1. Usinage pré-CNC: Design and Preparation for Surveillance Camera Prototypes
Avant de commencer Usinage CNC for the surveillance camera prototype, une étape systématique de conception et de préparation est essentielle pour répondre, de construction, et exigences pratiques. Cette étape suit une séquence linéaire, avec les détails clés organisés dans le tableau ci-dessous.
| Étape de conception | Exigences clés | Matériaux recommandés |
| Analyse de la demande de produits | Fonctions de base: High-definition lens compatibility (1080P/4K), 360° pan/tilt rotation (horizontal rotation speed 10°/s, vertical rotation range -15° to 90°), night vision (infrared LED range 10-30m); Exigences structurelles: Résistance aux intempéries (IP66/IP67), anti-vibration (pour usage extérieur), reserved space for circuit board, batterie (if wireless), and network interface; Apparence: Compact size (par ex., dome camera: diameter 100-150mm, height 80-120mm), low wind resistance design. | – |
| Conception structurelle | Structure interne: Lens mounting bracket (coaxiality tolerance ≤0.05mm), motor fixing slots (for pan/tilt rotation), circuit board cavity (with heat dissipation ribs), infrared LED mounting holes; External structure: Waterproof sealing grooves (width 2-3mm, depth 1-2mm) at dome and base joints, anti-theft mounting holes (diamètre 6-8mm) on the base, heat dissipation holes (Φ1-2mm, spacing 5mm) on the side. | – |
| 3Modélisation D & Simulation | Utiliser un logiciel de CAO (SolidWorks, ET NX) to create 3D models of split components (dome cover, camera body, base); Mark key dimensions: Lens hole diameter (matches lens outer diameter, gap 0.1mm), motor shaft hole (Φ8-10mm), battery compartment size (pour 18650 lithium battery); Use simulation software to test structural strength (withstand wind load 10m/s without deformation) et dissipation de la chaleur (circuit board temperature ≤60°C under continuous operation). | – |
| Sélection des matériaux | Choisissez des matériaux en fonction de la fonction de la pièce, environmental adaptability, et usinabilité, tout en privilégiant la compatibilité avec les procédés de production de masse. | Dome Cover: PC plastic (haute transparence, résistant aux chocs, épaisseur 2-3mm); Camera Body: Alliage d'aluminium 6061/6063 (good heat dissipation, résistant à la corrosion, wall thickness 1.5-2mm) or ABS/PC alloy (faible coût, léger); Base: Alliage d'aluminium (robuste, anti-theft) or galvanized steel (for outdoor fixed installation); Internal Bracket: PA66 nylon (insulated, résistant à l'usure) ou alliage d'aluminium (for lens/motor support). |
| Prétraitement des matériaux | Couper les matières premières en flans (laisser une surépaisseur d'usinage de 0,5 à 1 mm): Alliage d'aluminium via scie à ruban, PC/ABS via laser cutting; Alliage d'aluminium recuit (300-350°C pour 1-2 heures) pour réduire le stress interne; Dry PC plastic (80-100°C pour 2-3 heures) to remove moisture and prevent machining bubbles. | – |
2. CNC Machining Preparation for Surveillance Camera Prototypes
Une préparation adéquate avant l'usinage formel est la clé pour garantir l'efficacité et la qualité de Usinage CNC for surveillance camera prototypes. Cette section couvre principalement la sélection des matériaux et des outils, ainsi que la programmation et la conception des luminaires.
2.1 Sélection des matériaux et des outils
Le choix des matériaux et des outils affecte directement l'efficacité de l'usinage et la qualité des prototypes. Le tableau ci-dessous fournit des recommandations détaillées:
| Catégorie | Options spécifiques | Scénarios d'application |
| Matériaux de logement | Alliage d'aluminium 6061 plaque (épaisseur 3-5mm), PC plastic plate (épaisseur 2-3mm) | Aluminum alloy for camera body (good heat dissipation); PC for dome cover (haute transparence). |
| Metal Parts Materials | Galvanized steel plate (thickness 4-6mm) | Used for heavy-duty camera bases (anti-theft, résistant à la corrosion). |
| Outils d'usinage grossier | Φ10-12mm flat bottom knife, Φ8mm ox nose knife | Realize quick material removal for large-size parts (par ex., camera body, base). |
| Outils de finition | Φ2-3mm ball head knife, Φ1-2mm drill bit | Used for machining curved surfaces (dome cover edge) et des petits trous (infrared LED mounting holes), ensuring surface smoothness. |
| Outils de processus spéciaux | Thread tap (M6-M8 for base mounting holes), graveur laser (brand logo) | Process threaded holes for installation and engrave decorative/functional patterns. |
2.2 Programmation et conception de luminaires
La programmation scientifique et la conception raisonnable des accessoires peuvent efficacement éviter les erreurs d'usinage et garantir la précision de l'usinage..
