Crane OCR Installation: Survey, Mounting and Commissioning Steps
Installing OCR on a working container crane is a careful job. The crane has to keep earning, the work happens at height and the equipment must survive wind, salt and vibration. A clear plan makes the difference between a quick installation and a long one. This guide sets out the steps from survey to acceptance and what the terminal can prepare in advance.
Key takeaways
- A survey of each crane type comes first, because mounting points differ.
- Work is planned around crane downtime windows, with safety permits in place.
- Commissioning includes the PLC link, image checks and accuracy tests on live moves.
- Agree acceptance criteria and exception handling before go-live.
Step 1: Survey the cranes and the site
Check each crane type, the mounting points for cameras, cable routes, power, network access and how containers are handled. Note lighting conditions, glare and the typical container markings. The survey decides camera count and positions.
Step 2: Prepare permits, downtime and access
Agree downtime windows with operations, arrange work-at-height permits and plan how equipment will be lifted to the crane. Short, well-planned windows let installation proceed without stopping the berth for long.
Step 3: Mount, cable and power
Cameras, lights and enclosures are fitted and cabled along the crane to a processor. Cable runs must allow for crane movement, wind and vibration. Network and power protection should follow the terminal’s safety rules.
Step 4: Connect the PLC and configure the software
The OCR system is linked to the crane PLC for start and stop signals and to the terminal system for results, as set out in crane OCR integration with the TOS. Configure the container ID rules, the ISO code lists and the exception workflow.
Step 5: Calibrate, test and accept
- Align cameras and check image quality at night and in bright light.
- Run live moves and compare the OCR results with the real container numbers.
- Review exceptions and tune lighting and software.
- Sign off against the agreed acceptance criteria, then train operators and checkers.
Crane OCR installation and commissioning by Suraj Informatics
Suraj Informatics surveys, installs and commissions crane OCR systems on STS and yard cranes, and supports operators after go-live. See crane OCR for yard cranes for yard-specific points.
Crane OCR installation: common questions
How long does crane OCR installation take?
It depends on the crane type and downtime windows. A survey gives a realistic plan.
Does installation stop crane operations?
Work is planned in short downtime windows so operations are disturbed as little as possible.
What should the terminal prepare?
Permits, downtime windows, access, power and network points, and the interface details for the TOS.
How is accuracy checked?
By comparing OCR results with the real container numbers on live moves during commissioning.
Talk to our crane OCR team
Tell us about your cranes and current checking process, and we will suggest the right OCR setup.
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