Small voltage error, big brightness error
Most LED controllers regulate voltage. The LED's steep U-I curve turns tiny voltage variations into large current variations, and intensity follows current.
lumiSENS®
The fully digital technology platform for machine vision lighting.
by evotron · developed and made in Germany
Patent-pending lumiSENS® technology
Lighting that knows its own state.
lumiSENS® turns machine vision lighting from a simple light source into an active, data-capable system component. A sensor processor in every light measures what the LEDs really do. A digital controller keeps light, timing and lifetime under control. For the entire life of your machine.
Challenges
The blind spot
Everything in machine vision got better. Except the light.
Sensors resolve more, interfaces run faster, AI finds ever smaller defects. Yet most lighting is still an analog array of LEDs on 24 V. Nobody knows how bright it really is, how warm it runs or how much life is left. And every image your system evaluates is made from that light.
Progress of vision components, schematic
Image sensors▲▲▲
Interfaces▲▲▲
Optics▲▲
Software & AI▲▲▲
Lighting▬
Lighting has stayed the last blind spot of condition monitoring in machine vision.
Every flash a little different
Flashing by capacitor discharge cannot guarantee constant pulse energy. It depends on pulse length and charging time. HDR sensors see every deviation.
Brightness that slowly disappears
Heat reduces LED output within minutes, ageing over the years. Above 85 °C chip temperature, ageing accelerates. Thresholds drift, false rejects follow.
Set-up by gut feeling
Brightness is adjusted at hard-to-reach places, checked on the camera monitor, adjusted again. Timing is debugged with an oscilloscope. No LED is like the next one.
The old way
A multi-channel controller, four thick cables, one cabinet. For one ring light.
This is how a segmented lighting is typically wired today. And this is how it looks with lumiSENS®.
Conventional
lumiSENS®
- One controller channel and one cable per segment
- Thick multi-core special cables and connectors
- Cabinet space, extra hardware, extra heat
- No feedback: nobody knows how bright the light really is
- One single-channel controller for all segments and colours
- One standard M8 cable for power, sensor data and parameters
- Up to 75 % lower material cost, over 75 % less wiring
- Live process data from every light
Cable length matters
A long cable turns a sharp light pulse into a slow one.
Every metre of cable adds inductance that slows down the current rise in the LEDs. From about 5 m, signal quality and synchronisation suffer: pulses get smeared, light misses the exposure window and timing becomes uncertain. That is why the lumiSENS® controller sits in the cable, right at the light.
0.2 m15 m
1 µs20 µs
Rise time–
Trigger to light–
Light in exposure–
Jitter–
Clean pulse
LED current · 2 A pulse1 µs / div
ideal pulseactual LED currenttrigger
Values at 0.2 m measured on the DCC2404-1WS (2 A, 5 µs pulse, 200 mm cable). Longer cables: schematic model of cable inductance and interference, for illustration.
Whitepaper · GermanIn-cable lighting controllersThe advantages of in-cable controllers for machine vision, in detail.
How lumiSENS® works
Lighting and controller become one digital unit.
Four things happen continuously, in real time, over one standard M8 cable.
The lighting senses itself.
A Light Sensor Processor inside every lumiSENS® lighting continuously captures LED voltage, current, temperature and light intensity, and streams the data to the controller.
- Voltage
- Current
- Temperature
- Intensity
Plug in. It introduces itself.
Each light carries a digital type plate: a parameter set that describes it electrically, thermally and radiometrically. The parameter set is stored in the lighting itself, so every setting stays documented and traceable. The controller recognises the lighting, applies its limits and calibrates brightness. A replaced lighting is recognised automatically.
- Plug & Play
- Overload protection
- Traceability
- Replacement detection
Constant light, nanosecond timing.
An FPGA regulates the LED current with 14-bit resolution and a quartz-stable time base. It compensates temperature drift and ageing, and shapes high-power pulses along characteristic curves within the electrical, thermal and optical limits of the LEDs. Gallium nitride power stages do this with up to 98 % efficiency, in a controller the size of a cigar.
