Introduction to EMEROSN VE4022
Product Description
The EMEROSN VE4022 is a rugged, mid-range industrial video encoder/decoder designed for reliable visual monitoring and real-time video transmission in harsh industrial environments. As a key model in EMEROSN’s VE-series—specialized for process visualization, machinery inspection, and security surveillance—it excels at converting analog/digital camera feeds into compressed, low-latency streams, making it ideal for industries like manufacturing, oil and gas, transportation, and water treatment, where visual data is critical for operational efficiency and safety.
What sets the VE4022 apart from commercial video devices is its industrial-grade resilience and automation-focused features: it withstands extreme temperatures, vibration, and electromagnetic interference (EMI) from nearby equipment (e.g., motors, VFDs), and integrates seamlessly with industrial control systems (PLCs, SCADA) via standard protocols. Its compact DIN-rail design fits in crowded control cabinets, and support for Power over Ethernet (PoE+) simplifies wiring by powering IP cameras directly—reducing installation time and costs.
The model designation “VE4022” encodes core capabilities:
- VE: Denotes EMEROSN’s “Video Engineering” series (industrial video processing).
- 40: Indicates 4th-gen hardware (enhanced compression, 4K compatibility, edge analytics).
- 22: References 2 video input channels and 2 output channels (balanced for mid-scale monitoring, e.g., 2 cameras covering a production line).
Typical use cases include:
- Monitoring robotic assembly arms in an automotive factory (transmitting 4K video to a SCADA system for defect detection).
- Streaming live feeds from oil wellhead cameras to a remote control room (via 4G/LTE or Ethernet) for leak or equipment wear inspection.
- Securing a warehouse loading dock (recording motion-triggered events and integrating with access control systems to verify delivery vehicles).
Technical Parameters
To simplify understanding, specifications are organized by functional category, with practical relevance highlighted for clarity:
1. Video Processing Capabilities
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Parameter
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Details
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Channel Count
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2 video input channels (supports analog CCTV or IP cameras); 2 output channels (HDMI + Ethernet streaming).
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Resolution Support
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Up to 4K UHD (3840×2160) at 30 fps per channel; backward compatibility with 1080p (1920×1080), 720p (1280×720).
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Encoding Formats
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H.265 (HEVC) for 50% bandwidth/storage savings vs. H.264; H.264 (AVC) for legacy system compatibility; MJPEG for low-latency (≤80ms) applications.
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Bitrate Control
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Variable Bit Rate (VBR, for bandwidth efficiency) or Constant Bit Rate (CBR, for stable streaming); 512 kbps – 15 Mbps per channel.
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Audio Support
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2-channel audio input (line-in, 3.5mm) + 2-channel output (line-out); supports G.711, G.722, and AAC codecs for synchronized audio/video.
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2. Input/Output & Connectivity
- Camera Inputs: 1× BNC (analog PAL/NTSC) + 1× Gigabit Ethernet (PoE+, IEEE 802.3af/at, 30W per port) for IP cameras.
- Video Outputs: 1× HDMI 2.0 (4K@60Hz for local monitoring) + 1× Gigabit Ethernet (for streaming to NVRs/SCADA/cloud).
- Network Protocols: RTSP, RTP, RTMP, ONVIF Profile S/G/T (IP camera compatibility), Modbus TCP/IP (for PLC integration), MQTT (for IoT cloud connectivity).
- Storage: 1× microSD slot (up to 512 GB) for local recording; supports motion-triggered, scheduled, or continuous recording.
3. Environmental & Mechanical Ratings
- Temperature Range: Operating: -40°C to +70°C (-4°F to +158°F); Storage: -55°C to +85°C (-67°F to +185°F) — withstands outdoor or factory-floor extremes.
- Vibration/Shock: 10–500Hz, 2g peak (random vibration, IEC 60068-2-6); 30g peak (11ms duration, IEC 60068-2-27) — durable for manufacturing or transportation use.
- Protection: IP30 (DIN-rail housing); IP65 optional (weatherproof enclosure for outdoor cameras, e.g., traffic monitoring).
- Power Supply: 24V DC (18–36V DC wide range); Power consumption: ≤15W (typical, including PoE+ for 1 IP camera).
4. Certifications
- Industrial: CE (EMC compliance: EN 61000-6-2/4), UL 508 (industrial control), RoHS 2.0.
- Hazardous Environments: ATEX Zone 2 (II 3G Ex nA IIC T4 Ga), IECEx — safe for oil refineries or chemical plants.
- Safety: IEC 61508 SIL 1 (suitable for non-safety-critical visual monitoring).
