Integrated Lens Heating Outdoor Camera With Unrestricted View in Sub-Zero Temperatures

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VIA Optronics Holding AG

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Less energy, more performance: an integrated lens heater enables cameras to be used in vehicles even in snow, ice and high humidity. Modern energy management meets current sustainability requirements.

Camera systems play a crucial role in many industries today. This ranges from ADAS in the automotive industry to industrial automation, robotics and environmental measurement technology. In harsh outdoor environments, however, even a thin layer of frost or condensation can render a camera unusable. Reliable visibility is not only a matter of convenience, but also crucial for the safety and accuracy of the system. With a patented heating technology from VIA optronics integrated into the lens, high visibility is guaranteed even at sub-zero temperatures.

An Approach for Direct Heating of the Lens

Most systems are based on either heating the entire camera housing or placing an additional heated cover in front of the optics. Both increase energy consumption and lead to additional optical interfaces. VIA optronics deliberately takes a different approach: a wafer-thin heating element is integrated directly into the internal lens construction so that the heat is available exactly where it is needed.

This direct approach enables particularly fast defrosting of the optical surface and at the same time reduces the energy requirement to a minimum. As no additional cover glass layers are required, optical clarity is maintained. In addition, the mechanical footprint remains extremely compact. This is a key advantage for embedded systems where space and efficiency are equally important. A special driver circuit routes the power supply for the sensor and heater via a single coaxial cable, which simplifies integration while ensuring high reliability.

Precise Heating Without Bulky Additional Components

The heating foil heats the lens to just above the dew point, preventing fogging, icing and condensation without increasing the temperature of the entire camera module. This approach is complemented by a specially developed driver circuit that keeps the power supply stable even in the event of voltage fluctuations. This is particularly important for mobile and demanding outdoor applications.

In addition to the pure heating function, the entire camera system benefits from intelligent temperature control. Special power modulation ensures that the heating only delivers the power that is actually required, thus reconciling energy savings with constant power.

The robust design of the module with an operating range of -40 to 175 °F, protection class IP69K and selected robust materials for long-term adhesion and resistance enables use in heavy-duty transportation, construction machinery or agricultural equipment and other critical applications.

Improving Image Processing

The in-house camera technology has a bare-die image sensor that reduces stray light and improves the signal-to-noise ratio. In contrast to CSP or BGA housings, it does not require a cover glass on the sensor. The result is high signal quality, faster response times and clearer images. There are no limitations, even in poor lighting conditions or extreme temperatures.

For optimum optical performance, the manufacturer relies on an active, alignment-oriented design with full six-axis adjustment. With the active focus and alignment station and the six-axis manipulator (30 nm per step), the image sensor board is precisely positioned relative to the lens and the front housing. In this way, the optimum focus position of the image on the image sensor can be determined.

This results in several significant advantages: The in-house system enables flexible switching between different camera modules and therefore faster variant changes. The image is precisely centered on the sensor and optimum focus is achieved across the entire image for maximum image quality. At the same time, this makes the system more energy efficient, as yield losses due to incorrect alignment of the lens and sensor are minimized, while throughput increases.

Conclusion of the Integrated Lens Heater

By integrating a highly efficient heating element directly into the lens, vision is improved without compromising on optical quality. The combination of optimized lens heating, improved temperature control, bare-die sensor design, precise alignment processes and robust material technology ensures reliable, sharp imaging even under extreme outdoor conditions.

At the same time, the energy management meets modern sustainability requirements, while the overall design ensures consistent performance over many years, even under the most demanding conditions. Whether snowstorms, ice fog, high-pressure cleaners or high humidity—the cameras remain operational and deliver consistently high-quality images. (heh)

Christopher Tiongson is Global Product Manager Camera at VIA optronics.

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