- 14-bit current
- 20 ns steps
- < 5 ns jitter
- GaN
Process data for your automation.
Operating data, warnings, operating hours and remaining LED lifetime are available on the controller display, in the app, via API and as a status signal to the PLC. Lighting becomes visible to condition monitoring, MES and predictive maintenance. lumiSENS® is currently the only Plug & Play lighting technology on the market built for the industrial IoT.
- PLC
- API
- MES
- Industrial IoT
- Condition monitoring
The result: lighting is no longer a consumable. It is a measured, documented and reproducible part of your vision system.
Performance
Facts
Precision you can measure. And repeat.
Figures of the DCC2404-1WS in-cable controller. Settings directly on the controller, in the app or via API.
Flash timing jitter
< 5ns
Consistent over the entire lifetime of the lighting. Light delay, pulse width and camera trigger are set in 20 ns steps. Camera shutter delay can be compensated.
Intensity accuracy
0.1%
Pulse after pulse. No energy swings like with capacitor discharge.
Pulse width
1µs – 85 s
In a 20 ns grid, with constant light energy even at 1 µs.
Flashes per second
500,000
Up to 500,000 precisely timed light pulses per second, for fast moving objects.
Trigger to light
420ns
Short, fixed and known. Fast trigger output with less than 50 ns.
Sectors & sequences
10,000fps
Up to 8 sectors and 16 sequence steps, fully synchronised to image acquisition, from one single-channel controller.
Synchronised units
128
Interference-free trigger distribution via RS-485 over up to 100 m. Under 2 minutes set-up per camera.
Efficiency & brightness
up to 98%
Low-loss GaN power stages waste almost no energy. And because the controller sits in the cable, not in the housing, no extra heat reaches the LEDs: they can be driven harder for more light, and they age more slowly.
Constant light
Heat and age dim every LED. Your images stay the same.
Conventional controllers do not notice when LED output falls. lumiSENS® measures it, compensates with current reserve, and tells you early when that reserve runs low. Try it.
Operating conditions
Move the sliders and compare both camera images.
25 °C85 °C max.
new60,000 h
Scenarios
Conventional controllervoltage control
Brightness100 %
Mean grey value192
Image OK
lumiSENS®auto calibration
Brightness100 %
Mean grey value192
Constant
Conventional
lumiSENS®
compensated by lumiSENS®
Schematic illustration based on typical LED behaviour, not measured data of a specific product.
Lexicon · GermanAgeing and driftHow ageing and drift affect lighting and cameras in machine vision.
Multicolour
One light. The right colour for every feature.
The right colour decides which feature your camera sees. lumiSENS® switches between the colour channels of multicolour and multispectral lighting while the machine is running, with one single-channel controller and one cable. Pick a colour and watch the monochrome camera image change.
Red 635 nm
Green 515 nm
Blue 456 nm
=
Colour image
In production
The right colour for every part, automatically.
A sensor detects the next part, the PLC sends the matching colour to the controller, and the RGB light switches between two parts. The camera always sees the part in its best contrast.
Monochrome camera images
Schematic illustration. The colour is set via the controller interface; achievable cycle rates depend on the application.
Spectrum
Standard wavelengths across the range
Schematic spectra with typical LED bandwidths. More wavelengths and beam angles on request.
Lexicon · GermanMeasuring lightBackground on measuring light, explained by our academy.Standard wavelengths: 440, 450, 455, 465, 520, 624, 625, 645, 655, 660, 730, 860, 940 and 950 nm, white 4000 to 6700 K, RGB 456 / 515 / 635 nm.
Applications
Use cases
Wherever images must be exact, fast and repeatable.
Proven in demanding inspection and measurement tasks. These are typical ones.
High-speed inspection in motion
Freeze fast moving parts with short, high-energy flashes that hit the exposure window exactly, every time.
