How Is a Container Number Recognition System Deployed on a Rail-Mounted Gantry Crane? A Complete Guide to the Installation Process

Automatic container number recognition technology is becoming a key component of smart port development. Deploying a container number recognition system on a rail-mounted gantry crane (RMG) can significantly improve operational efficiency while reducing errors caused by manual recording. So, how exactly is this system installed and deployed on an RMG? This article explains the complete implementation process.

一. Hardware Selection and Installation Locations

The key to container number recognition on an RMG is to capture clear images and ensure accurate recognition. Based on the structure and operating characteristics of the crane, cameras are usually installed at several critical positions:

1. Under the Trolley Frame on Both Sides of the Spreader

This is the most important installation position. A set of industrial cameras and LED illuminators are installed on both sides of the spreader. When the spreader lowers to pick up a container, the cameras can capture the container number area at close range, ensuring clear and accurate character recognition.

2. Inner Side of the Crane Legs on the Landside Channel

Side-view recognition cameras can be installed on the inner side of the crane legs to capture container numbers on the side panels. This deployment method is commonly used together with yard gate systems to achieve multi-angle redundant recognition and improve overall accuracy.

3. Top of the Main Beam (For Long-Distance Recognition)

For some high-level automated container yards, long-focus cameras can be installed on the top of the main beam to capture container numbers in advance while the spreader is moving. This solution is suitable for scenarios requiring extremely fast recognition and automated operations.

二. Power Supply and Network Deployment

A container number recognition system requires stable power and reliable data transmission support.

Power Supply Solution:

Power is usually supplied from the RMG electrical control cabinet. A voltage stabilizer and UPS uninterruptible power supply are added to prevent equipment restart caused by voltage fluctuations. Since illuminators consume relatively high power, sufficient power capacity must be reserved during system design.

Data Transmission Solution:

Industrial cameras generate large amounts of image and video data. A dual-link transmission solution combining fiber optic communication and wireless bridge backup is recommended. Equipment installed on the spreader transfers data through cable chains or power rails to the operator cabin, and then connects to the central control platform through fiber networks.

三. Software Integration and Trigger Mechanism

After hardware installation, software integration and commissioning determine the final recognition performance.

The recognition system needs to communicate with the RMG PLC control system and obtain signals such as:

- Spreader landing detection

- Spreader locking status

- Lifting height information

These signals are used to accurately determine the optimal image capture timing.

When the spreader completes container locking and starts lifting, the system automatically triggers the cameras to capture images. The images are then transmitted to the recognition server, which returns the container number result within 1–2 seconds.

Through standard API interfaces, recognition results are transmitted in real time to the Terminal Operating System (TOS). The system automatically compares the recognized container number with the planned operation data. If an incorrect container number or recognition failure is detected, an alarm message will immediately appear on the control interface, allowing operators to handle the situation quickly.

四. Vibration Protection and Environmental Adaptability Design

During operation, RMG cranes generate continuous high-frequency vibration, creating challenges for equipment stability.

During installation, cameras and illuminators should be mounted with dedicated shock-absorbing brackets. Industrial-grade wide-temperature devices should be selected to withstand harsh port environments, including:

- Salt spray corrosion

- High temperatures

- Dust and moisture

For special operating conditions such as nighttime, rainy weather, and backlight environments, intelligent brightness adjustment technology should be applied to the lighting system to ensure reliable recognition performance around the clock, with recognition accuracy maintained above 98%.

The deployment of a container number recognition system on a rail-mounted gantry crane is a comprehensive engineering project integrating hardware, software, and industrial automation technologies.

A successful implementation depends on four key factors:

- Proper camera installation planning

- Stable power supply and data transmission

- Accurate triggering logic

- Reliable industrial-grade protection design

Only by optimizing every deployment step can the full value of automatic container number recognition be realized, enabling smarter, faster, and more efficient terminal operations.