Long distance HD video over copper for minicam
minicam needed to upgrade its camera systems from SD to HD without replacing existing copper cabling
Challenge
- minicam needed to upgrade its camera systems from SD to HD without replacing existing copper cabling.
- The solution had to deliver low-latency HD video and telemetry over distances of 500m+, maintain reliability in harsh environments, and provide a roadmap for future enhancements such as higher video resolutions and AI-driven features.
- Fibre was ruled out due to robustness, cost and termination complexity, so the challenge was to achieve the required performance using legacy infrastructure.
Solution
- Consult Red recommended a robust long-distance transmission technology, paired with a low-latency compression technology.
- We validated the approach through feasibility studies, FPGA-based PoC, optics/sensor selection and matching, and custom hardware development.
- The final design integrated video processing and control into a compact, custom FPGA-based platform, ensuring consistent performance and scalability for future upgrades.
Learnings
- The selected transmission technology proved adaptable and reliable for long-distance HD video, with future potential for other applications.
- FPGA design met all performance goals but required more time and specialist expertise than anticipated, particularly for synthesis and PCB complexity.
- Early engagement with PCB vendors and clear planning for FPGA resource constraints are critical for future projects.
Impact and Value
- Technically and physically robust HD video – delivered over 500m of copper, eliminating costly fibre upgrades
- Reduced development time and inventory by leveraging existing cabling
- Created a flexible architecture supporting higher bandwidth, multi-camera setups, and advanced image optimisation
- Positioned minicam competitively against fibre-based solutions with a simpler, more cost-effective approach
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