Best Thermal Cameras for PCB Inspection by Infrared Imaging Temperature Mapping

PCB (Printed Circuit Board) assembly inspection is part of an electronics manufacturing process checklist nowadays, especially with highly complex circuit boards. It can detect any potential premature failure right after the manufacturing process. A few optical tools can be used, such as PCB inspection microscope camera with magnifier glass, which can provide zoomed in visual image of PCB assembly. There are a few methods PCB inspection jobs can be performed, such as Manual PCB inspection, AOI PCB inspection, AXI PCB inspection, Ultraviolet (UV) PCB inspection, and OpenCV PCB inspection. However, the thermal imaging camera offers another method for reliable and quick PCB inspection. 

To the users and manufacturers of electrical, mechanical and machinery equipment, the benefits of thermal inspection are endless, potentially useful and this has made it a valuable diagnostic tool for various industrial applications. Perfect temperature indications from the appropriate devices are capable of locating and revealing defective connections or components before failure which may result in fire, immense damage or dangerous explosions. The decreased liability of a thermally inspected system now includes to lower discounted rates insurance providers not to mention the reduced repair cost and decreased lost production hours when system fault s are brought to a timely check. 

Streamlining the scope of the thermal inspection to PCB Inspection only, the notion of predictive electrical maintenance is the primary solution purported by manufacturers of thermal cameras to enable thermographers “see,” measure, record temperatures and find defects in raw and populated PCB as well as hot spots. Electricians always find it hard to detect overstressed components, poor heat sinks, and bad solder joints because the human eye can only see a tiny part of the electromagnetic spectrum. Thus, owing to the rising development trend for high density and lead-free and halogen-free environmental requirement, the demand for PCB Inspection becomes increasingly essential to circumvent against issues of bad wettability, crack, and delamination which may put the question of high quality and reliability of PCBs In doubt. Hot spot inspection becomes the perfect thermography inspection scheme to detect hot spots in electrical connections and equipment. When conducted on circuits with high system loads, it affords experienced inspectors and engineers to reveal existing or potential hot spots and ensure that remedial measure is undertaken to guarantee safety and reduces the cost of repairs.

So, the purpose of this article is to bring to light the features of the best innovative Thermal Cameras alongside their advantages. In essence, this serves as a guide for OEMs in picking the most suitable thermal camera based on the likelihood of cost and product requirement. For the lay-mind out there, the process of the inspection by thermal cameras is not much of a big deal; a typical thermal camera simply permits the rapid scan of switchyard buses and equipment terminals to detect temperature differences. So, to give the inspector visual control over the process, the signals from photovoltaic detectors are electronically amplified and transferred to a small viewing screen producing an image that corresponds with the thermal patterns of the scanned area. Practically, these temperature differences are portrayed in different colors or shades of gray.

A scrutinized lists of top-notch thermal cameras as PCB inspection equipment system including but not limited, Fotric 225s, Flir ETS320, Fotric 226GRD, and Fotric 616C station. An automated optical PCB inspection program with the above thermal camera was set up in some manufacturing plant to implement quality control. 

 

1)    FOTRIC 225s Thermal Camera, 76,800 pixels (320 x 240) infrared detector

Features and Advantages

• Adjustable Focus Lens F1.0 – You can always focus on the area needed. F1.0 large aperture IR lens help you take high quality infrared radiometric images and videos.
• Temperature range between -20°C to 650°C
• High Measurement Precision - ±2°C or ±2%. Emissivity set for each ROI (Region of Interest).
• Short Radiometric Video - With Fotric 225s, you can record a single radiometric video directly in the camera with a smartphone with up to 1,000 frames up to 5 frames per second (fps).
• 1TB Long Radiometric Video - With Fotric 225s and FREE software - Fotric AnalyzIR, you can continuously record a single radiometric video file with up to 1TB up to 30 fps to your computer with USB interface. Ideal to capture sudden temperature change for post-failure analysis.
• Long Battery Time – 10+ hours battery use time after each charge. Can be AC powered too for long time working. 
• 5” LCD HD touch screen – User can upgrade the Android phone
• FREE Super Powerful Analysis Software – Various trigger recording. Real-time temperature history plot. Temperature difference analysis mode. The 3D plot of T and ∆T

Cons

• Test Bench – Test bench is not included. It's an optional accessory which can be useful in the lab settings. 
• No Macro Lens

The Fotric 225s is a perfect PCB inspection tool with good resolution and high-sensitivity imaging initiative and cost-effective. With a wide temperature range of -4°F~662°F, its stunning accurate camera can detect temperature fluctuation and express them in simple multi-color representation for temperature recording and analysis. 225s has high sensitivity (<.06C) to detect tiny temperature difference so you can quickly identify hot spots and potential points of failure. It sits on an adjustable 360-degree position with a changeable focus distance. It is a perfect professional grade PCB inspection system including Fotric 225s thermal camera, optional test bench, and FREE Android smartphone.

 

2)    Flir ETS320 Thermal Camera Bench Top Test Kit, 76,800 pixels (320 x 240)

Features and Advantages

• Temperature range between -20°C to 250°C
• Thermal Sensitivity: < 0.06°C
• 3” screen 320x240 pixel LCD
• Battery operating time: 4 hours

Cons

• Fixed Lens – Focus of the camera cannot be adjusted.
• Measurement Accuracy – ±3°C or ±3%, 
• Radiometric Video – Cannot record radiometric video on the camera. 
• No Macro Lens option

ETS320, its infrared camera can detect little temperature up to < 0.06°C with a measurement accuracy of up ±3°C. Its features and accessories make it a good choice for workers carrying out hotspot inspection or PCB inspection for quality test. The lens focus is fixed in one direction, so the object view area size is fixed, which limits the usage in some applications. 

