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SuperGate
Damage
and
Container OCR Portal System
CONFIDENTIAL
Camco Technologies
Technologielaan 13
B- 3001 Heverlee
Phone: 0032 (0) 16 389272
Fax: 0032 (0) 16 389274
Email : Jan.Bossens@Camco.be
Outside:
• Concrete area with conduits for cabling
• Metal portal to fix the camera and lighting equipment
• 3 IP-Line Scan Cameras, 2 sides and one for the top
• 2 x IP-1,3 Mpixel color cameras for truck/container front and back
• 2 x IP-1,3 MPixel B/W cameras for license plate
• Specific lighting system for the line scan cameras and front license plate
• Triggering system, to stop and start the image capture process. All pictures
are taken on one position (middle of the portal).
• Electricity/data cabinet
Image acquisition
• A first picture is made with the front camera, looking to the top-front
of the trailer or container.
• A fraction of a second later the line-scan cameras start making the
picture of the 2 sides and the top. During acquisition the JPEG image is
built by compressing in real time the image information.
• Another process measures the speed on base of the scanned images.
The scanning frequency is adapted to the measured speed.
• A different process measures the contrast/brightness of the pictures,
the shutter-time or iris is changed during acquisition to obtain the best
quality.
• When the vehicle leaves the portal a new signal is generated that
triggers the back cameras. This is also the moment the line scan
cameras are stopped
• JPEG images and OCR results are send to the servers.
Operator Console
A few seconds after a pass trough of a vehicle, the pictures and corresponding
OCR results are presented on the Operator Console. The Operator Console
allows a real-time control and view on one or more lanes from a distance.
Host interface
The same time the information (OCR, pictures) are send to the customers
Terminal Operating System.
Backup en Internet
The zip-file is not only stored locally but also distributed towards the second
AGS server, a Storage Server and the Internet Server. Every server on his
own rebuilds a database starting from the information available in the zip-files.
This means that the images are available from internet a few seconds after
the drive-trough.
2.1.1 Overview
Equipment not supporting Ethernet is linked via the LEC (Lane Equipment
Controller).
All the cameras are intelligent; They execute on their own processor the most
CPU intensive tasks as image acquisition, OCR and JPEG compression etc.
This parallel computer system makes the concept very scalable, as adding
cameras will not create extra charges on the AGS Server.
Camera mounting
All cameras are mounted on specific beams allowing an accurate vertical and
horizontal positioning of the camera housings.
The cameras are delivered with aluminum beams; cables are integrated into
the beam (protection against damage). Cables are always protected by
flexicon tube.
The Camco LSC-2113 camera produces legible images of one of the 3 sides
(top, left and right) of passing vehicles. The LSC-2113 is a line scan camera;
it scans at high speed and high resolution (2 or 4 mm/pixel) the surface of
the vehicle. Because of the high scan rate the produced images are very
sharp even of fast moving objects. It is the same technology used as in
flatbed scanners. A sophisticated speed measurement system adjust
continuously the scanning frequency, this avoids images are to long or to
short. The Kodak sensor used in the camera is the best on the market today,
it uses separate pixels for the three basic colors, therefore the images are of
an exceptional color and brightness.
The camera is equipped with ACCR. ACCR is Automatic Container Code
Reader software. The camera produces JPEG color images in different formats.
Motorized lenses
The lenses on the Linescan and 4Mpixel cameras are standard 35mm lenses
(used on 35mm reflex cameras). Unique is the fact we developed software to
drive motorized Canon and Canon compatible lenses. Practically our camera
can change the focus and iris. Controlling the mechanical iris is very
important in open air solutions (systems without canopy).
Every unit contains 3 TL80 Watt lamps and 3 separate electronic ballasts. In
case a lamp or ballast is broken, it will only slightly influence the brightness of
the pictures. Both lamps and ballast are standard of the shelf products.
Another benefit of this approach is the fact TL lamps have a long lifetime
(20.000 hour or >1,5 year) what makes this solution very economical. The
lighting systems uses less then 3KW/portal and can be activated via the LEC
in order to gain electricity during day and closing time.
One lane needs 10 lighting units (3 on each side and 4 for the top). Those are
all attached to the lighting portal. The lighting unit is made in aluminum,
weights about 10Kg/piece. To replace the lamps, the front cover can manually
be opened by use of 8 tub-screws.
License plate
SuperGate
For each LPR area two lamps on a separate beam are configured, one
on the opposite side of the camera and one on the same side. The
lamps are Schreder NEOS2 type with a specific mirror to light the front
of the truck without disturbing the driver. The Lamps are based on
150Watt CDM/T lamps (low power, high output, and 8.000hrs lifetime).
The ballasts of the Lamps are HF-types to avoid 50Hz interference with
the high speed license plate cameras. Advantage of visual light is the
fact the front of the truck is completely visible.
Gate Lanes
In the gate lanes we use different type of camera (trucks are standing
still). For this camera we use Infrared lamps. With infrared light only
the license plate is visible. As it is used for matching it is no issue.
LEC
The LEC (Lane Equipment Controller) is Camco developed embedded device
running specific firmware to control all non-Ethernet devices as loop-
controllers, laser beams, traffic lights, Seal RFID readers, and barriers. It has
several Ethernet interfaces, several I/O ports and RS232 ports. The firmware
talks with the Lane Manager software running on the AGS Server. The LEC
also switches the power of the cameras and lighting system allowing full
remote maintenance of the system. For reason of maintenance the LEC is
equipped with a dual CPU’s, the second CPU allows re-programming and re-
boot of the master CPU from distance.
Ground loops
Generally ground-loops are not reliable and therefore to be avoided in
systems requiring a very high MTBF. Camco uses the own developed
Speedbox as triggering device.
