Industrial Image Stitching Software by Intelgic

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Custom Software for Sensor Data Acquisition, Processing & Analytics
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Develop full‑resolution, distortion‑corrected images from many frames—fast, precise, production‑ready. Intelgic engineers custom image processing and complex stitching software for manufacturing, R&D, and inspection. We handle line‑scan and area‑scan, multi‑camera arrays, encoder‑synchronized capture, and stage‑based mosaics to produce seamless, metrically accurate images ready for defect detection, measurement, reporting, and analytics.

Advance Image Stitching

Vision tasks often exceed a single field of view—long parts, wide webs, large panels, micro features at high magnification. Intelgic’s stitching stack turns fragmented frames into a single, georeferenced canvas so your teams can detect, measure, and trace with confidence.

Key Capabilities

Any Capture Modality

Area‑scan (2D), line‑scan (1D), TDI, multi‑camera arrays, rotating fixtures, XY/XYZ stages, conveyor/encoder sync.

Robust Registration

Feature‑based (SIFT/ORB/AKAZE), phase correlation, sub‑pixel registration, RANSAC outlier rejection, affine/projective/homography models, bundle adjustment.

Industrial‑Grade Geometry

Lens distortion correction (radial/tangential), telecentric calibration, stage mapping & non‑linearity compensation, encoder scale/phase calibration, motion‑induced shear correction.

Photometric Consistency

Gain/exposure compensation, flat‑field correction, vignetting removal, HDR merge + tone mapping, color balancing & ΔE reports.

Seam Optimization & Blending

Seam finding, multi‑band blending, ghost removal, parallax‑aware warps, dynamic seam reflow around ROIs.

Performance at Scale

GPU‑accelerated pipelines, tiled/streaming stitching for meter‑scale images, out‑of‑core memory, on‑the‑fly pyramid generation for zoomable viewers (Deep Zoom/IIIF).

Accuracy You Can Trust

Pixel‑to‑mm calibration, traceable rulers/grids, uncertainty budgets, NIST‑traceable artifacts.

Ready for Inspection

Layered defect overlays, region‑wise statistics, measurements (length/area/perimeter), annotations, recipe‑based acceptance.

APIs & SDK

C++/C#/Python APIs, REST/gRPC services, file watchers, and message bus integration (MQTT/Kafka).

Capture Scenarios We Support

Conveyor/Web Inspection (Line‑scan)

Continuous stitching synchronized with encoder counts; handles speed variation, slippage, missing ticks.

Conveyor Inspection

Rotary/360° Unwrapping

Cylindrical unroll for tubes, bottles, shafts with top‑dead‑center alignment and axial blending.

Rotary Unwrapping

XY Stage Mosaics

Raster or serpentine scans for microscopes, PCBs, dies, slides; stage backlash compensation and overlap tuning.

XY Stage Mosaics

Multi‑Camera Arrays

Overlapping FOVs, timing alignment, color equalization, shared calibration.

Gigapixel Surfaces

Gigapixel Surfaces

Glass, metal sheets, wooden panels, textiles, printed tiles/ceramics—stitch + overlay defect maps and CMYK deltas against master references.

Gigapixel Surfaces

Aerial/Large‑Area Imaging

Orthorectified composites (if provided IMU/pose), map‑like outputs.

Gigapixel Surfaces
Pipeline Step 1

How the Intelgic Stitching Pipeline Works

  • Ingest & Sync: Capture from cameras/stages/encoders with hardware triggers; store‑and‑forward buffering for reliability.
  • Calibrate: Intrinsic/extrinsic camera parameters, encoder scaling, stage non‑linearity, illumination flat‑field.
  • Register: Feature/phase‑based alignment, coarse‑to‑fine; reject outliers with RANSAC; refine with sub‑pixel estimators.
  • Warp & Blend: Apply tuned geometric model (affine/projective/cylindrical), choose optimal seams, blend photometrically.
  • Compose & Index: Tile the composite, build pyramids, attach world coordinates (mm), and persist metadata.
  • Inspect & Report: Run AOI/ML recipes, render overlays, compute KPIs, and export PDF/Excel/DQC.

Performance Benchmarks

Calibration Tools

Checkerboard & dot grid patterns, single‑shot line‑scan distortion charts, telecentric validation.

Runtime Control

Encoder‑linked strobes, adaptive overlap %, motion‑blur guards, rolling‑shutter compensation.

Quality Gates

Seam visibility score, intensity continuity score, registration residuals, per‑tile sharpness MTF.

Data Management

Lossless image codecs (TIFF/PNG), high‑bit‑depth (12–16‑bit), tiled TIFF/BigTIFF, cloud buckets or on‑prem NAS.

Scalability

Multi‑GPU nodes, distributed stitching, microservices with autoscaling; resumable jobs for long scans.

Integrations

  • Upstream: PLCs (OPC UA/DA, Modbus, EtherNet/IP via gateways), encoders, triggers, frame grabbers.
  • Downstream: MES/ERP (SAP/Oracle), WMS, SCADA, CMMS; webhooks for pass/fail/diverter control; REST/gRPC for third‑party AOI.
  • Intelgic Live Vision AI: Optional modules for defect detection, classification, SPC, and analytics dashboards.

Deliverables

  • Requirements & imaging plan (FOV, overlap, speed, resolution)
  • Calibration and test protocol
  • Stitching engine + operator UI (viewer with zoom/measure/overlay)
  • Integration connectors & APIs
  • Validation report with accuracy & throughput benchmarks
  • Training and admin guide

Performance Benchmarks (Typical)

  • Throughput: 100–300 MP/s per GPU (area‑scan); 200–800 mm/s web speed (line‑scan) depending on resolution/overlap.
  • Accuracy: Registration residuals ≤ 0.2–0.5 px; metric error ≤ 0.05–0.2% after calibration.
  • Seam Quality: Seam score ≥ 95/100 on normalized edge energy tests. (Benchmarks vary with optics, lighting, motion stability, encoder fidelity, and GPU spec.)

Deployment Options

  • Edge: Deterministic stitching near the line; local UI & PLC feedback.
  • On‑Prem Server: Multi‑line consolidation and analytics.
  • Hybrid Cloud: Central dashboards, enterprise‑wide data, and remote support.
Security: TLS, RBAC, audit logs, encrypted at rest, allow‑lists, offline fallbacks.

Frequently Asked Questions

Yes—phase/scale calibration, slip compensation, and speed drift handling are built‑in.

Yes—we provide geometric unwrapping with axial alignment and diameter calibration.

No—our calibrated pipeline preserves metric fidelity with sub‑pixel registration and error reporting.

Absolutely—Intelgic’s AOI/ML modules run on the stitched canvas or on tiles for throughput.

Gigapixel‑scale images are supported with tiled storage and pyramid viewers.

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