| Lien | Opérations clés | But & Effet |
| Programmation FAO | – Usinage de sous-zones: First process the outer shape of large parts (camera body, base), then machine internal cavities (circuit board cavity, battery compartment) to avoid interference.- Layered cutting: Set roughing layer thickness 1mm, épaisseur de la couche de finition 0,2 mm; For curved surfaces (dome cover), use multi-axis linkage machining to ensure curvature consistency. | Améliorer l’efficacité de l’usinage, ensure the precision of complex structures, and reduce tool wear. |
| Conception des luminaires | – For aluminum alloy plates: Use a precision vise with soft jaws (prevent surface scratches) for clamping; For large-size bases, use a multi-point support fixture to avoid deformation.- For PC plastic dome covers: Use a vacuum adsorption platform for fixation to ensure uniform stress and prevent cracking. | Empêcher le déplacement des pièces pendant l'usinage, assurer la planéité et la précision dimensionnelle du prototype. |
3. Core CNC Machining Process for Surveillance Camera Prototypes
Le formel Processus d'usinage CNC is the core link in transforming design models into physical surveillance camera prototype parts. Elle doit être réalisée en stricte conformité avec les étapes du processus pour garantir la précision et la fonctionnalité du prototype..
3.1 Usinage des composants principaux
Different components have different machining requirements, and the table below details the key steps for machining main parts:
| Composant | Étapes d'ébauche | Étapes de finition |
| Camera Body (Alliage d'aluminium) | 1. Mill the outer cylindrical shape (diameter matches design size, conserver une marge de 0,5 mm);2. Drill infrared LED mounting holes (array layout, Φ2mm);3. Mill the circuit board cavity (depth 15-20mm, size matches circuit board). | 1. Polish the outer surface (Ra1.6-Ra3.2) pour améliorer la résistance à la corrosion;2. Machine waterproof sealing grooves (width 2mm, depth 1.5mm) at the top joint with the dome cover;3. Tap M6 threaded holes at the bottom for base connection (depth 8-10mm). |
| Dome Cover (PC Plastic) | 1. Mill the hemispherical shape (radius matches design size, retain 0.3mm allowance);2. Cut the edge to ensure the matching size with the camera body. | 1. Polish the inner and outer surfaces (Ra3.2) to improve transparency (light transmittance ≥90%);2. Chamfer the edge (C0,5mm) to avoid sharp edges scratching the operator. |
| Base (Acier galvanisé) | 1. Mill the square/round base shape (size matches design, retain 0.8mm allowance);2. Drill anti-theft mounting holes (Φ8mm, 4-6 holes evenly distributed). | 1. Deburr the mounting holes to ensure smooth screw installation;2. Perform galvanizing treatment (thickness 5-10μm) to enhance outdoor corrosion resistance. |
3.2 Usinage des détails clés
Key detail machining directly affects the functionality and reliability of the surveillance camera prototype:
- Lens Mounting Bracket Machining: Use aluminum alloy to machine the bracket with a coaxial hole (Φ20-25mm, tolérance ±0,02 mm) for lens installation. Ensure the bracket is perpendicular to the camera body (90°±0.1°) to avoid lens deviation affecting shooting accuracy. Add positioning pins (Φ3mm) to fix the lens and prevent rotation.
- Motor Shaft Hole Machining: For pan/tilt rotation motors, machine a shaft hole (Φ8mm, tolerance ±0.01mm) with a keyway (width 2mm, depth 1mm) to ensure the motor shaft and rotating component are tightly connected. Après usinage, test the rotation flexibility (no stuck phenomenon, rotation resistance ≤0.5N·m).
