Case Study
Truktronics was tasked with replacing the Port Entry Light system with the aim of improving performance and reliability as well as modernising the user interface for more seamless system control.
The incumbent control system was built around off the shelf remote IO devices built into a free wired electrical panel which had many additions through out its life. The lamps were also hard wired making maintenance difficult.
None of the parts were designed to live in the harsh salt water environment and it was time for an upgrade.
The system contains two independent bi-directional locations controlled from the same interface both remotely via a web UI and locally via a physical control panel.
One is the control of a harbour, the other is the control of a river channel. The river side also controls a fog horn for the whole port.
Solution
The Truktronics solution replaces the entire system from the control to the signal lights.
The control system is a Truktronics developed remote web UI interfaced over a private WAN running on a server across the country. Truktronics also redesigned the back up physical controls based on site at the location. Both the web UI and physical controls respond to updates from each other anywhere on the private WAN.
The light controllers positioned at the base of the signal light towers are bespoke with a totally custom PCB design specific for the application. One location also interfaces and controls the existing port fog horn. These controllers are designed with a minimum 10 year life and safety in mind.
The final part are the bespoke signal lights them selves. Across the 12 light system there are eight light variants based on colour options, intensity and beam angle. The entire light units are bespoke to the PEL application taking into account the 10 year design life and the environmental conditions. The light design is extremely robust with a 20 mm marine grade aluminium base plate and 5 mm polycarbonate UV stabilised main body.
All materials used in the system were specifically chosen for the environment and the entire system is designed as maintenance free* for a minimum period of 10 years.
*the 10 year design life is based on ‘design for reliability’ methodology using appropriate materials/design techniques for the environment and application as well as derating electronic components to prevent stress failure. The chance of premature failure due to component manufacturing defects or physical damage to any part of the system cannot be controlled through the product design process