High Speed Infrared Cameras Enable Demanding Thermal Imaging Applications

Recent developments in cooled mercury cadmiumoutputting only portions of the camera's detector array.
telluride (MCT or HgCdTe) infrared detectorThis is ideal when there are smaller areas of interest in
technology have made possible the development ofthe field-of-view. By observing just "sub-windows"
high performance infrared cameras for use in a widehaving fewer pixels than the full frame, the frame
variety of demanding thermal imaging applications.rates can be increased. Some infrared cameras have
These infrared cameras are now available withminimum sub-window sizes. Commonly, a 320x256
spectral sensitivity in the shortwave, mid-wave andcamera has a minimum sub-window size of 64x2 and
long-wave spectral bands or alternatively in two bands.will output these sub-frames at almost 35Khz, a
In addition, a variety of camera resolutions are available640x512 camera has a minimum sub-window size of
as a result of mid-size and large-size detector arrays128x1 and will output these sub-frame at faster than
and various pixel sizes. Also, camera features now3Khz.
include high frame rate imaging, adjustable exposureBecause of the complexity of digital camera
time and event triggering enabling the capture ofsynchronization, a frame rate calculator is a convenient
temporal thermal events. Sophisticated processingtool for determining the maximum frame rate that can
algorithms are available that result in an expandedbe obtained for the various frame sizes.
dynamic range to avoid saturation and optimize3.3 Dynamic range expansion
sensitivity. These infrared cameras can be calibratedOne of the complications of having a very high
so that the output digital values correspond to objectsensitivity infrared detector is that the overall scene
temperatures. Non-uniformity correction algorithms aredynamic range will be limited. For example, if a raw
included that are independent of exposure time. Thesecount corresponds to 5 mK/digital count, a 14-bit signal
performance capabilities and camera features enablerange will deliver less than 80 degrees C in dynamic
a wide range of thermal imaging applications that wererange. This range is further reduced because of pixel
previously not possible.non-uniformity. As a consequence, the range of object
At the heart of the high speed infrared camera is atemperatures that can be viewed in one frame may
cooled MCT detector that delivers extraordinarybe too narrow for the application.
sensitivity and versatility for viewing high speed thermalTo increase the apparent dynamic range, a unique
events.solution can be implemented which allows the user to
1. Infrared Spectral Sensitivity Bandsartificially expand the dynamic range without sacrificing
Due to the availability of a variety of MCT detectors,the high sensitivity performance of the camera. (This
high speed infrared cameras have been designed tomode is sometimes called Dynamic Range ExtendIR,
operate in several distinct spectral bands. The spectralDR-X, superframing, multi-IT). When the dynamic range
band can be manipulated by varying the alloyexpansion mode is engaged, the camera sequentially
composition of the HgCdTe and the detector set-pointcaptures multiple frames, each frame having a
temperature. The result is a single band infrareddifferent exposure time. The short sequence includes
detector with extraordinary quantum efficiencyframes that are highly sensitive (because of long
(typically above 70%) and high signal-to-noise ratio ableexposure times) and also less sensitive frames for
to detect extremely small levels of infrared signal.imaging objects at higher temperatures (because of
Single-band MCT detectors typically fall in one of theshorter exposure times). For the method to be
five nominal spectral bands shown:effective, the overall time for the frame sequence
• Short-wave infrared (SWIR) cameras - visible tomust be short enough to avoid motion blur. If this is the
2.5 microncase, then camera software combines the frames into
• Broad-band infrared (BBIR) cameras - 1.5-5 micronone image frame having the entire dynamic range for
• Mid-wave infrared (MWIR) cameras - 3-5 micronthe sequence.
• Long-wave infrared (LWIR) cameras - 7-10 micronAs an example, consider the following sequence of
responseimages showing the process of mixing a cold fluid to a
• Very Long Wave (VLWIR) cameras - 7-12 micronflask of boiling liquid. If an exposure time was selected
responsebased on the full temperature range, the thermal
In addition to cameras that utilize "monospectral"resolution of the cooler objects will be poor.
infrared detectors that have a spectral response inConversely, if the exposure time is selected to
one band, new systems are being developed thatimprove the thermal resolution of the cold fluid, the
utilize infrared detectors that have a response in twohotter objects may cause saturation. As a result, with
bands (known as "two color" or dual band). Examplesdynamic range expansion, multiple integration times can
include cameras having a MWIR/LWIR responsebe selected that span the entire scene dynamic range.
