as those used in conveyors, demand fast and consistent reads. Robotic vision systems, on the other hand, require high accuracy and flexibility to handle diverse tasks.
Barcode scanning is used across a wide range of operations, including vehicle tracking and logistics, inventory and parts management, and quality inspection. The right camera solution must address these varied use cases while ensuring consistent and reliable decoding performance.
Now, let’s look at how to define the right industrial camera for warehouse applications.
Defining Camera Requirements for Barcode Scanning
Reliable camera designs begin with a clear set of requirements. Skipping or rushing at this stage leads to costly redesigns later. For barcode scanning on industrial vehicles, three parameters form the foundation.
Pixels per Module (PPM):
Every barcode (1D, 2D, QR, DataMatrix, etc.) consists of tiny elements called modules. To decode it accurately, the camera must capture a minimum number of pixels per module. For example, if a barcode has very fine modules, it either requires a higher-resolution camera or a camera placed at a closer working distance. Setting the right PPM ensures fast, consistent barcode decoding.
Working Distance and Field of View (FOV):
Working distance is the distance between the camera and the barcode or object. The FOV defines the area the camera needs to cover. For instance, if the forklift must scan barcodes from both near (2m) and far (3m), the lens and resolution requirements change significantly. These parameters also determine how many cameras are needed to cover all use cases.
Sensor Selection
A common mistake in industrial camera design is selecting an available sensor rather than one suited to the application. The sensor should be evaluated across the following criteria:
- Resolution: Once the PPM requirement is calculated across the full working distance range, the sensor must be selected to match it precisely. A low-resolution sensor might work for large barcodes at close range, but high-density 2D codes from farther away require a high-resolution sensor. The resolution must strike a balance between accuracy, cost, and processing power.
- Low-light sensitivity: Sensors with high quantum efficiency and low read noise enable reliable imaging in the dim areas common in warehouse environments, reducing dependence on artificial illumination.
- Shutter speed: Choose an appropriate shutter speed based on the barcode’s speed and available lighting. Faster shutter speeds reduce motion blur, while slower shutter speeds improve image brightness in low-light conditions, ensuring accurate barcode detection and decoding. If the exposure time is not optimized, motion blur can occur regardless of whether the camera uses a rolling-shutter or a global-shutter sensor.
- Frame rate: Higher frame rates reduce the time between acquisition attempts, improving throughput in fast-moving scanning operations.
- Dynamic range: A wide dynamic range enables reliable barcode capture under high-contrast lighting conditions commonly found in warehouses.
Performance Comparison: 13MP Camera vs. 20MP Camera
At e-con Systems, we performed tests with cameras of different resolutions placed at a 30cm working distance to evaluate barcode reading performance.
- See3CAM_CU135M (13MP), featuring AR1335 sensor
- See3CAM_CU200M (20MP), featuring AR2020 sensor
The working distance, barcode target, illumination and exposure and gain settings are kept the same for both cameras.
The left-side image shows the output of the See3CAM_CU135M (13 MP) camera, and the right-side image shows the output of the See3CAM_CU200M (20 MP) camera.
Both cameras perform well across a wide range of barcode-scanning applications. For use cases involving very small module barcodes, a camera placed at a closer working distance or a high-resolution camera is required to offer improved decoding accuracy, as illustrated in the image above.
A Structured Approach to Camera Design for Barcode Scanning Applications
We use a step-by-step approach to map these requirements into a practical industrial camera.
- Camera module selection: Based on the PPM calculations and resolution needs, we identify the most suitable sensor. We also consider sensor sensitivity, as warehouse vehicles often operate in low-light conditions.
- System configuration: In applications where a single camera cannot provide sufficient field coverage while maintaining the required PPM, multiple synchronized cameras must be deployed to cover the entire FOV.
- Lens selection: The lens plays a crucial role in clarity and coverage. The camera lens with the right focal length and field of view ensures sharp focus across the entire field.
This systematic workflow ensures that the solution is not just designed on paper but is validated for practical, rugged forklift environments.
Designing Barcode Scanning Cameras for Real-World Warehouse Conditions
Inconsistent lighting
The warehouse aisles can be dimly lit, while loading docks may be exposed to bright light. Without proper lighting, barcode scanning becomes inconsistent. Integrated LED illumination can solve this. Also, exposure and gain settings must be tuned to adapt to dynamic scenes.
Motion blur
An embedded camera mounted on a moving vehicle introduces blurring, as the barcode may shift position during long exposure times. Even at moderate vehicle speeds, a barcode image that moves by just 1–2 pixels during exposure can affect decoding performance.
Eliminating motion blur requires a combination of short exposure times, sufficient illumination to compensate for the reduced exposure, and a global shutter camera.
Stationary vs. dynamic scanning requirements
Conveyor systems require stationary scanning, while others require on-the-move scanning. Movable applications require scanning with faster shutter speeds and higher frame rates.
Camera systems designed only for stationary scanning will fail in dynamic use cases, and vice versa can be over-engineered for simpler deployments.
Vibration and mechanical ruggedness
Industrial vehicles operated on uneven surfaces can induce vibration, affecting camera performance. Hence, the camera module, lens mount, and housing must be rugged and vibration-tested.
Conclusion
Selecting the right camera for warehouse barcode scanning requires a deep understanding of real-world conditions, application requirements, and system-level trade-offs. For instance, many environmental and application-specific factors must be considered when selecting a camera for warehouse barcode scanning.
High-quality barcode images and reliable decoding performance are determined by the camera’s resolution, configuration, and the specific operational requirements of the application.
e-con Systems’ Reliable Barcode Scanning Cameras For Warehouse Automation
Since 2003, e-con Systems has been designing, developing, and manufacturing OEM and ODM cameras. We offer cutting-edge camera solutions that meet the demands of challenging industrial environments. We also go beyond off-the-shelf offerings to ensure high camera performance, seamless integration and long-term deployment stability. Our recommended cameras for warehouse barcode scanning applications include:
AR2020-based cameras
- See3CAM_CU200M
- See3CAM_CU200
- e-CAM200_CUOAGX
- e-CAM200_CUONX
- NileCAM200
AR1335-based cameras
Use our Camera Selector to view the full portfolio of our embedded cameras.
To find the perfect camera for your application, contact us at camerasolutions@e-consystems.com.
Suresh Madhu is the product marketing manager with 16+ years of experience in embedded product design, technical architecture, SOM product design, camera solutions, and product development. He has played an integral part in helping many customers build their products by integrating the right vision technology into them.