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Broadcast Video Router Product

Overview

A broadcast video router is the traffic cop of a television station. In a facility with multiple cameras, graphics engines, satellite feeds, and replay servers, the router decides which video source goes to which destination—the transmission line, a monitor wall, a tape recorder, or a secondary path. Hundreds or thousands of connections might exist, but only a fraction are active at any moment. A [[video-router-mainframe|modular rackmount system]] with a [[video-router-control-processor|smart processor]] and a [[video-router-crosspoint-card|crosspoint switch matrix]] lets operators instantly reconfigure the video flow without manual patching or cable changes.

Crosspoint switching

At the heart is the [[video-router-crosspoint-card|crosspoint switch]]—an integrated circuit (or set of ICs) that acts like a telephone switchboard for video. Imagine a grid: rows are inputs (camera 1, camera 2, graphics, replay, etc.), columns are outputs (transmission, monitor wall, archive tape, etc.). Each intersection is a switch that can be turned on or off. When you close the switch at row 3, column 1, video from input 3 is routed to output 1.

The [[video-router-control-processor|main processor]] manages this grid. An operator presses buttons on the [[video-router-control-panel|operator panel]] or sends a command via Ethernet, saying "put input 5 on output 2." The processor updates the [[video-router-crosspoint-card|crosspoint matrix]], closing the appropriate switches and opening others, all within a single frame time (16.7 ms at 60 Hz). To the viewer watching the transmission output, the switch is seamless—no flash, no glitch, just a cut from one camera to another.

Modular IO

Most large routers use [[video-router-input-module|plug-in input cards]] and [[video-router-output-module|output cards]] rather than fixed rear panels. This modular approach allows customization: install SDI cards for cameras, component cards for graphics, fiber cards for long-distance feeds. If a facility needs to add more cameras next year, just slide in a new input card. The [[video-router-backplane|backplane]] provides power and high-speed interconnect; all audio/video signals route through the [[video-router-crosspoint-card|crosspoint switch]].

Synchronization

All video in the facility must sync to a master clock—typically a [[broadcast-tripod-pedestal-timing-sync|blackburst reference]] from the master control. The [[video-router-control-processor|processor]] locks its frame timing to this reference, and the [[video-router-crosspoint-card|crosspoint switch]] changes state only during vertical blanking (the brief gap between frames). This ensures zero glitches when switching—the operator can cut between cameras on air without artifact.

Redundancy

Broadcast routers are mission-critical. A facility that loses video routing loses all on-air transmission. So modern systems are designed for fault tolerance:

  • Dual [[video-router-redundant-power-supply|power supplies]] with automatic failover
  • Modular [[video-router-input-module|input/output cards]] so a single card failure doesn't take down the entire system
  • Optional dual [[video-router-control-processor|processors]] for hot-standby failover
  • Watchdog timers that detect a processor hang and automatically switch to the backup

Some installations use dual routers in parallel, each capable of handling the full video load independently.

Control options

The [[video-router-control-panel|button matrix]] on the front allows intuitive operation: press input 5, then press output 2, and the switch is made. Most routers also store preset configurations—e.g., "show opening," "show A," "show B"—that instantly recall complex routing patterns with one button. Remote control via Ethernet and SNMP allows a master control room or even a remote facility to manage the router over the network.

Performance metrics

Video routing latency is critical for live production. The [[video-router-crosspoint-card|crosspoint switch]] introduces <1 frame of delay (typically 8–16 ms), which is imperceptible to viewers but noticeable to engineers watching multiple monitors. The [[video-router-input-module|input cards]] include optional [[video-router-equalizer-ic|cable equalizers]] to compensate for signal loss over long runs, and [[video-router-output-driver|output drivers]] buffer the signal for distribution to multiple destination devices.

Optional features

High-end routers offer optional [[video-router-optical-bus|fiber optic backplanes]] for maximum EMI immunity and remote IO placement, downstream [[video-router-output-module|keyers]] for real-time graphics overlay, and integrated audio routing (synchronized with video so a lip-sync tie-up to a camera also brings its associated audio).

In small facilities, a single [[video-router-input-module|input card]] with a few cameras might suffice. Large broadcast centers run routers with 64+ input and 64+ output cards, switching terabytes of video daily.

