Engineered Camera Systems
Customization Capabilities
Our camera systems are configurable, allowing for simple integration into new and existing machinery. However, when standard configurations aren't enough to capture a clear image in a challenging environment, MeltTools engineers custom solutions. We specialize in designing and manufacturing custom welding cameras, specialized mounts, controllers, and advanced transmission and display systems.
Camera Body & Optical Customization
The right fit is just as important as a clear image, and sometimes you can't get a clear image without it. We offer a vast array of configurations to ensure your camera fits the physical constraints of your application and delivers the most useful image possible.
- Optical Configurations: Custom lenses, optical directions, sensor orientations and specialized focus mechanisms to fit any welding application.
- Environmental Protection: Engineered solutions for extreme heat cooling and optical pathway protection against spatter and fumes.
- Unique Form Factors: If your application requires a completely unique camera body shape to fit within tight tolerances, we will design, machine and deliver it.
Custom Camera Mounts and Machine Interfaces
When a standard camera mount is insufficient, we engineer the interface needed between the camera and your machine. We evaluate attachment points, weight and space limits, rigidity requirements and the necessary range of adjustment.
- CAD Interoperability: We work directly with your engineering models. We utilize Solidworks, Siemens, Autodesk and other major platforms.
- Rapid Prototyping: Send us a 3D model, a photo, or a physical sample of your torch, bracket, mandrel, or robotic arm and we will design a custom mounting solution.
Controller Customization
Our camera controllers provide quick access to camera parameters and LED control while serving the critical function of protecting upstream and downstream electronics (grounded to the machine).
- Signal Conversion & Conditioning: Video signals pass through our controllers and can be converted to display exactly where you need them.
- Custom Routing: We customize both controllers and secondary junction boxes for specific cable types, transmission requirements and display needs.
Transmission and Display Solutions
Reliable power, control and video transmission between the camera and display requires the right infrastructure.
- Cable Solutions: Depending on the environment, we provide off-the-shelf X-coded cables, high-temperature shielded cables, glanded cables, fiber optics or networked solutions.
- Wireless Transmissions: For extreme transmission distances or moving robotics where cabling is a hazard, we configure robust wireless video solutions.
Recording & Triggering: Tell us how and where you want to control the camera, display the feed, or trigger recording, and we will configure the system using cost-effective components.
In-House Manufacturing & AI Capabilities
By keeping our manufacturing and software development in-house at our Portage, Michigan facility, we maintain ultimate flexibility and speed for our clients.
- In-House Design and Machining: We machine custom cameras, mounts and controllers on-site. This allows us to rapidly prototype our designs and deliver optimized, ready-to-integrate solutions directly to our customers.
- AI Defect Detection & Tracking: Ready to go beyond basic visualization? We can implement our artificial intelligence systems into your custom camera setup to automatically detect weld defects and create consistent, reliable alarms for machine operators.