Miniature Visible-Band Video Camera for Afterburner Probes, Hypersonic Propulsion Systems, and Combustion Driven Test Facilities

Developing a miniature high-speed camera for turbine engine augmentor testing presents several technical challenges, including capturing high-resolution, high-frame-rate video in extreme environments, ensuring data integrity over long distances, maintaining color accuracy under high-temperature emissions, and designing a rugged yet compact system. The system must support real-time image acquisition and multi-camera synchronization while adhering to low size, weight, and power (SWaP) constraints in high-vibration, high-heat conditions. This document outlines Surface Optics Corporation’s (SOC) proposal for a high-performance visible-band video camera for water-cooled probes used in turbine engine augmentor testing, hypersonic propulsion, and combustion-driven facilities. Leveraging SOC’s experience in ruggedized imaging, this effort builds on the Motz5 prototype, which successfully completed in-operando testing at AEDC. The new camera incorporates AEDC-driven design improvements, offering higher resolution, improved frame rates, enhanced durability, increased manufacturability, and a replaceable coaxial cable for power, camera command, and high-speed data transfer. At its core, the ams OSRAM Mira220 global shutter sensor provides 1600x1400 resolution at 90 fps for distortion-free, high-speed imaging of dynamic combustion events. Advanced data transmission is enabled through a GMSL-based single coaxial cable (LMR-240-UF) for long-distance, high-speed communication while reducing system complexity. SOC will also explore USB4 integration to enhance data transfer rates and system efficiency. The opto-mechanical design ensures compatibility with AEDC’s water-cooled probe housings, using interchangeable lenses with built-in NIR cutoff filters for accurate color representation. Since no commercial camera meets the required combination of shutter speed, durability, size, and global shutter capabilities, SOC has developed a modified housing solution, successfully tested at AEDC. SOC’s expertise in low-SWaP imaging, in-house machining, optical characterization, and ISO 9002-certified coatings ensures a high-confidence execution of this proposal. Future research will focus on iterative design improvements based on AEDC engineer feedback, potentially including shorter integration times, higher frame rates, and improved multi-camera synchronization. SOC will also develop fully functional software for real-time image acquisition and processing, supporting multi-angle and multi-phase analysis. Durability testing will compare data integrity between USB 3 and USB4, evaluating this advancement’s viability.