*Source of the original article: "The Need for Speed – May 2025", by FLIR.
Research and development involving fast-moving or dynamic targets presents a significant challenge for scientists. To capture detailed stop-motion infrared data, thermal cameras must not only achieve high frame rates but also offer extremely fast integration times, down to microseconds. The latest generations of research and development cameras make it possible to perform dynamic analysis of jet engine turbine blades, supersonic projectiles, explosions, and more, without losing areas of the frame to windowing.
Why Traditional Methods Fall Short
In industries such as automotive, precise temperature measurement is vital for the development of internal combustion engines, brake rotors and tires, and high-speed airbags. Contact methods like thermocouples are impractical for mounting on moving objects, while non-contact spot guns or even consumer-level thermal cameras are simply not fast enough to "stop" motion on these high-speed targets. For instance, a handheld thermal camera would not offer the frame rates or integration speed needed to collect relevant data on temperature changes in systems such as heated car seats.
The Risks of Inadequate Tooling
Without appropriate thermal measurement and testing tools, automotive design engineers can experience lost time, reduced efficiency, and risk missing critical defects that may lead to hazardous products and costly recalls. A notable example is the recall of millions of vehicles in the US due to faulty airbags, with problems ranging from micro-cracks in passenger activation systems to defective inflators. Such failures not only endanger drivers but also negatively impact manufacturers' profitability, leading to lawsuits, fines, and a decline in public trust.
The Solution: Next-Generation Infrared Cameras
Advanced infrared camera technologies may offer engineers a solution. These cameras are equipped with high-resolution detectors (from 640×512 up to 1280×1024 pixels) capable of capturing full-frame images at speeds up to 1004 Hz. Models like the FLIR X6980-HS and X8580-HS incorporate Indium Antimonide (InSb) detectors for mid-wave infrared applications or Strained Layer Superlattice (SLS) detectors for longwave imaging. When programmed to synchronize and trigger remotely, these technologies provide engineers and technicians with the tools they need to address the difficulties of high-speed automotive testing.
Key Technical Capabilities
Integration time is as crucial as frame rate; it's analogous to shutter speed in a digital camera. Longer integration times will result in blurred images of fast-moving objects. High-speed IR cameras also feature high pixel processing speeds, typically at least 200 MP/sec, whereas most low-performance cameras run at pixel clock rates below 50 MP/sec. The temperature of your target can impact integration speed and ultimately the digital count, which the camera converts into radiance values for temperature readings. Hotter targets emit more radiant energy, but accurately measuring colder targets at fast frame rates (which require shorter integration times) presents a challenge. This is compounded by older detectors' non-linearity at low well fills. However, next-generation Read Out Integrating Circuit (ROIC) designs offer linearity to low well fill, allowing for accurate measurements at high speeds (short integration times) on colder targets, making this a critical feature for high-speed infrared cameras.
Advanced Data Management
The ability to manage high-resolution data streaming is critical. Sophisticated cameras, such as the FLIR X-Series HS, can stream full-frame thermal imagery and data without dropping frames via high-speed interfaces like 10 GigE, CXP 2.1, or CameraLink Full. They also include a built-in 4 TB removable solid-state drive (SSD) for extended high-speed recording, capable of saving over 1.5 hours of data with zero dropped frames. Advanced triggering and synchronization capabilities, coupled with IRIG time stamping on each image frame, ensure optimal accuracy and increased testing efficiency.
FLIR X6980-HS and X8580-HS: The Advantages
These FLIR cameras provide the speed and sensitivity required for the most demanding thermal analysis scenarios. Their advantages include simplified setup when recording directly to a PC via high-speed interfaces (10 GigE, CXP 2.1, CameraLink Full), direct recording to the internal SSD for extended periods at the fastest frame rate without dropping frames, custom-designed lenses with precise and remote focus adjustments, and full integration with Research Studio software for enhanced camera and image control.