covering both 3-5 micron and 7-11 micron, orExposure time 110 microseconds / Frames 1,4,7 /
alternatively certain SWIR and MWIR bands, or evenObject Temperature Range 65-150 degrees C
two MW sub-bands.Exposure time 600 microseconds / Frames 2,5,8 /
There are a variety of reasons motivating theObject Temperature Range 35-70 degrees C
selection of the spectral band for an infrared camera.Exposure time 1375 microseconds / Frames 3,6,9 /
For certain applications, the spectral radiance orObject Temperature Range 5-40 degrees C
reflectance of the objects under observation is whatIn this example, three exposure times have been
determines the best spectral band. These applicationsselected (1375 microseconds, 600 microseconds, and
include spectroscopy, laser beam viewing, detection110 microseconds) to cover a wide scene temperature.
and alignment, target signature analysis,The camera then cycle through each exposure time
phenomenology, cold-object imaging and surveillance inat the full frame rate. If the camera is operating at 240
a marine environment.frames/second, the first frame will be at the first
Additionally, a spectral band may be selected becauseexposure time, the second frame will be at the second
of the dynamic range concerns. Such an extendedexposure time, the third at the third exposure time. The
dynamic range would not be possible with an infraredfourth frame will begin the sequence again at the first
camera imaging in the MWIR spectral range. The wideexposure time. The system will effectively generate
dynamic range performance of the LWIR system isthree sequences, three frames apart, each at a rate
easily explained by comparing the flux in the LWIRof 80 frames/second with the three exposures times.
band with that in the MWIR band. As calculated fromThrough image processing, the sequential frames can
Planck's curve, the distribution of flux due to objects atbe recombined into one complete sequence making a
widely varying temperatures is smaller in the LWIRpixel by pixel determination as to the apparent signal,
band than the MWIR band when observing a scenefurther increasing the dynamic range. The resulting
having the same object temperature range. In otherimage is shown below (with a 5-150 degrees C object
words, the LWIR infrared camera can image andtemperature scale):
measure ambient temperature objects with highThe exposure times correspond to different camera
sensitivity and resolution and at the same timesensitivities. In operation, the camera is programmed to
extremely hot objects (i.e. >2000K). Imaging wideselect the appropriate exposure time frame by frame.
temperature ranges with an MWIR system wouldThe resulting data will either be multiple sequences
have significant challenges because the signal fromcreated from multiple integration times, or a combined
high temperature objects would need to be drasticallysequence that takes the most appropriate data based
attenuated resulting in poor sensitivity for imaging atupon the scene. In addition, the user can choose to
background temperatures.vary the number of frames per integration time, as
2. Image Resolution and Field-of-Viewwell as have the option to utilize an internal filter
2.1 Detector Arrays and Pixel Sizesmechanism for attenuation or spectral data.
High speed infrared cameras are available havingCertain applications require very wide thermal dynamic
various resolution capabilities due to their use ofranges, which may not be possible with a single
infrared detectors that have different array and pixelintegration time. The high speed infrared camera's
sizes. Applications that do not require high resolution,dynamic range expansion mode will allow the user to
high speed infrared cameras based on QVGAcycle through exposure times at the fastest rate
detectors offer excellent performance. A 320x256possible for the camera.
array of 30 micron pixels are known for their3.4 Event Triggering
extremely wide dynamic range due to the use ofIn order to capture high speed events, infrared
relatively large pixels with deep wells, low noise andcameras must be properly synchronized. In the
extraordinarily high sensitivity.tire-testing example in Section 3.1 above, it is possible
Infrared detector arrays are available in different sizes,to have an optical encoder on the rotating tire that
the most common are QVGA, VGA and SXGA asallows precise position location. The TTL signal
shown. The VGA and SXGA arrays have a densergenerated by the optical encoder can be fed into the
array of pixels and consequently deliver higherinfrared camera to trigger the start of the recording
resolution. The QVGA is economical and exhibitssequence for the camera. The result is that every time
excellent dynamic range because of large sensitivethe encoder sends the pulse, the camera exposes the
pixels.infrared detector for a certain exposure time creating
More recently, the technology of smaller pixel pitch hasan image. This allows a real-time stop image sequence
resulted in infrared cameras having detector arrays ofto be created via software.
