Sony Industrial Sensor Matrix Analysis: From IMX927 to IMX949, How to Match Precision Vision for Machine Vision

Sony Industrial Sensor Matrix Analysis: From IMX927 to IMX949, How to Match Precision Vision for Machine Vision

In the field of industrial machine vision, there is no one-size-fits-all sensor—only the most suitable solution. Sony's newly launched IMX927 series comprises 16 models, covering a wide range from 12-megapixel to 105.5-megapixel sensors, offering unprecedented flexibility for automated inspection. This article analyzes the differentiated positioning and technical logic of this sensor family through a comparative lens.

I. Pixel Count vs. Frame Rate: The Art of Balancing Speed and Precision

The core strength of the IMX927 series lies in enabling users to make precise trade-offs between resolution and capture speed based on actual requirements.

IMX927 and IMX937: The Detail Champions of the 100-Million-Pixel Era

Both sensors feature approximately 105.51 million effective pixels, a pixel size of 2.74 micrometers, and a sensor diagonal length of 39.7 mm (2.5 inches). Their distinction lies in output speed: IMX927 supports full-pixel output at 102 frames per second in 10-bit mode, while IMX937 maintains a frame rate of 51 frames per second in 10-bit mode. This means IMX927 is the preferred choice for capturing fast-moving subjects; whereas for slower motion with extreme image quality demands, the IMX937's reduced frame rate design may deliver superior signal quality.

IMX928 and IMX938: The 68-Megapixel Mainstays

These sensors reduce pixel count to approximately 68.16 million while shrinking sensor size to 31.9mm diagonal (2.0 inches), though maintaining a 2.74-micron pixel pitch. The IMX928 achieves 126 frames per second at 10-bit, while the IMX938 delivers 64 frames per second. This combination suits scenarios requiring a balance between resolution and speed, such as medium-scale PCB board inspection.

IMX929 and IMX939: High-Speed Models at 50 MP

With approximately 50.79 million pixels and a sensor diagonal of 28.1 mm (1.8 inches), the IMX929 achieves a frame rate of 201 frames per second at 10-bit, while the IMX939 reaches 102 frames per second. These models represent the high-speed segment of the series, suitable for production lines demanding stringent inspection cycle times.

IMX947 and IMX949: Large-Pixel Sensitivity Advantages

These sensors feature radically different pixel designs: individual pixels enlarged to 5.48 micrometers—twice the size of other models. The IMX947 offers approximately 26.37 million effective pixels with a 39.7mm sensor size, while the IMX949 delivers about 12.69 million pixels on a 28.1mm sensor. Larger pixels deliver superior light sensitivity and higher saturation capacity, offering distinct advantages in short-exposure and high-speed capture scenarios. The IMX947 achieves a frame rate of 383 frames per second at 10-bit color depth, while the IMX949 reaches an impressive 722 frames per second.

II. The Technical Logic Behind Pixel Sizes

The choice between 2.74-micron and 5.48-micron pixel sizes reflects two distinct technical paths in industrial inspection.

The 2.74-micron pixel leverages Sony's Pregius S back-illuminated global shutter technology, achieving a balance between high sensitivity and high saturation capacity within a compact pixel size. This approach aims to pack more pixels into a limited optical footprint, meeting the growing demand for resolution in fields like semiconductor inspection and precision machining.

The 5.48-micron pixel, however, is designed for scenarios demanding ultimate sensitivity. Its larger light-sensitive area allows each pixel to capture more photons, ensuring sufficient signal strength even during extremely short exposures. This is crucial for applications involving high-speed motion capture or short-pulse illumination.

III. Functional Layering: Options from Basic to Advanced

The IMX927 series also exhibits distinct functional tiers in its configuration.

Differentiated Merge Readout Modes

The color variants IMX927, IMX928, IMX929, along with IMX937, IMX938, and IMX939, all support multiple merge readout modes. Beyond the standard 2×2 pixel binning, options include 2×1 vertical/horizontal and 1×2 binning. This design enables users to enhance sensitivity and output speed while preserving resolution in a specific direction, offering practical value for inspection tasks requiring directional precision.

Monochrome vs. Color Variants

Every sensor in the series is available in both monochrome and color versions, denoted by suffixes AMB (monochrome) and AQB (color). The monochrome version omits the color filter array, theoretically offering higher sensitivity and resolution, making it suitable for defect detection where color information is irrelevant. The color version retains the Bayer array for scenarios requiring color differentiation.

Specific Color Readout Functionality

The color versions of IMX927, IMX928, IMX929, IMX937, IMX938, and IMX939 also support selective reading of specific color pixels. This design enables a single sensor to switch between standard color imaging and specific wavelength imaging, such as targeted inspection under monochromatic light sources.

IV. Interface and Packaging: Industrial System Integration Considerations

The interface and packaging design of the IMX927 series reflects Sony's systematic approach to industrial applications.

All 16 models utilize a newly developed ceramic package with connectors, uniformly sized at 45mm x 52mm. The heat sink mounting space on the package's rear enables efficient thermal management, ensuring stable long-term operation. Crucially, the entire series employs universal connectors with pin compatibility. This allows camera manufacturers to design a single motherboard and swap sensors of different specifications as needed, significantly reducing development costs and cycles.

For output interfaces, the entire series supports the latest SLVS-EC standard with a maximum data rate of 12.5Gbps per channel. This high-speed interface, combined with Sony's global shutter technology, provides sensor-side support for next-generation industrial camera interface standards at the 100Gbps level, such as CoaXPress-over-Fiber and 100GigE.

V. Application Scenario Matching Guide

Based on the above technical characteristics, suitable sensors can be recommended for different industrial inspection needs:

Semiconductor and Precision Machinery Inspection:

Prioritize the 100-megapixel versions of IMX927 or IMX937. Their 2.74-micron pixel size adequately resolves minute defects, while frame rates around 100fps meet most production line cycle requirements. For faster motion speeds, choose IMX927; for ultimate image quality, IMX937 may be preferable.

Large Display Inspection: Similarly requiring high resolution to cover large screens, the IMX927 series' 39.7mm diagonal sensors capture larger areas per shot, reducing stitching frequency. Color variants are valuable for inspecting display color uniformity.

High-Speed Production Line AOI: For extremely fast production lines, the IMX929's 201fps or IMX949's 722fps offer significant advantages. The former delivers high-speed output at 50-megapixel resolution, while the latter, despite lower pixel count, ensures image quality under short exposures through its large-pixel design.

3D Inspection (Structured Light/Light Cutting): Structured light inspection demands higher resolution, where the high-pixel variants of the IMX927 series deliver denser point cloud data. Light cutting prioritizes laser line clarity and continuous frame rates, with the IMX929's high-speed output and IMX947's large-pixel design each addressing distinct needs.

Multispectral or Special Wavelength Detection: The color variant's specific color reading capability enables a single device to switch between standard detection and specialized wavelength detection without hardware replacement, making it suitable for R&D or dynamic production environments.

Conclusion

The launch of the IMX927 series marks Sony's transition from single-product offerings to a comprehensive matrix in industrial image sensors. This portfolio of 16 products across 8 categories spans a broad range: from 12MP to 100MP resolution, 100fps to 700fps frame rates, and pixel sizes from 2.74μm to 5.48μm. For machine vision system integrators and equipment manufacturers, this product line offers not a single solution but a toolkit precisely tailored to diverse inspection requirements. The key lies in users clearly understanding their inspection targets, motion speeds, and precision demands to select the most suitable tool from this comprehensive suite.