≥ 1 µs pulses< 5 ns jitter0.1 % intensity
Photometric stereo & computational imaging
Make surface topography visible independent of colour and texture, for example embossed Braille. One camera, one sector ring light, one single-channel controller.
4 sectors · 4 images2,000 Hz sectors80 µs exposure
Multi- and hyperspectral with one light
Change the wavelength while the system is running. Several colour channels from one single-channel controller, switched by API.
RGB 456 / 515 / 635 nmArea & dome lights1-channel controller
Robot-guided vision
RCAM combines camera, lighting and LED controller in one compact robot tool for dynamic image capture during motion.
ISO 9409-1 flange5 MP GigE4 colour variants
Reliable AI training data
AI learns from images, and images are made of light. Changing light looks like changing product quality. Constant light keeps it out of AI decisions.
Faster trainingHigher accuracy
Measurement & series machine building
Stable gauge capability, identical machines from series to series, and retrofit of existing systems with standard cables.
Lighting clonesLong-term availability
Flagship project
12 cameras. One shared heartbeat.
High-speed structure measurement of thin-film solar panels in motion. Twelve cameras and their lights fire in exact synchronisation, distributed via RS-485. A demanding exception, and proof of what the platform can do.
1.6 m/sfeed rate
1.6 µmper pixel
1.4 µsexposure
1 million luxat the object
0.1 %intensity accuracy
128units possible
IndustriesSolarSemiconductorFoodPackagingRoboticsMetrologySeries machine building
Synchronisation
PLC, camera and light. In perfect time.
Every trigger starts a precisely timed period in the controller: one light pulse and, synchronously, a trigger for the camera. Delays and widths are set in 20 ns steps, so the light lands exactly in the exposure window.
The PLC or an encoder sends the trigger to the controller. The controller fires the light pulse and sends a synchronous TRIGGER-OUT to the camera. Each camera has a shutter delay. Shift the camera trigger and the light pulse until the pulse sits inside the exposure.
Light inside exposure–
Example camera with 1.2 µs shutter delay and 3 µs exposure. Light pulse 2 µs.
The PLC triggers the camera directly. The camera's exposure output triggers the controller, which fires the light pulse with a fixed, known delay of 420 ns. The pulse can be shifted further in 20 ns steps. Ideal when the camera is already integrated into the machine control.
A master controller synchronises further controllers via TRIGGER-OUT, also controllers from other makers. Each controller fires its own light pulse with locally set timing, for example one after another for several lighting directions. For large systems, an RS-485 signal distributor synchronises up to 128 units over up to 100 m, with under 2 minutes set-up per camera.
TTL to 24 VTrigger input for 5 V TTL up to 24 V PLC signals, PNP, NPN or push-pull, programmable edge
Up to 500 kHzTrigger frequency, with a digital filter against interference pulses
20 ns gridAdjustable delay and pulse width for light and camera trigger, each 1 µs to 85 s. Fixed trigger-to-light latency: 420 ns
< 50 nsFast trigger output for highly synchronous camera triggers
Camera supplyThe I/O port also supplies the camera with up to 500 mA, so the camera connects directly to the controller
Status to PLCIn case of a fault the controller switches the light off, sets STATUS-OUT and reports the error code
Process improvement
No more trial and error.
Four everyday situations in machine building, and what changes with lumiSENS®.
Set up lighting in minutes
Before
Adjust brightness behind the machine guard, walk to the monitor, check, repeat.
With lumiSENS®
Select the controller via WLAN and set all parameters in the app while watching the camera image.
Lighting clones by copy and paste
Before
Every LED lighting runs at its own current and brightness and must be adapted individually.
With lumiSENS®
Copy the parameter set. The controller calibrates a new light of the same type to identical values. Gauge capability stays 1:1, from the first machine to a global roll-out.
Transparent timing
Before
Unknown latencies, signal analysis with an oscilloscope on components spread across the machine.
