Industrial CCTV Solutions

Written by Tom Connor

Wednesday, 16 January 2008

Everyone knows that surveillance cameras were primarily designed with the intent of providing security for a building, however out side that realm there can be advantages to having inexpensive, high resolution cameras monitoring areas where products are made or tested. Not only can this enhance the level of quality control a company exerts over its product line, it also can provide valuable reference footage down the road when trying to improve products or processes. Here, more than anywhere else, surveillance equipment is an investment.

Surprisingly, though it may seem counterintuitive, setting up an industrial CCTV system can usually be accomplished a bit easier than if the system was intended to be used for security. For instance, picking out cameras is generally a more streamlined process. Since very few manufacturing plants operate in complete darkness, infrared cameras are seldom needed, and since lighting conditions must be at least decent so employees can see what they’re doing, generally the lighting dilemma of color (which is at a disadvantage in poor light) versus black and white becomes a matter of taste; color (like the KG-230CWB ) works if needed, black and white (in which case, the KG-190SWB ) gets the job done if cost is more of an issue. Distance from the camera to the target is still a factor (and always will be), however in an industrial environment, where cosmetics aren’t an issue and there’s no need to try to conceal cameras, layout can be a lot easier, too, meaning it is possible to place cameras as conveniently as possible.

Still, there are hurdles to contend with, and anyone who works in a manufacturing or testing capacity knows that these vary widely depending upon what has to be done. Areas that have warehouse ceilings or where the only mounting options are far away will need more powerful lenses, for instance, while darker areas may require low light cameras. Still further, areas of sensitive testing or quality control would require higher resolution cameras (or, to combine the three, a KG-806 with a 6~60mm varifocal lens would provide high resolution, low-light shots at a distance). A trained surveillance professional can help navigate the myriad of options to the correct camera for a specific application, but there are general notes to consider with or without help.

One of the most important of these points is weatherproofing; just because a camera is indoors does not mean that it doesn’t need protection. For instance, monitoring a process that uses liquids would necessitate weatherproof cameras just as a matter of precaution, however a facility that has a lot of dust in an otherwise dry environment could prove very hostile to exposed lenses even if they never see moisture. Similarly, areas that have extreme heat or cold would also benefit from having weatherproofed cameras, again as a matter of precaution. As paranoid as this may sound, in general, unless cameras will be going into temperature controlled, perfectly dry and clean environments, it’s generally best to err on the side of caution and opt for weatherproofed cameras (all we have discussed so far have been weatherproof, the bullets by themselves and the 806 when secured inside of a weatherproofed housing).

Another thing that sets industrial camera systems aside from their residential or commercial counterparts is that fact that it may occasionally be appropriate to include Pan\Tilt\Zoom cameras in the system, however even here they work best when narrowly applied. For instance, if it is necessary to proactively monitor a manufacturing area where it is not safe to have a set of human eyes onsite, including both a PTZ (for instance, the PT-105 or its weatherproof equivalent the PT-205 ) and a few fixed cameras can offer complete coverage that is enhanced by having the option of moving or zooming the PTZ to pay special attention to areas as the situation demands. It is important to remember, though, that PTZs should never be used to replace fixed cameras; only to enhance them. Though they are some of the most versatile cameras available today, working alone a PTZ is at a disadvantage: if it moves, it instantly creates a blind spot somewhere else. With this in mind, only the most critical and sensitive of applications need consider PTZ cameras (and even then they should have fixed cameras supporting them), for most applications adding one is generally overkill.

Finally, just like it was important to allow the application to dictate the cameras, it is just as crucial to let the goals of the system pick out the DVR. For a small, low-intensity system meant for general monitoring, an Aver Media 1304NET DVR (which can handle up to four cameras) would be ideal, however in any locations where high framerates and high resolution need to be combined, a much more realistic option would be the PC Witness Pro V/RT , which can handle more cameras (up to 16) and more demanding combinations of framerate and resolution. Still, extremely sensitive applications may require more power than even the V/RT can provide. For the most demanding research and development applications where recording must take place down to the millisecond at high resolutions, a PC Witness Pro RT would be ideal thanks to its ironclad construction and design to handle the most critical and demanding jobs a facility has to offer.

At the end of the day, though, it is generally best to allow a surveillance professional help pick cameras out once management knows what the cameras will have to accomplish and (at least generally) where they will go. It is simply impossible to discuss all the possible uses and permutations for industrial surveillance systems here, however a friendly and experienced professional can narrow down options and act as a designer. Still, it is important to know from the outset what the goals and expectations of the system will be; without that even the most experienced consultant is left playing a guessing game.

And as always, never be afraid to ask questions!

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Tom Connor
		About the author:
		One of the newest additions to the aboutcctv staff, Tom Connor works as a Commercial Surveillance Solutions Architech with CCTV Wholesalers, assisting residential, commercial, and governmental entities with their security needs while at the same time keeping other departments in the company abreast of new problems and trends brought to us by our customers. With broad experience in sales, project management and customer service, Tom is a proven asset on the CCTV Wholesalers team. Call Tom toll free at 800.291.0523 ext. 134 and get a free professional consultation and instant price quote.
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