15 micron pitch, delivering some of the most impressiveIn addition to the ability to accept an external TTL
thermal images available today. For higher resolutiontrigger, infrared cameras have other capabilities that
applications, cameras having larger arrays with smallerimprove their ability to capture high speed events. For
pixel pitch deliver images having high contrast andexample, certain trigger features permit the infrared
sensitivity. In addition, with smaller pixel pitch, optics cancamera to synchronize the trigger with the desired
also become smaller further reducing cost.image capture. Because digital image frames are
2.2 Infrared Lens Characteristicscaptured in real time, a pre-trigger permits the
Lenses designed for high speed infrared camerassoftware to identify the beginning of a desired
have their own special properties. Primarily, the mostsequence that actually occurs before the trigger signal!
relevant specifications are focal length (field-of-view),Post-trigger delays are also available for aligning the
F-number (aperture) and resolution.frame capture with an event that follows the trigger
Focal Length: Lenses are normally identified by theirafter a programmable delay.
focal length (e.g. 50mm). The field-of-view of a cameraIn addition, most high speed thermal cameras today
and lens combination depends on the focal length ofhave the ability to provide a trigger output to allow
the lens as well as the overall diameter of the detectorexternal devices to be synchronized with the thermal
image area. As the focal length increases (or thecamera. Therefore the camera can slave or be
detector size decreases), the field of view for thatslaved. Having both a trigger input and output is useful
lens will decrease (narrow).in an application that involves using multiple cameras to
A convenient online field-of-view calculator for a rangeview the same target from different angles. In this
of high-speed infrared cameras is available online.case, the data can be assembled - via software - into
In addition to the common focal lengths, infrareda 3-dimensional rendering of the thermal profile.
close-up lenses are also available that produce high3.5 Calibration: non-uniformity correction and radiometry
magnification (1X, 2X, 4X) imaging of small objects.One of the challenges in obtaining the best data from
Infrared close-up lenses provide a magnified view ofa high performance infrared camera system was in
the thermal emission of tiny objects such as electronicmaintaining a proper calibration. Calibration often refers
components.to two different operations. One, non-uniformity
F-number: Unlike high speed visible light cameras,correction, is necessary to calibrate the sensor for
objective lenses for infrared cameras that utilizeoptimal image quality. The other calibration has to do
cooled infrared detectors must be designed to bewith determining the temperature of objects based on
compatible with the internal optical design of the dewartheir image brightness.
(the cold housing in which the infrared detector FPA isNon-uniformity correction is required to assure that the
located) because the dewar is designed with a coldinfrared detector array delivers the best possible
stop (or aperture) inside that prevents parasiticimage quality. Each pixel in the detector array inevitably
radiation from impinging on the detector. Because ofhas a slightly different gain and offset value. In addition,
the cold stop, the radiation from the camera and lenssome pixels may have other anomalous properties
housing are blocked, infrared radiation that could farthat deviate from the norm. The gain and offset for all
exceed that received from the objects underthe pixels in the array need to be adjusted so that
observation. As a result, the infrared energy capturedeach pixel performs identically to the others. Variations
by the detector is primarily due to the object's radiation.can occur for a variety of reasons, including detector
The location and size of the exit pupil of the infrarednon-uniformity and optical affects such as the lens
lenses (and the f-number) must be designed to matchillumination non-uniformity that attenuates the apparent
the location and diameter of the dewar cold stop.radiance near the edge of the image. Anomalous pixel
(Actually, the lens f-number can always be lower thansignals must be replaced with nearest neighbor
the effective cold stop f-number, as long as it isaverages as is appropriate for the application.
designed for the cold stop in the proper position).To correct for the gain and offset, a calibration called
Lenses for cameras having cooled infrared detectorsNon Uniformity Correction (NUC) must be created. The
need to be specially designed not only for the specificprocess typically requires that the user expose the
resolution and location of the FPA but also todetector to a "cold" and "hot" blackbody source. An
accommodate for the location and diameter of a coldalgorithm then corrects the detector signal
stop that prevents parasitic radiation from hitting thenon-uniformity. A similar process called Bad Pixel
detector.Replacement (BPR) is required for any pixels that are
Resolution: The modulation transfer function (MTF) of aconsidered "bad" which means they deviate from
lens is the characteristic that helps determine the abilitycertain thresholds set for evaluating uniformity or due
of the lens to resolve object details. The imageto noisy behavior.
produced by an optical system will be somewhatNon-uniformity correction is complicated because there
degraded due to lens aberrations and diffraction. Theare variations in pixel performance for each integration
MTF describes how the contrast of the image variestime. Therefore, this process would need to be
with the spatial frequency of the image content. Asperformed for every integration time that the user
expected, larger objects have relatively high contrastselects. As high performance cameras can operate
when compared to smaller objects. Normally, lowfrom 1us to >10ms, this means that in theory 10,000
spatial frequencies have an MTF close to 1 (or 100%);calibrations need to be made. However, because of
as the spatial frequency increases, the MTF eventuallythe linear response of the detector, recent advances
drops to zero, the ultimate limit of resolution for a givenhave been possible to make this process transparent
optical system.to the user. A process called TrueThermal allows the
3. High Speed Infrared Camera Features: variableuser to select any integration time and the camera will
exposure time, frame rate, triggering, radiometryautomatically reference a look up table of both NUC
High speed infrared cameras are ideal for imagingand BPR properties that were established either at the
fast-moving thermal objects as well as thermal eventsfactory or at the user's site. In this situation, once a
that occur in a very short time period, too short foruser selects the appropriate integration time, the
standard 30 Hz infrared cameras to capture precisecamera system applies a predefined NUC and BPR
data. Popular applications include the imaging of airbagtable to allow instant and seamless operation.