Speedbox
Speedbox is a device based on infrared light beams. The system is used to
trigger the cameras and to measure the initial speed of the truck. The
speedbox is fully redundant; also sensors and IR beams are tested before
every passage. Speedbox has special sun-covers to avoid sun over lighting
the sensors;
Cabinet
As SuperGate is based on embedded systems, including the cameras, no
outdoor electrical cabinet is needed for housing PC’s and other IT-material.
Only a footpath cabinet is used to host both electricity and 19” data
equipment. The cabinet is pre-wired at Camco.
Electricity (AC)
Cabling is straight forward; all the cameras/lane are on a separate 240V 16A
circuit that can be controlled via the LEC (Lane Equipment Controller). This
allows a restart from distance (remote maintenance). The lighting system
uses 2 outlets controllable via the LEC (3KW). An UPS is not needed as
cameras are power down proof.
Electricity (DC)
Low voltage connections are only needed between the LEC and the ground-
loop controllers (if any are configured). Ground loop controllers are installed
in separate boxes. The power can be switched remotely in order to reset them.
Data (Cat5)
The same cabinet hosts also the LEC, a CAT5 patch panel and an Ethernet
switch with optional fiber optic connection to the computer room. From the
patch panel we have 7 CAT5 cables to the cameras.
E quipm ent/Lane Nom inal (W ) M ax (W ) Qty ins talled Total Nom inal (W ) Total M ax (W )
The varia section includes low voltage equipment for traffic control, relays and
switching. The cameras, lighting units, network switch, SpeedBox unit and
varia can operate at 240 V.
If the prime power source isn’t able to deliver high-quality output (e.g.
voltage drops, distortion…) a small battery-based UPS system (2 kW / lane)
can be used as filter for the camera power circuit, network switch… only
(excluding all lighting).
Customer responsibility
Camco expects from the customer power and fiber cabling up to the electrical
cabinet. From there Camco does the rest of the installation.
Camera drivers
In function of the connected camera a specific library is used. Communication
towards the cameras is done via a PCI Video frame grabber (Camco
development).
OCR engines
Every camera has its own OCR engine. Depending of the function (license
plate, container, and chassis) a different module is loaded.
JPEG compression
The Linescan cameras have a special JPEG compression module; it generates
the JPEF on the fly.
AREA 1
AREA 3
AREA 2
This zone has also the height restrictor, to avoid damage to the system (see
yellow construction).
4.3. Foundation
The camera system needs a stable underground in zone 2 and 3 (preferably light
grey concrete). The concrete foundation is specific in the sense:
• includes piping for the cables
• calculated to fix and hold the portal
• includes road (stable underground) and road-borders (to prevent damage
to the lighting fixtures and cameras)
Trigger quality
Although obvious, it is not always simple to take the images at the right time. For
triggering the Car lane system we use Lidars (Laser rangers), SuperGate uses
modulated infrared beams. We avoid using ground-loops as triggering is unstable
and the life-time is unpredictable (depends of underground)
Some examples:
With 2 cameras (back and top) only 94% (in best case) container read rate
can be achieved. This at the condition it is a single container.
In case the truck has two 20” containers, the rear-end of the first container is
not visible. The OCR system depends in that case only from the top camera.
The result will drop to less then 90%.
SuperGate reads always the maximum number of codes that can be read on a
container box:
- 6 numbers on a 20” or 40” container
- 5 numbers per container on combined cargo (2x20” containers on one
chassis)
• The 98% number is based on the global traffic (all trucks driving
through the camera systems are counted) and not on a selection of
“computer readable” images –as some do.
• It is counted during a 24h period
• The unit is container and not truck (truck with 2 containers is counted
as 2)
• Up to 3 customers selected days are audited, spread of a period of 3
weeks.
• During an audit we check every picture manually against the OCR
result
• The audit report is very detailed, it includes the pictures of the bad
OCR reads
Therefore we propose to only use the lists to speed up the OCR, not to correct
our OCR results. This means that we would not allow any mismatch between
the lists and the raw OCR result (although when the OCR finds several
possible results, it will choose the one that matches the lists). When two or
more cameras find the same result, we will present the result as being 100%
confident.
Although OCR results of all cameras are already combined while performing
the OCR, only when two cameras come up with the same result independently
of each other, a 100% confidence will be returned.
At the speed of 30km/h it takes 2 seconds to drive and 2 seconds OCR for a
single container giving a total of 4 seconds or 15 trucks/minute (900
trucks/hour).
* For SAPO we use different kind of camera technology in the gate lanes as the
trucks are standing still in front of a dialog boxes.
Cameras
All cameras work independently from each other and work completely
autonomous. Although they exchange information between each other during
the OCR process, they can work without this facility. If one or several OCR
cameras stop working, it will influence only marginally the OCR performance.
Segmentation beams
The infrared beams in the Line scan cameras are doubled; each camera has a
sender and a receiver. Only one pair is used (the one that first reports that
the beams are functioning correctly).
Speedbox
For reasons of redundancy every Speedbox has a double pair of infrared
transmitter/receivers. If one pair is down, the other pair is used. Also the
power supply is split up, some beams uses the power supply of the Line scan
cameras, some uses a separate built-in power supply.
Ground-loops
None
LPR light
2 units are configured, of one fails the OCR quality will drop a little bit.
Gate lane uses Infrared lights based on long-life LED technology.
Traffic Lamp
High life Led based lamp is advised
Ethernet switch
No fallback solution is configured. Cabling via patch panel can easily be
rerouted.
This picture shows the statistics of 9 camera SuperGate system during several
weeks. Every green stripe is the performance of one day. The red stripes are
days where a camera performed less because of unknown reason (dirty glass
or unfocused for instance).
Remote monitoring