System Overview
The EMEROSN VE4022 acts as a “visual data hub” in industrial automation systems, integrating four core functional layers to ensure reliable video capture, transmission, and integration:
1. Video Acquisition Layer
This layer collects visual data from cameras and prepares it for processing. For example, in a manufacturing plant:
- An analog CCTV camera (BNC input) monitors a welding station for sparks or misalignment.
- An IP camera (PoE+ Ethernet input) captures 4K footage of a conveyor belt sorting products.
- The VE4022 automatically detects camera type, adjusts resolution (e.g., 1080p for welding, 4K for sorting), and applies initial noise filtering to reduce EMI from nearby machinery.
2. Compression & Processing Layer
The module’s 4th-gen video processing unit (VPU) compresses raw video to minimize bandwidth usage without losing critical detail:
- H.265 encoding reduces a 4K stream from 25 Mbps to 10 Mbps, enabling smooth transmission over factory Ethernet (even with other control data).
- Edge analytics (optional) detects anomalies in real time — e.g., “conveyor belt jam” or “welding spark intensity above threshold” — and triggers alerts without relying on a remote server.
3. Transmission & Integration Layer
This layer sends processed video to end systems and integrates with industrial control tools:
- Local Monitoring: HDMI output displays live feeds on a control room monitor, letting operators spot issues instantly (e.g., a misaligned product on the conveyor).
- Remote Streaming: Ethernet sends compressed streams to an NVR (for recording) or SCADA system (for overlaying video with sensor data, e.g., “conveyor speed = 0.5 m/s” + live feed).
- PLC Integration: Modbus TCP/IP lets the VE4022 send trigger signals to a PLC (e.g., “stop conveyor if jam is detected”) — closing the loop between visual data and machine control.
4. Monitoring & Diagnostics Layer
The VE4022 simplifies maintenance with built-in tools:
- Status LEDs: Per-channel LEDs indicate camera connectivity (green = active), encoding status (flashing green = streaming), or faults (red = no signal).
- Web Dashboard: Accessible via browser, it shows stream health (bitrate, latency), camera status, and recording storage. Technicians can remotely adjust settings (e.g., increase bitrate for 4K) or download footage.
- Alerts: Email/SMS/MQTT alerts trigger for issues like “camera disconnect” or “motion detected in restricted area” — reducing response time to potential problems.
Example: Water Treatment Plant Monitoring
A water treatment plant uses the VE4022 to monitor two critical areas:
- Input Channel 1: An IP camera (PoE+) watches a chemical dosing tank, streaming 1080p H.265 video to the SCADA system. If the chemical level drops below a threshold, edge analytics trigger an alert.
- Input Channel 2: An analog camera monitors a pump station, with footage recorded to a microSD card. If the pump vibrates abnormally (detected via video motion analysis), the VE4022 sends a Modbus signal to the PLC to shut down the pump.
- Output: HDMI displays both feeds on a control room monitor, while Ethernet streams data to a cloud dashboard for remote engineers to review.
Related Models in the VE-Series
The VE-series offers variants tailored to different channel counts, environments, and capabilities—here are key alternatives to the VE4022:
- EMEROSN VE4044:
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- 4 input + 4 output channels (double the VE4022) with dual Ethernet ports for redundancy.
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- Ideal for large facilities (e.g., a factory with 4 production lines) needing more camera coverage and reliable streaming.
- EMEROSN VE4022-AI:
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- AI-enhanced model with built-in machine learning (e.g., YOLOv8 for object detection).
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- Detects specific objects (e.g., “missing safety helmet” in a refinery) or process defects (e.g., “cracked pipe”) — suitable for safety-critical or quality-control applications.
- EMEROSN VE4022-EX:
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- Explosion-proof variant (ATEX Zone 1, IECEx) with reinforced housing and intrinsic safety barriers.
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- Safe for hazardous environments (e.g., oil rigs, chemical processing plants) where flammable gases are present.
- EMEROSN VE4022-W:
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- Weatherproof (IP67-rated) with 4G LTE/Wi-Fi 6 for wireless streaming.
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- Optimized for outdoor use (e.g., solar farms monitoring panel arrays, highway traffic cameras).
- EMEROSN VE3022:
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- 3rd-gen entry-level model (max 1080p resolution, no edge analytics).
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- Cost-effective for basic monitoring (e.g., a small warehouse’s loading dock security).
- EMEROSN VE4022-PoE:
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- Enhanced PoE+ model with 2 PoE ports (60W total) to power high-power cameras (e.g., thermal imaging cameras for electrical panel inspection).
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- Eliminates the need for external power supplies for energy-hungry devices.
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