deployment, turbine blades analysis, dynamic brakeOnce the sensor is calibrated for uniform image quality,
analysis, thermal analysis of projectiles and the studythe camera can be calibrated for radiometry, or
of heating effects of explosives. In each of thesetemperature measurement. If an infrared camera is
situations, high speed infrared cameras are effectiveproperly calibrated, the object temperature can be
tools in performing the necessary analysis of eventsdetermined based on the radiance signal in the thermal
that are otherwise undetectable. It is because of theimages, the background ambient temperature, possible
high sensitivity of the infrared camera's cooled MCTatmospheric effects and the objects emissive
detector that there is the possibility of capturingproperties. It is often particularly useful to be able to
high-speed thermal events.use the infrared camera to measure the temperature
The MCT infrared detector is implemented in aof objects (such as projectiles) traveling at high
"snapshot" mode where all the pixels simultaneouslyspeeds. This finds applicability in several important
integrate the thermal radiation from the objects undersituations, including: tracking of missiles, spacecraft and
observation. A frame of pixels can be exposed for aother objects, in determining the trajectory of bullets
very short interval as short asand projectiles and automatically identifying their origin
Because of the benefits of the high performancebased on trajectory information, and in creating thermal
MCT detector, as well as the sophistication of thesignatures for military targets.
digital image processing, it is possible for today'sSome users require that the thermal data be calibrated
infrared cameras to perform many of the functionsfor radiometry. Again, this radiometric data will be
necessary to enable detailed observation and testingdependent upon a specific integration time and must
of high speed events. As such, it is useful to reviewinclude the NUC and BPR corrections. In the past, for
the usage of the camera including the effects ofeach integration time, a unique radiometric calibration
variable exposure times, full and sub-window framewould be required. Today, the TrueThermal calibration
rates, dynamic range expansion and event triggering.function facilitates the process, not only correcting for
3.1 Short exposure timesNUC and BPR, but also applying the appropriate
Selecting the best integration time is usually aradiometric calibration table to the data. This now
compromise between eliminating any motion blur andallows the user to, in real time, change integration times
capturing sufficient energy to produce the desiredand have fully corrected data for NUC, BPR and
thermal image. Typically, most objects radiate sufficientradiometric calibration.
energy during short intervals to still produce a very high4. Infrared Camera Applications
quality thermal image. The exposure time can beIR Inspection in Design, Test and Manufacturing:
increased to integrate more of the radiated energyThermal imaging has become an extremely valuable
until a saturation level is reached, usually severaltechnology in many industries as a tool to inspect and
milliseconds. On the other hand, for moving objects ortest different designs and processes. The thermal
dynamic events, the exposure time must be kept assignatures can be a result of electrical,
short as possible to remove motion blur.electro-mechanical, chemical or other causes. Thermal
Tires running on a dynamometer can be imaged by aimages reveal heat dissipation, thermal conductance,
high speed infrared camera to determine the thermalnon-uniformities as well as other important diagnostic
heating effects due to simulated braking and cornering.factors.
One relevant application is the study of the thermalHyperspectral and Gas Imaging, Remote Sensing:
characteristics of tires in motion. In this application, byBroadband infrared cameras are very useful for
observing tires running at speeds in excess of 150 mphhyperspectral imaging (which involves the accumulation
with a high speed infrared camera, researchers canof a spectral set of times), gas imaging (which occurs
capture detailed temperature data during dynamic tireat a sometimes very narrow portion of the infrared
testing to simulate the loads associated with turningspectrum) and remote sensing (imaging the
and braking the vehicle. Temperature distributions onbackscatter, reflection and emission differences of
the tire can indicate potential problem areas and safetyvarious materials). Powerful image processing
concerns that require redesign. In this application, thesoftware is available to facilitate the analysis of the
exposure time for the infrared camera needs to beresulting infrared images.
