Miniaturized Low-Power Video Unit
A new portable multi-purpose camera unit was designed, prototyped and tested. Below are the key features of the unit:
Multi-purpose functionality: The unit can be easily placed in different holders, adapting to various usage scenarios.
Compact and lightweight design: With its slim profile, the unit can be conveniently stored in a wallet or pocket.
Extended battery life: Optimized for over 12 hours of wireless video transfer on a single charge, ensuring uninterrupted usage.
Proprietary wireless charging: Simplifying the charging process and enhancing user convenience.
Streamlined mass-production and cost reduction strategy: Ensuring scalability and affordability.
Innovative low-power, high-volume data transfer solution: Enabling efficient and reliable transfer of large data.
Innovative Factors
In order to achieve efficiency and cost-effectiveness, several unique design features were implemented in this project. While specific details cannot be disclosed, the following innovative factors were utilized:
Three-piece mechanical puzzle for the enclosure: To facilitate faster and more affordable mass-production, a three-piece mechanical design with a simple locking mechanism was employed. This involved a molded plastic piece and two stamped covers, streamlining the assembly process.
Novel contact-charging system: To maintain water and dust-proof properties, the design opted for an internal battery charging solution that eliminated the need for external connectors. A contact-based charging mechanism was developed, ensuring efficient charging without compromising the external enclosure.
Efficient data transfer circuitry: A novel approach was adopted to design the wireless transfer circuitry, focusing on reducing power consumption. This innovative circuitry design enhances energy efficiency while enabling seamless data transfer.
Data processing and the App: The software and application responsible for video processing incorporated an algorithm specifically developed for this unit. This algorithm enhances power efficiency, optimizing the overall performance of the camera unit.
Additional sensors: The design includes additional sensors that offer enhanced functionality. These sensors can be programmed through the app, allowing users to customize and define new features according to their preferences.
Bill of Material and Mass Production
Below is the BoM prepared for the mass-production on the unit. Please note, the numbers are for 10,000 of built quantity.
Small FHD camera: unit price ~$3.5
Stamped metallic covers: unit price ~$0.25
Plastic Ring: unit price ~$1
Rubber cover holders: unit price ~$0.5
BLE chip: unit price ~$2
Sensor: unit price ~$1
PCB and circuitry: unit price ~$2
Testing and QA: unit price ~$1
TOTAL: (high volume cost (10,000 units): $11.25
Based on our initial study, by moving the production offshore, we believed we could bring the unit price as low as $5-7 for mass production (i.e. over 10,000 units) . On the marketing side, our research showed a group price of 3 for $49.99 would result in a successful outcome with about 50% profit margin (considering the cost for advertisement and etc.)
Project Duration
The objectives for this project are as follows:
Provide a comprehensive hardware design: This includes both a top-level system design and detailed hardware specifications.
Develop a core algorithm, software, and Android application.
Design the mechanical hardware components.
Create assembly instructions and guidelines for factory testing and quality assurance.
Conduct preliminary market research to gather insights and evaluate potential demand.
Prepare a preliminary Bill of Materials (BoM) outlining the required components and materials.
Perform performance budget analyses, such as power and data budgets, to ensure efficient operation.
Outcome: A demo unit was successfully built and tested, utilizing the developed algorithm and application.
Project Duration: The project spanned a total of 6 months, involving approximately 500 hours of work.