With lumiSENS®
Known delays, trigger shifts in 20 ns steps. Camera triggers light, or light triggers camera.
Data instead of surprises
Before
The lighting fails, or slowly gets darker until the inspection breaks. Unplanned downtime.
With lumiSENS®
Light reserve and remaining operating hours are known in advance. Replacement is planned, not urgent.
Configuration · DCConfig app
Lighting management in minutes, not hours.
Select the controller, connect, and set every lighting parameter while you watch the camera image. Even complex sequences.
- Constant light at a glanceAuto calibration keeps brightness stable and shows how much it compensates.
- Sequences without programmingCombine segments and steps graphically, synchronised to your cameras.
- Know the state of every lightDigital type plates of controller and lighting with live operating data and remaining lifetime.
- Clone in secondsSave a complete configuration and restore it on any controller. Firmware updates included.
WindowsLinuxUSB-CIndustrial WLANAPI
App screenshot follows
App screenshot follows
App screenshot follows
App screenshot follows
See the full app live.A live online demo based on your application, or a test device on your desk.
Business case
More capability. Not a higher price.
lumiSENS® products do more than conventional lighting, but they do not cost more for it. Advanced manufacturing technology compensates the added functionality. The savings come on top, over the whole life of the machine.
=price
No premium for more capability
Advanced manufacturing technology compensates the added functionality of every lumiSENS® product.
0re-teach
After replacement
A new light of the same type is calibrated to identical values. Gauge capability is preserved without extra calibration.
1spare
Per product series
Lights are individualised by copying parameter sets. Your spare parts store shrinks.
−75%
Hardware for segmented & multicolour lights
Example 4-segment ring light: one single-channel controller instead of a multi-channel set-up, and over 75 % less wiring.
Your application
Where does your application gain?
Every application is different. Select what applies to yours.
With every lumiSENS® lighting
- Constant light over temperature and lifetime
- Process data and remaining lifetime
- Up to 98 % controller efficiency
- No price premium for the added capability
Select the characteristics of your application to see your specific gains.
What else buyers value
Plannable maintenanceCondition-based instead of reactive. Fewer unplanned stops on machines that must run 24/7.
One platform for many lightsLess integration effort, fewer part numbers, less training, lower stock costs.
Replace only what is defectiveLighting and controller are separate components. If one fails, only that part is replaced, not the whole set-up.
Made in GermanyDeveloped and manufactured in Germany, with regional certified suppliers.
Delivery reliabilityStandardised modules, short delivery times and long-term availability for series machines.
Future-proofBuilt for the industrial IoT, with standard interfaces to PLC, MES and data-based maintenance systems.
Full traceabilityEvery lighting parameter is stored digitally and documented. A strong argument in every quality audit.
Longer LED lifeHousings optimised by thermal FEM simulation keep heat away from the LEDs. More usable light, less ageing.
Identical worldwideReproduce the same machine state at every site, with the same light types. Ideal for global roll-outs and standardised spare-part strategies.
Hardware and wiring savings for the 4-segment ring light according to the DCC2404-1WS technical manual. Effort for commissioning, service and downtime depends strongly on the application.
Products
Start with a controller. Go all the way with lumiSENS® lighting.
The in-cable controllers work with your existing LED lights right away. Combined with lumiSENS® lighting, you get the full platform.
3D model follows
3D model follows
3D model follows
3D model follows
3D model follows
lumiSENS® lighting
Telecentric & more
Telecentric lights support all lumiSENS® features. Also available: line, spot, three- and four-side lights, and custom designs.