- Heat Dissipation Structure Machining: On the camera body side, machine heat dissipation ribs (height 3-5mm, spacing 4mm) and array small holes (Φ1.5mm) to enhance heat exchange. For high-power circuit boards, mill a heat dissipation platform (area ≥50cm²) to install heat sinks.
3.3 Inspection de la qualité de l'usinage
Conduct in-process inspection during machining to ensure product quality:
- Contrôle dimensionnel: Use a digital caliper to measure the outer diameter, diamètre du trou, and cavity depth of parts (tolérance ±0,05 mm); Use a coordinate measuring machine (MMT) to test the coaxiality of the lens bracket and motor shaft hole (error ≤0.03mm).
- Contrôle de la qualité des surfaces: Use a surface roughness meter to verify the surface finish of key parts (Ra ≤3.2μm for visible parts, Ra ≤6.3μm for internal parts); Vérifiez les rayures, bavures, and other defects on the part surface (no scratches >0.5mm).
- Structural Fit Test: Test-fit the machined camera body, dome cover, and base (gap ≤0.1mm at joints); Install the lens and motor to check if they fit into the reserved positions (no interference).
4. Post-Processing and Assembly of Surveillance Camera Prototypes
Après Usinage CNC, post-processing and assembly are required to make the prototype have better performance and complete functionality.
4.1 Traitement de surface
Different materials require targeted surface treatment to improve the prototype’s performance and appearance:
| Matériel | Méthode de traitement de surface | But & Effet |
| Aluminum Alloy Camera Body | Anodisation (noir/argent) + Sablage | Anodization enhances corrosion resistance (salt spray test ≥72 hours); Sandblasting creates a matte texture (reduces light reflection and avoids affecting shooting). |
| PC Dome Cover | Anti-scratch Coating Spraying | The coating (thickness 5-10μm) improves scratch resistance (no scratches after 500 steel wool friction tests) and maintains high transparency. |
| Galvanized Steel Base | Revêtement en poudre | The coating (thickness 60-80μm) enhances outdoor weather resistance (resists UV radiation and rain erosion) and improves aesthetics. |
| Internal Plastic Brackets | Flame Retardant Coating | Meet flame retardant standards (UL94V-0) to prevent circuit short circuits from causing fires. |
4.2 Assemblage et Test
Scientific assembly and strict testing ensure that the surveillance camera prototype meets design requirements and can work normally in actual scenarios.
4.2.1 Processus d'assemblage
Suivez cette séquence étape par étape pour éviter les erreurs d'assemblage:
- Vérification avant assemblage: Inspecter la taille et la qualité de surface de toutes les pièces usinées (no dimensional deviations, no surface defects); Préparer le matériel auxiliaire (silicone gaskets for waterproofing, vis, fils).
- Installation des composants:
- Install the circuit board in the camera body cavity: Fix it with M2 screws (couple 0,8-1N·m), and connect the lens, moteur, and infrared LED wires to the circuit board (ensure correct polarity, no short circuits).
- Assemble the pan/tilt motor: Fix the motor to the internal bracket, align the motor shaft with the shaft hole, and install the rotating component (test rotation flexibility).
- Install the dome cover: Place a silicone gasket in the waterproof groove of the camera body, cover the dome cover, and fasten it with M3 screws (even force, pas de lacunes).
- Fix the base: Connect the camera body to the base with M6 screws (torque 2-2.5N·m), and install anti-theft bolts if needed.
- Vérification de l'assemblage final: Après assemblage, vérifier les pièces détachées (no rattling during shaking); Verify that the lens can rotate 360° horizontally and adjust the vertical angle freely.
4.2.2 Procédures d'essai
Effectuer des tests complets pour vérifier les performances et la fiabilité du prototype:
- Tests fonctionnels:
- Image Quality Test: Connect the camera to a monitor, test 1080P/4K resolution (no blurring, color distortion ≤5%), and night vision effect (clear imaging within 10-30m in dark environments).