3)    FOTRIC 226GRD Thermal Camera, 110,592 pixels (384 x 288) infrared detector

Features and Advantages

• Adjustable Focus Lens F1.0 – You can always focus on the area needed. F1.0 large aperture IR lens help you take high quality infrared radiometric images and videos.
• Temperature range between -20°C to 650°C
• High Measurement Precision - ±2°C or ±2%. Emissivity set for each ROI (Region of Interest).
• Short Radiometric Video - With Fotric 226GRD, you can record a single radiometric video directly in the camera with a smartphone with up to 1,000 frames up to 5 frames per second (fps).
• 1TB Long Radiometric Video - With Fotric 226GRD and FREE software - Fotric AnalyzIR, you can continuously record a single radiometric video file with up to 1TB up to 30 fps to your computer with USB interface. Ideal to capture sudden temperature change for post-failure analysis.
• Long Battery Time – 10+ hours battery use time after each charge. Can be AC powered too for long time working. 
• 5” LCD HD touch screen
• FREE Super Powerful Analysis Software – Various trigger recording. Real-time temperature history plot. Temperature difference analysis mode. The 3D plot of T and ∆T…

Cons

• Test Bench – Test bench is not included. It's an optional accessory which can be useful in the lab settings. 
• No Macro Lens

The Fotric 226GRD is a professional perfect PCB inspection thermal camera with high resolution (44% more pixels than Fotric 225s and Flir ETS320) and high-sensitivity imaging initiative and cost-effective. With a wide temperature range of -4°F~1,202°F, its stunning accurate camera can detect temperature fluctuation and express them in simple multi-color representation for temperature recording and analysis. 226GRD has high sensitivity (<.06C) to detect tiny temperature difference so you can quickly identify hot spots and potential points of failure. It sits on an adjustable 360-degree position with a changeable focus distance. It is a perfect professional grade PCB inspection system including Fotric 226GRD thermal camera, optional test bench, and FREE Samsung smartphone.

4)    FOTRIC 616C Thermal Camera Bench Top Test Kit, 110,592 pixels (384 x 288), optional 50um macro lens

Features and Advantages

• Adjustable Focus Lens F1.0 – You can always focus on the area needed. F1.0 large aperture IR lens help you take high quality infrared radiometric images and videos.
• Temperature range between -20°C to 650°C
• High Measurement Precision - ±2°C or ±2%. Emissivity set for each ROI (Region of Interest).
• Macro Lens - Optional 50μm macro lens to measure small components.
• Test Bench - Adjustable and rotatable test bench
• 1TB Long Radiometric Video - With Fotric 616C and FREE software - Fotric AnalyzIR, you can continuously record a single radiometric video file with up to 1TB up to 30 fps to your computer. Ideal to capture sudden temperature change for post-failure analysis.
• Network Interface - Multiple interface connection available including ONVIF, RS-485 etc. Can be used as an local IP thermal camera. 
• FREE Super Powerful Analysis Software – Various trigger recording. Real-time temperature history plot. Temperature difference analysis mode. The 3D plot of T and ∆T.

Cons

• Screen Display – No screen display. Need a Windows PC to work with.  

The Fotric 616C is a professional and dedicated PCB inspection thermal camera station with high resolution (44% more pixels than Fotric 225s and Flir ETS320) and high-sensitivity imaging initiative and cost-effective. With a wide temperature range of -4°F~1,202°F, its stunning accurate camera can detect temperature fluctuation and express them in simple multi-color representation for temperature recording and analysis. 616C has high sensitivity (<.05C) to detect tiny temperature difference so you can quickly identify hot spots and potential points of failure. It sits on an test bench with an adjustable focus distance. 

  Main Specification Comparison

	Fotric 225s	Flir ETS320	Fotric 226GRD	Fotric 616C Station
IR Resolution	320 x 240 (76,800 pixels)	320 x 240 (76,800 pixels)	384 x 288 (110,592 pixels)	384 x 288 (110,592 pixels)
Thermal Sensitivity/NETD	< 0.06°C	< 0.06°C	< 0.06°C	< 0.05°C
Accuracy	±2°C or ±2%	±3°C or ±3%	±2°C or ±2%	±2°C or ±2%
Macro Lens	No	No	No	50μm
Field of View (FOV)	40° x 30°	45° x 34°	28° x 21°	30° x 22°; 12° x 9.1° (50um macro lens)
Focus	Adjustable	Fixed	Adjustable	Adjustable
Camera f-number	f/1.0	f/1.5	f/1.0	f/1.0
Temperature Range	-20°C to 650°C (-4°F to 1,202°F)	-20°C to 250°C (-4°F to 482°F)	-20°C to 650°C (-4°F to 1,202°F)	-20°C to 650°C (-4°F to 1,202°F)
Short Radiometric Video	Up to 1,000 frames, up to 5 fps	Available when working with computer	Up to 1,000 frames, up to 5 fps	Available when working with computer
Long Radiometric Video	Up to 1TB, long time	TBD	Up to 1TB, long time	Up to 1TB, long time
Display	5.5 in 1280 x 720 pixel	3 in 320 x 240 pixel	5.5 in 1280 x 720 pixel	Computer Screen
Battery Use Time	12+ hours	4 hours	10+ hours	AC power
Professional Software	Fotric AnalyzIR - Included	Flir ResearchIR - $$$$	Fotric AnalyzIR - Included	Fotric AnalyzIR - Included
Warranty	2 Year	1 Year	2 Years	2 Years