TelecentricLineSpotCustom
Your existing lights
Works with your lights. Shines with ours.
evotron in-cable controllers also drive LED lighting from other manufacturers. Timing, sequences, app and overload protection work right away. The sensor functions need lumiSENS® lighting.
| Feature | Third-party LED light | lumiSENS® lighting |
|---|---|---|
| Precise flash timing, sequences, app, API | ✓ | ✓ |
| User current limits, overload protection | ✓ | ✓ |
| Auto calibration against drift and ageing | – | ✓ |
| Digital type plate, Plug & Play | – | ✓ |
| Temperature, irradiance, remaining lifetime | – | ✓ |
| Segments and colours from one single-channel controller | – | ✓ |
evotron academy
Need the know-how? Learn it from the people who built it.
Lighting decides what a camera can see. Our training and consulting connect machine vision, automation and industrial IoT, from the basics to your specific application.
“Image processing begins with light.”Taught by practitioners in machine vision since 1988, authors of the “Lexikon der industriellen Bildverarbeitung” and co-authors of the “Handbook of Machine Vision”.
Fundamentals of industrial image processingBasic seminar, one day. In Suhl, in-house or online.
Lighting and optics: the turbo for machine visionAdvanced seminar, two days. In Suhl, in-house or online.
Consulting and supportHelp with your application, before, during and after the purchase. Plus a technology seminar on vision-based metrology.
Further reading
Talk · Industrial Vision Days 2026 · ENDigital precise timing: synchronised lighting for faster machine vision
Whitepaper · 2024 · DEFuture-proof properties of in-cable lighting controllers
Article · inVISION 2/2026 · DENo more trial and error: set up and parameterise lighting digitally
Lexicon · DEShutter: why light and exposure must be synchronised
FAQ
Good questions.
What is lumiSENS®?
lumiSENS® is evotron's patent-pending, fully digital technology platform for machine vision lighting. A light sensor processor in every lumiSENS® lighting measures voltage, current, temperature and light intensity. A digital in-cable LED controller uses this data to keep brightness and flash timing constant over temperature and lifetime, and provides process data for automation and condition monitoring.
Which machine vision lights are available with lumiSENS®?
The evotron range includes ring lights, area lights including an RGB version, line lights, spot lights, telecentric lights and three- and four-side lights, in standard wavelengths from 440 to 950 nm and white. Other wavelengths, beam angles and custom designs are available on request. The in-cable LED controllers also drive LED lights from other makers.
Can I use the controllers with my existing LED lights?
Yes. The in-cable controllers drive LED lights from other manufacturers within their power class. Timing, sequences, app control and user current limits are available. Auto calibration, the digital type plate and lifetime data require lumiSENS® lighting.
How do I connect lumiSENS® to my PLC or software?
Three industrial I/O channels can be configured as PNP, NPN, push-pull or input, for trigger, status and user signals. Trigger inputs accept TTL to 24 V. For software integration, documented programming interfaces are available to registered customers.
Do I need the app to operate the controller?
No. Basic settings can be made directly on the controller with its display and button, or fully via API. The DCConfig app for Windows and Linux makes set-up, sequences and monitoring much faster.
What happens when a light has to be replaced?
The controller detects the new light automatically. With a lumiSENS® light of the same type it calibrates brightness to the stored values, so the machine continues with identical parameters and no new teach-in is needed.
Where is the controller mounted?
Directly in the lighting cable, in the cable duct, on the wall or on a NS15 or NS35 DIN rail in the control cabinet. Screw connectors on both sides use standard M8 or M12 cables, also drag-chain or robot-suitable types.
Can I limit the brightness, for example for eye safety?
Yes. Below the factory limits you can set your own maximum current. This protects people in the working area from glare, and LED lights from other manufacturers from overload.
Can I test lumiSENS® before buying?
Yes. Test devices are available on loan. Request one below and tell us about your application.
Get started
See it in your own machine.
Request a test device, a sample or a quote. We will get back to you personally.
- Test devices on loan, ready to ship
- Works with your existing LED lights
- Application advice from machine vision experts
Prefer to talk? +49 3681 807 64 60 · info@evotron-gmbh.de
✓Thank you!
Your request is on its way to evotron. We will get back to you personally.