sufficiently short in order to remove motion blur thatTarget Signature Measurement and Tracking:
would reduce the resulting spatial resolution of theThe spectral characteristics of vehicles, weapons and
image sequence. For a desired tire resolution of 5mm,countermeasures have been found to be important for
the desired maximum exposure time can be calculatedmany applications. Broad spectral range, high resolution
from the geometry of the tire, its size and location withand high sensitivity are key features of infrared
respect to the camera, and with the field-of-view ofcameras for these applications. We offer multi-spectral
the infrared lens. The exposure time necessary isimaging systems with a wide range of optics. In
determined to be shorter than 28 microseconds. Usingaddition, we offer powerful data acquisition systems
a Planck's calculator, one can calculate the signal thatfeaturing real-time image capture and radiometric
would be obtained by the infrared camera adjustedanalysis.
withspecific F-number optics. The result indicates thatResearch and Development:
for an object temperature estimated to be 80°C, anThermal imaging is used extensively in engineering and
LWIR infrared camera will deliver a signal having 34%scientific research centers around the world. Thermal
of the well-fill, while a MWIR camera will deliver a signalimaging provides insight into critical information about an
having only 6% well fill. The LWIR camera would beobject's thermal and spectral characteristics. In certain
ideal for this tire testing application. The MWIR cameracircumstances, information can be obtained on
would not perform as well since the signal output in thehigh-speed events (available with high frame-rate
MW band is much lower requiring either a longercameras) as well as circumstances requiring large
exposure time or other changes in the geometry anddynamic range (available with variable integration
resolution of the set-up.cameras). Key to the use of these imagers is often
The infrared camera response from imaging a thermalapplication-specific software that permits the detailed
object can be predicted based on the black bodyanalysis of both two-dimensional images as well as
characteristics of the object under observation,arrays of image sequences.
Planck's law for blackbodies, as well as the detector'sMedical Imaging, Body Temperature Detection:
responsivity, exposure time, atmospheric and lensMany physiological conditions produce variations in
transmissivity.body temperature and temperature distribution across
3.2 Variable frame rates for full frame images andthe human body. As an example, the installation of
sub-windowingthermographic cameras at airports has become a key
While standard speed infrared cameras normallySwine Flu and SARS screening tool for many areas
deliver images at 30 frames/second (with anaround the world. Thermography has also been used
integration time of 10 ms or longer), high speed infraredas a screening tool for applications such as breast
cameras are able to deliver many more frames percancer and pain management.
second. The maximum frame rate for imaging theNon-Destructive Test (NDT):
entire camera array is limited by the exposure timeThermal imaging is a non-invasive technique which
used and the camera's pixel clock frequency. Typically,when applied with specific stimulus provides a view
a 320x256 camera will deliver up to 275 framesinto subsurface defects in difficult test samples.
second (for exposure times shorter than 500Inspection of composite aircraft parts is gaining wide
microseconds); a 640x512 camera will deliver up to 120acceptance in airframe manufacture and service.
frames/second (for exposure times shorter than 3ms).Advanced materials are finding their way into
The high frame rate capability is highly desirable inautomotive and consumer products and thermographic
many applications when the event occurs in a shortNDT is a fast and wide area screening technique that
amount of time. One example is in airbag deploymentis very cost effective.
testing where the effectiveness and safety areSummary
evaluated in order to make design changes that mayBecause of the impressive performance of MCT
improve performance. A high speed infrared cameradetector technology, high performance infrared
reveals the thermal distribution during the 20-30 mscameras have become available that enable a wide
period of airbag deployment. As a result of the testing,variety of demanding thermal imaging applications. A
airbag manufacturers have made changes to theirselection of infrared cameras are available having
designs including the inflation time, fold patterns, tearmid-format to large-format detectors and with spectral
patterns and inflation volume. Had a standard IRsensitivity ranging in the short, mid and long-wave
camera been used, it may have only delivered 1 or 2spectral bands. The cameras owe their versatility to
frames during the initial deployment, and the imagescertain features that include: high frame rate imaging,
would be blurry because the bag would be in motionadjustable exposure time, event triggering enabling the
during the long exposure time.capture of temporal thermal events, dynamic range
Airbag effectiveness testing has resulted in the needexpansion, non-uniformity correction and radiometric
to make design changes to improve performance. Acalibration. These performance capabilities and camera
high speed infrared camera reveals the thermalfeatures enable a wide range of thermal imaging
distribution during the 20-30ms period of airbagapplications that were previously not possible, including:
deployment. As a result of the testing, airbagIR Inspection in design, test and manufacturing,
manufacturers have made changes to their designshyperspectral imaging, gas detection, remote sensing,
including the inflation time, fold patterns, tear patternstarget signature measurement and tracking, R&D,
and inflation volume.medical imaging and NDT.
Even higher frame rates can be achieved by