Contents
Project Context
A leading transportation system integrator in South America was upgrading a toll plaza traffic management system and required multiple customized LED devices from a reliable supplier.
The project involved seven different types of LED products, including fog warning lights, toll rate indicators, user information displays, lane control signs, and marquee LED sign segments.
The customer was looking for a professional LED manufacturer capable of providing:
- Multiple Customized Products: Development and delivery of several product types under a tight schedule.
- Consistent Design and Manufacturing Quality: Coordinated product development across devices with different structures, pixel configurations, communication methods, and mechanical designs.
- Technical Integration Support: Support for communication integration and system commissioning.
Comsight quickly evaluated the requirements and provided a complete custom LED traffic display solution for the toll plaza project, covering product design, communication methods, software support, and manufacturing.
Technical Challenges in the Toll Plaza Project
The toll plaza project required several custom LED devices to work together within one traffic management system.
The main challenges involved coordinating different product designs, meeting outdoor reliability requirements, and adapting devices with different control methods to the customer’s existing traffic management system.
1. Developing Multiple Customized LED Products Under a Tight Schedule
Unlike standard LED displays, this project involved seven different product types with unique specifications. These products required different display structures, pixel configurations, communication methods, and mechanical designs.
Comsight needed to develop and manufacture all products efficiently while maintaining consistent quality and compatibility across the complete project.
2. Meeting Outdoor Reliability Requirements
All products were designed for outdoor toll plaza environments and required:
- Clear Daytime Visibility: High-brightness LED performance for readable information in daylight.
- Front Protection: UV-resistant and impact-resistant front protection.
- Weather Protection: IP65 protection for outdoor use.
- Durable Aluminum Housing: Designed for long-term outdoor operation.
The LED signs needed to withstand demanding outdoor conditions while maintaining stable 24/7 operation.
3. Providing a Complete Traffic Management Display Solution
The customer was not looking for a single product but a complete series of traffic control devices, including:
- Fog Warning Traffic Lights
- Toll Rate Indicators
- Variable Message Displays
- Lane Control Signs
- Directional Arrow Signs
- Marquee LED Sign Segments
These traffic LED signs served different functions and required different control methods. Comsight therefore needed to coordinate their design and communication interfaces so that each product could integrate with the customer’s existing toll plaza traffic management system.
Comsight’s Custom LED Traffic Management Solution
As a professional custom LED display manufacturer, Comsight provided a one-stop solution covering design optimization, engineering development, production, and delivery.
1. Customized LED Traffic Sign Development
Based on the customer’s requirements, we designed and manufactured seven customized LED traffic products:
- Fog Warning Traffic Light
A compact outdoor LED warning light featuring a high-impact, UV-resistant polycarbonate housing, high-brightness amber LED lighting, and an integrated flashing function for fog warning applications.
- Toll Rate Indicator
A multi-color LED tariff display supporting 8 color categories, with 120 mm digit height and 10 mm pixel pitch, providing clear and flexible toll information display.
- User Display
A programmable LED information display supporting up to 3 lines of variable text, with RS232/RS485 communication and optional Ethernet TCP/IP connectivity for system integration.
- Double Arrow Deviation Sign
A high-definition LED traffic sign displaying green or red directional arrows, designed with low power consumption, aluminum housing, IP65 protection, and UV-resistant front protection.
- Lane Control Sign (Cross/Arrow)
A durable LED lane control indicator designed for toll lane management, supporting red cross and green arrow signals with reliable outdoor operation.
- Marquee LED Sign Segments
Two customized LED modules displaying “Cashier” and “Multitag”, featuring aluminum cabinets, polycarbonate protection, and IP65 outdoor protection.
2. Communication Method Optimization Through Technical Discussion
During the engineering stage, Comsight worked closely with the customer’s technical team to evaluate the most suitable communication methods for different LED products.
Based on the application requirements and the customer’s existing control system, the communication solutions were optimized as follows:
Lane Control Signs, Double Arrow Deviation Signs, and Marquee LED Sign Segments
We initially recommended RS485 communication to create a unified communication method across these LED products.
After reviewing the customer’s existing control architecture, the customer preferred a simpler and more direct method. We therefore adopted dry-contact control, which provided:
- Easier Integration: A better match with the customer’s existing control platform.
- Simplified Operation and Maintenance: A more direct control method for daily operation.
- Reduced Deployment Complexity: Less communication configuration during system deployment.
User Display and Toll Rate Indicator
The User Display and Toll Rate Indicator needed to exchange data with the customer’s information management system. For these two products, we adopted RS485 communication with the MCS protocol.
