VisionCraft needed to convert a working prototype of the viSEN AI sensor from development boards into a form that could be stably produced and operated in the field. We designed a custom motherboard, integrated the power supply, battery, modem, cameras, cooling, and mechanical design of the device. The key was to maintain anonymous data processing directly in the device, sensor mobility, and reliable operation even at higher temperatures. The result is hardware that VisionCraft uses for dozens of devices per year, which can be further modified to suit a new battery or design.
What is the viSEN sensor and why it doesn’t store images or video
When you have a working prototype of electronics, but you need to move it to a state where it can be mass produced and marketed, you need to professionalize the design. That’s exactly what VisionCraft came to us with – a Brno-based start-up that develops smart viSEN sensors for anonymous tracking of movement in public space.
Unlike conventional traffic cameras that take photos or video, the viSEN sensor only records the trajectories of moving objects (pedestrians, cyclists, cars), so the result is completely anonymous.
In addition, the image is processed directly inside the device and only anonymous metadata such as the type of object, its speed and direction of movement leaves the device. All this with minimal data transfer requirements.
Project goal: hardware for mass production and field operation
At the beginning of development, VisionCraft had a working prototype built on development boards, but this was not suitable for mass production. So they turned to us to professionalize the device – designing robust and stable hardware for the sensor that could be repeatedly manufactured and operated in harsh environments.
One of the requirements was also a power supply solution for the sensor. According to the original design, the sensor was to be operated for most of the day by a special battery that would be recharged overnight for several hours. It was also important to keep the device mobile so that it could be quickly and easily installed wherever it was needed.
The owners of the start-up partnered with a company that prepared a customized battery for them. It was up to us to completely integrate the device, design the custom motherboard, solve the power supply, custom mechanical design and ensure the stability of the system as a whole.
How we solved battery overheating and stable operation
We built the entire solution on the powerful NVIDIA Jetson computing platform. We custom designed a motherboard that connects all components: cameras, modem, power and charging circuits and active cooling. The board itself provides:
- reliable battery charging with overheat protection,
- Stable power supply of the entire system even in harsh conditions,
- ventilation to cool the powerful charger.
We also specifically addressed the overheating of the charger. We control the charging current so that the battery charges even in high heat – slower, but without risk of damage. Thanks to this modification, the device remains safe even during prolonged operation in the summer heat. If there is a power failure and charging is not taking place, the system will detect this itself and report it to the administrator.
Data transmission is handled by a modem with a SIM card, so the device is fully independent of the local infrastructure. In addition to the data transmission, the modem also takes care of the location of the device.
Tailor-made mechanical design and easy installation in the field
Due to the requirement to maintain the mobility of the device, we designed a complete customized mechanical structure. This has given us complete freedom in the arrangement of all internal components and greatly simplifies the final assembly of the entire sensor in our factory. Installation in the field is then as simple as possible for the customer’s technician. All you have to do is attach the complete device to the designated location.
Long-term cooperation and future prospects
We have been working with VisionCraft for a long time, we produce dozens of devices for them every year. In addition, we are currently working on a new hardware design: the size of the board, its layout and the power supply part will be changed to accommodate the new battery type.
This is exactly the kind of collaboration that makes sense – bringing together a start-up and professionals who help bring ideas to reality and are available if an upgrade to an existing solution is planned.
When does such a professionalization of the prototype make sense?
- If you have a working prototype but need a hardware design for mass production
- If you’re running equipment in the field, dealing with power, cooling and service, and don’t have much experience with it
- If you are dealing with data transfer and security and have not yet found the ideal way
We will be happy to take care of your project.
