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Customized Bi-Directional TSSI LED Display for USA Toll Highway
A purpose-built P12.5 LED solution engineered for enforcement visibility, reliability, and real-time monitoring.
A U.S. toll highway authority required a bi-directional, high-brightness TSSI LED display to be installed over each lane on the toll gantry.
The display is used by CHP enforcement vehicles during inspection and must achieve strict visibility, durability, communication, and safety requirements.
Comsight delivered a fully customized LED solution—model WZG20x20-1W-12.5-ODF—combining special pixel pitch, ultra-high brightness LEDs, PoE power, MCS protocol integration, and CSA-certified safety performance.
Context & Requirements
To satisfy the tollway’s operational enforcement needs, the LED traffic display had to support rigorous performance metrics:
- Bi-directional visibility: Legible from both directions of traffic.
- long-distance readability： Minimum 305 mm character height.
- Extreme Brightness: ≥ 9,000 nits brightness at 50% LED loading to combat sunlight.
- Intelligent Monitoring: Real-time LED failure detection with automatic reporting to the control center→ RSS → MOMS.
- Flexibility: Ability to display any letter or digit required by enforcement.
- Durability: Outdoor-grade durability capable of 24/7 operation on a toll gantry.
These requirements demanded a complete understanding of hardware architecture and control protocols.
Project Challenges
The project presented several engineering hurdles that standard off-the-shelf products could not resolve:
Non-Standard Technical Specifications
- Required 12.5 pixel pitch with a 20 × 20 custom resolution
- No off-the-shelf modules available; a new PCB architecture was required
Exceptional Visibility in Harsh Conditions
- Needed 18,000 cd/m²(white LEDs)—far brighter than standard signage
Highway-Grade Durability
- Exposure to impact, vibration, rain, dust and long-term UV
- Required IP66 and rugged mechanical protection
System Integration
- Must operate using PoE power
- Two-way communication with the central control system
- Continuous LED status monitoring, instant reporting of failures
Safety Certification
- Full compliance with CSA standards for North America
Our Solution
To deliver a reliable enforcement-grade display, Comsight leveraged its expertise as a custom display manufacturer to engineer a complete solution covering structure, electronics, optics, and system communication.
Custom Display Module Design
- Developed a proprietary 20 × 20 pixel PCB with a custom 12.5 pixel pitch.
- Integrated ultra-high-brightness LEDs (≥7,000mcd per LED) to achieve 18,000 cd/m².
- Optimized viewing angles specifically for gantry-mounted enforcement.
Rugged Outdoor Mechanical Structure
- Stainless-steel enclosure: Corrosion-resistant with a dual-layer internal design for heat isolation.
- Low Maintenance: Fanless architecture ensures long life.
- Protection: Front protection uses an impact-resistant acrylic panel, achieving full IP66 weather protection.
- Dual-Sided Design: Independent master/slave housings ensure reliable bi-directional visibility.
Power & Communication System Integration
- PoE + DC-DC power architecture: simplified gantry installation.
- Protocol Support: Complete support for the MCS protocol.
- Self-Diagnostics: The built-in system monitors each LED in real-time and sends immediate failure alerts to the control center.
- Sends failure alerts immediately to the control center → RSS → MOMS
- Displays any alphanumeric characters or digits sent remotely
Dual-Sided Independent Housing (Master/Slave)
The double-separate cabinets ensure reliable bi-directional visibility for enforcement in both directions.
Compliance
Fully designed and tested to satisfy CSA safety certification.
Results
The custom WZG20x20-1W-12.5-ODF bi-directional TSSI LED display successfully met and exceeded all engineering and operational requirements.
Key Results:
- Crystal Clear Visibility: Effective enforcement signaling even under direct sunlight.
- Reliable Operation: Stable performance in extreme outdoor environments.
- Smart Feedback: Instant LED status reporting to the MOMS system.
- Efficient Deployment: Faster installation thanks to PoE power design.
- Compliance: Full adherence to CSA safety standards.
The customer recognized Comsight’s engineering capability and customization expertise, expressing strong satisfaction with both the product performance and project execution.
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