CCTV Camera

CCTV CameraA novel CCTV camera incorporating high power Infra Red (IR) LEDs for night vision was developed for one of our clients. This product covers a niche within the CCTV market where night vision previously required an array of large unsightly peripherals. This concept uses the latest in high power IR LEDs to incorporate all in an aesthetic package that is easy and quick to install.

Design for assembly, manufacture and installation were rigorously pursued along with clean aesthetic lines. The whole product was extensively rapid prototyped and tested prior to tooling. This enabled all tooling to proceed to production with little or no modification. Manufacture was an international affair between the UK, Europe and China. Processes used were quite diverse and involved sintered metal drive components, complex plastic injection mouldings, elastomer injection mouldings, pressure diecastings, sheetmetal parts and machined components. The optically clear and true hemisphere was tooled and plastic injection moulded by a specialist as any blemish would mar the camera image.Pan Motor Assembly Image

A lot of development went into the camera to wall bracket interface. This was critical as it had to be quick and easy to install/remove at height and yet be very secure to avoid the camera from falling and causing injury or damage.

CCTV CameraAs the camera pans (rotates) and tilts, there were a lot of dynamic considerations and design problems to solve. The drive design had to accommodate the system dynamic movement and inertia. All this was designed well in advance of any physical model by using the 3D CAD mass properties data. Within an already tight enclosure, a design was developed that tilted and paned along with all the electrical connections and electronics. The drive train on this type of camera often suffer from problems due to temperature variation. This was avoided by careful design, lateral thought and proof testing.

Thermal management came into incorporating the high power IR LEDs. They had to be kept cool enough for use around the world and not affect the internal electronics. Novel solutions were found for these problems that were simple and cost effective.

Several camera variants were also designed to give a camera system. This was extended to include a mounting system of brackets including swan neck and pendant mounts to cover all normal camera locations.