The customer’s software team could modify its existing information system according to Comsight’s MCS communication protocol. This enabled direct communication and data updates between the management system and the LED displays.
The solution provided:
- Flexible Integration: Compatibility with the customer’s existing software platform.
- Reliable Long-Distance Communication: Stable data exchange for the project environment.
- Support for Future Expansion: A standardized communication protocol for subsequent system development.
3. Custom Test Software to Accelerate System Integration
To accelerate system integration and simplify commissioning, we developed dedicated test software for the Toll Rate Indicator.
During the software integration stage, the customer needed to modify its own information system according to the MCS communication protocol. Without a testing tool, it would be difficult to verify the communication results and directly observe how the display responded to different commands.
The customized test software enabled the customer to:
- Verify RS485 communication performance before final system integration
- Send test commands directly to the Toll Rate Indicator
- Modify display data and check the real-time output
- Troubleshoot communication issues efficiently during commissioning
This significantly reduced integration difficulties and helped accelerate project progress.
4. Professional Project Support and Close Communication
With several customized products and control methods progressing in parallel, the customer needed clear and timely project updates.
Throughout the design and production process, we maintained close communication with the customer and provided:
- Product design confirmations
- Engineering suggestions
- Production progress updates
- Product photos during manufacturing
- Testing results and software support
This regular communication gave the customer a clear view of the project’s progress and allowed technical questions to be discussed before final delivery.
The customer highly appreciated Comsight’s professional support and commented:
“I would like to sincerely thank you for the information provided and for the excellent support and close follow-up you have given us throughout this process.”
Project Results: Coordinated Delivery Across Multiple LED Products
Comsight successfully completed the development and delivery of all custom LED traffic products for the toll plaza project. The products covered multiple categories and used different communication and control methods, but were developed and delivered as one coordinated solution.
The project demonstrated Comsight’s capabilities in:
- Multi-Product Custom Development: Developing several LED traffic products with different structures and functions within one project.
- Communication Integration: Adapting dry-contact control, RS485 communication, and the MCS protocol to the customer’s existing system.
- Traffic Display Engineering: Supporting toll rate displays, user information displays, lane control signs, warning lights, directional signs, and marquee LED segments.
- Customer-Specific Software Support: Providing dedicated test software for communication verification and system commissioning.
- Coordinated Project Execution: Managing engineering, production, testing, technical communication, and delivery across the complete product range.
Beyond manufacturing LED displays, Comsight provides engineering-level support to optimize system integration, communication methods, and project implementation.
Our experience in toll-road applications also includes a custom bi-directional TSSI LED display for a USA toll highway, another project involving customized hardware and communication integration.
Why the Customer Chose Comsight?
The customer selected Comsight because the project required more than standard LED products. It needed strong customization capabilities, communication integration support, and coordinated production across several traffic display devices.
These requirements aligned with three of Comsight’s key strengths:
- Strong Custom LED Display Development Capability
With more than 25 years of experience in LED display manufacturing, Comsight specializes in customized LED solutions for complex industrial and commercial applications.
From small LED indicators to large-scale traffic information displays, Comsight provides professional engineering support to transform customer requirements into reliable products.
Beyond manufacturing LED displays, Comsight provides engineering-level support to optimize system integration, communication methods, and project implementation.
- Complete LED Display Support for ITS Applications
Comsight is not only an LED display supplier but also a solution partner capable of providing custom LED products and engineering support for:
- Toll plazas
- Highway traffic management
- Lane control systems
- Variable message signs (VMS)
- Intelligent Transportation Systems (ITS)
With Comsight, you only need one experienced manufacturer for your custom LED traffic display project. We coordinate product development, communication support, production, testing, and delivery, helping you maintain consistent engineering quality and project communication from start to finish.
- Fast Response and Flexible Production
Projects involving several custom products often require frequent technical decisions and close coordination between engineering, software, and production teams.
For this toll plaza project, Comsight provided timely technical evaluation, design feedback, production updates, testing support, and flexible manufacturing coordination. This helped the customer manage the project more efficiently and prepare the products for system integration and deployment.
Comsight: Your Reliable Partner for Custom LED Traffic Display Solutions
From concept to final delivery, Comsight provides tailored LED solutions for transportation, tolling, and intelligent traffic management applications.
Planning a toll plaza or ITS display project? Send us your required product types, control methods, communication protocols, and installation conditions. Our engineering team can help you develop a coordinated custom LED traffic display solution.
Your Idea, Our Solution
— Complete Custom LED Traffic Display Solutions Provider