Build & assembly graph

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Bill of materials

11 top-level lines · 59 rows shown · 164 parts total · indented to 3 levels
# Item / sub-assembly Part no. Qty/assy Ext. qty Parts Type
1 Mainframe 5 parts video-router-mainframe 1 6 assembly
1.1 Frame Extrusion video-router-frame-extrusion 1 part
1.2 Front Panel video-router-front-panel 1 part
1.3 Rear Panel video-router-rear-panel 1 part
1.4 Side Panels video-router-side-panels 2 part
1.5 Fastener Set fastener-set 1 part
2 Control Processor 6 parts video-router-control-processor 1 56 assembly
2.1 Bare PCB pcb-bare 1 part
2.2 Microcontroller mcu 1 part
2.3 System RAM video-router-system-ram 1 part
2.4 Flash Storage video-router-flash-storage 1 part
2.5 Connector connector 2 part
2.6 SMD Passive (R/C/L) smd-passives 50× 50 part
3 Crosspoint Card 6 parts video-router-crosspoint-card 1 45 assembly
3.1 Crosspoint Switch IC video-router-crosspoint-switch-ic 1 part
3.2 Video DAC video-router-video-dac 1 part
3.3 Buffer Amplifier video-router-buffer-amp 1 part
3.4 Bare PCB pcb-bare 1 part
3.5 SMD Passive (R/C/L) smd-passives 40× 40 part
3.6 Connector connector 1 part
4 Input Module 5 parts video-router-input-module 1 14 assembly
4.1 Input Connector video-router-input-connector 4 part
4.2 Cable Equalizer video-router-equalizer-ic 4 part
4.3 ADC IC video-router-adc-ic 4 part
4.4 Input PCB video-router-input-pcb 1 part
4.5 Connector connector 1 part
5 Output Module 4 parts video-router-output-module 1 10 assembly
5.1 Output Driver video-router-output-driver 4 part
5.2 Output Connector video-router-output-connector 4 part
5.3 Output PCB video-router-output-pcb 1 part
5.4 Connector connector 1 part
6 Backplane 4 parts video-router-backplane 1 6 assembly
6.1 Backplane PCB video-router-backplane-pcb 1 part
6.2 Connector Frame video-router-connector-frame 1 part
6.3 Ribbon Cable video-router-ribbon-cable 3 part
6.4 Fastener Set fastener-set 1 part
7 Control Panel 5 parts video-router-control-panel 1 5 assembly
7.1 Button Matrix video-router-button-matrix 1 part
7.2 Panel LCD video-router-panel-lcd 1 part
7.3 Panel PCB video-router-panel-pcb 1 part
7.4 Serial Port video-router-serial-connector 1 part
7.5 Connector connector 1 part
8 Power Module 5 parts video-router-redundant-power-supply 2 5 assembly
8.1 PFC Stage video-router-pfc-stage 2 part
8.2 Main Converter video-router-main-converter 2 part
8.3 Transformer video-router-isolation-transformer 2 part
8.4 Output Filter video-router-output-filter 2 part
8.5 Connector connector 2 part
9 Cooling Module 5 parts video-router-cooling-module 1 5 assembly
9.1 Blower Motor blower-motor 1 part
9.2 Thermal Sensor video-router-thermal-sensor 1 part
9.3 Fan Controller video-router-fan-controller 1 part
9.4 Air Filter video-router-air-filter 1 part
9.5 Fastener Set fastener-set 1 part
10 Optical Backplane 3 parts video-router-optical-bus 1 5 assembly
10.1 Optical Transceiver video-router-optical-transceiver 2 part
10.2 Optical Coupler video-router-optical-coupler 1 part
10.3 Fiber Connector video-router-fiber-connector 2 part
11 Fastener Set fastener-set 2 part

Sourcing — likely vendors

Companies that make this · indicative price $50–$3k · MOQ & lead are typical
VendorHQSpecialtyMOQLead time
🇯🇵Sony
sony.com ↗
Tokyo, JP Consumer electronics 1,000 units 8–12 wks
samsung.com ↗ Suwon, KR Electronics & displays 1,000 units 8–12 wks
🇺🇸Harman
harman.com ↗
Stamford, US Audio (JBL, AKG) 1,000 units 8–12 wks
🇺🇸Bose
bose.com ↗
Framingham, US Audio 1,000 units 8–12 wks
yamaha.com ↗ Hamamatsu, JP Audio & instruments 1,000 units 8–12 wks

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