- Rotation Test: Test horizontal pan (360° rotation continue, non coincé, speed error ≤1°/s) and vertical tilt (range -15° to 90°, smooth adjustment).
- Network Test: For network cameras, test data transmission speed (≥10Mbps) and remote access (pas de retard, stable connection).
- Environmental Adaptability Test:
- Waterproof Test: Conduct IP66/IP67 test (spray water at 100L/min for 3 minutes or immerse in 1m water for 30 minutes, no water ingress).
- High/Low Temperature Test: Place the prototype in a -30°C to 60°C environment for 24 heures, fonctionnalité de test (pas d'échec, normal operation).
- Essai de vibrations: Appliquer une vibration de 10 à 500 Hz (acceleration 10m/s²) pour 2 heures, check for component loosening or structural damage.
- Safety Test:
- Test d'isolation: Check the insulation resistance between the circuit and the housing (≥100MΩ) to prevent electric leakage.
- Anti-theft Test: Test the base mounting strength (withstand 500N pull force, no deformation or disassembly).
5. Application Scenarios of CNC Machined Surveillance Camera Prototypes
CNC machined surveillance camera prototypes have a wide range of application scenarios, fournir un soutien solide au développement de produits et à la promotion du marché:
| Scénario d'application | Utilisations spécifiques | Avantage de l'usinage CNC |
| Vérification de la conception du produit | Verify the feasibility of structural design (par ex., étanche, rotation mechanism) et design fonctionnel (par ex., lens compatibility, night vision); Optimize the design based on test results (par ex., adjust heat dissipation structure to reduce temperature). | L'usinage CNC a une haute précision, qui peut restaurer avec précision les détails de conception, helping designers find and solve problems in a timely manner. |
| Market Research and Display | Display the prototype at security exhibitions to collect user feedback on appearance, fonctionnalité, and installation convenience; Use the prototype for customer demonstrations to promote product orders. | The prototype has a complete structure and realistic appearance, which can intuitively show the product’s advantages and attract customer attention. |
| Personnalisation en petits lots | For special scenarios (par ex., high-altitude monitoring, underwater monitoring), customize prototypes with special structures (par ex., enhanced waterproof, anti-icing); Produire ≤50 unités sans ouvrir les moules. | L'usinage CNC est flexible, suitable for small-batch customization, and can quickly respond to personalized needs, reducing development costs. |
| Educational and R&D Fields | Use the prototype as a teaching tool to demonstrate the structure and working principle of surveillance cameras; Fournir des échantillons expérimentaux pour R&D institutions to study new technologies (par ex., AI recognition, intelligent tracking). | The prototype has clear internal structure and complete functions, which is convenient for disassembly, observation, and experimental research. |
6. Key Precautions for CNC Machining Surveillance Camera Prototypes
To ensure the quality and efficiency of CNC machining surveillance camera prototypes, les précautions clés suivantes doivent être respectées:
- Contrôle de précision: Strictly control the coaxiality of the lens and motor (≤0,05 mm) to avoid affecting shooting accuracy and rotation stability; The tolerance of waterproof grooves should be controlled at ±0.03mm to ensure the waterproof effect. Pendant l'usinage, use a CMM to inspect key dimensions every 2 heures.
- Adaptation des propriétés matérielles: Lors de l'usinage d'un alliage d'aluminium, use cutting fluid to cool the tool and workpiece to prevent material hardening and deformation; When machining PC plastic, control the cutting speed (4000-6000tr/min) to avoid melting caused by excessive temperature.
- Optimisation des coûts: CNC machining is suitable for small-batch prototype production (≤100 unités); Pour la production de masse (>1000 units), il est recommandé de passer au moulage par injection (pour pièces en plastique) or die casting (pour pièces métalliques) to reduce production costs. Pendant la phase de conception, simplify complex structures (par ex., remplacer les surfaces courbes irrégulières par des surfaces régulières) to reduce machining time.
- Opération de sécurité: Pendant l'usinage, les opérateurs doivent porter des lunettes et des gants de sécurité pour éviter les blessures causées par les copeaux volants; When performing surface treatment (par ex., anodisation, revêtement en poudre), use professional equipment and follow safety procedures to avoid toxic gas inhalation.