Automation has transformed modern transportation infrastructure, and toll collection systems are a prominent example of this evolution. These systems have become sophisticated centers for data collection and control, generally integrated into the broader ecosystem of Intelligent Transport Systems (ITS).
Intelligent Transport Systems known by the acronym ITSrepresent a set of technologies applied to mobility with the goal of optimizing urban circulation and supporting the development of more connected and efficient cities. These solutions are widely used in traffic control and monitoring, promoting greater traffic flow and increased safety. This contributes to more sustainable mobility and improves the quality of life for citizens in urban areas.
The transportation industry is undergoing changes toward more sophisticated and fully automated toll systems. This impulse's main goal is automation in logistics and transportation to achieve faster, more precise, and more efficient operations, reducing errors and waiting times.
In this transformation scenario, Tecsidel, a Spanish company with a strong presence in Brazil and specialized in tolls, has established itself as a leader in the implementation of advanced systems for the national road sector.
The turning point for Tecsidel arose from a critical operational challenge: despite already having automation, the unavailability of the previously used product created a gap in its infrastructure. This unforeseen circumstance generated an urgent need for a reliable, high-performance, and readily available replacement solution to ensure uninterrupted operational continuity of the systems. The immediate priority was to find a rugged and compatible technology that could be implemented quickly, minimizing downtime and ensuring the continuous delivery of services.
The challenge of operational continuity
The search for a compatible and readily available solution became imperative for new projects.
In this high-pressure context, Tecsidel's decision to partner with Altus was driven by two crucial factors: the availability of equipment in the market and the quality of technical support. These elements stood out as decisive differentiators in a market largely dominated by other players.
In the industrial automation sector, especially for critical infrastructures like toll systems, supply reliability and immediate access to specialized support are often just as essential as the technical characteristics of the products used. This strategic choice by Tecsidel reinforces Altus's competitiveness in the market, highlighting two of its main differentiators: in-house manufacturing and specialized technical support.
This presence in Brazil allows Altus to offer an effective solution for critical moments and to be a partner capable of ensuring operational resilience in crisis scenarios with a quick response and a rugged supply chain to face unexpected interruptions and demanding deadlines.
The solution in action: precision and reliability with Nexto XP
The integrated I/O capabilities was the central piece in Tecsidel's toll systems, acting as the intelligent core, orchestrating critical operations such as vehicle detection and classification, through track sensors, and the control of the toll collection system, vehicle counting, and analysis of vehicle types.
See details of the XP300's technical capabilities for the rugged performance of this application:
- – High-speed processing: equipped with a powerful high-speed 32-bit ARM processor, the XP300 is designed for real-time data processing. This capability allows the system to handle the rapid data flow from track sensors and ensure instant control of toll gates. This ensures that vehicle detection, classification, and response are executed with precision and minimal latency, even in high-volume traffic scenarios.
- – Integrated I/O: the XP300 has 16 integrated digital inputs and 16 integrated transistor digital outputs, providing a direct connection to various field devices. The 4 fast inputs and 4 fast outputs are essential for applications that require precise timing, such as the exact counting of vehicles and high-speed gates.
- – Rugged communication: the versatile Ethernet interface of the XP300 supports Modbus/TCP, a key protocol used in the project for continuous and efficient data exchange with higher-level systems in a customized C application developed for comprehensive information acquisition.
- – Advanced software environment: the XP300 is programmed using Altus's MasterTool IEC XE software, which Tecsidel specifically praised for its “ease of programming.” MasterTool supports all 6 programming languages of the IEC 61131-3 standard, offering features such as online changes and offline simulation. These functionalities significantly simplify the development, debugging, and commissioning processes for engineering teams.
The XP expansion modules
The XP300's integrated I/O capabilities were extended and enhanced by Altus's modular expansion modules for a precise customization of I/O points for each toll lane.
The XP101, XP106, XP201, XP600, and XP610 models are I/O modules that offer expansion solutions for the Nexto XP family. With a compact design, they connect with the PLC through the CANopen protocol, acting in slave mode.
The configurable transmission rate of CANopen (ranging from 20 to 1000 kbit/s) and the rugged error control mechanisms ensure high-speed data exchange for real-time control in a dynamic and demanding environment like a busy toll lane.
The inherent modularity provided by CANopen allowed for precisely scaling the I/O points according to the requirements of each individual lane, optimizing hardware performance, ensuring interoperability with a wide range of devices, and simplifying the integration of the entire system, making the Altus solution highly adaptable to future technological advances and the evolving scenario, a crucial strategic advantage for long-lifecycle infrastructure projects.
Enhanced network connectivity through the power of switches
Along with the Nexto XP familywas used in the application the CET2-0500A 5-port Fast Ethernet (RJ45) industrial switch plays a crucial role in ensuring network connectivity within the system. With an IP30 rating and a rugged metal alloy casing, this switch offers high resistance to severe vibrations, a wide operating temperature range (-10ºC to 65ºC), and immunity to electromagnetic interference, ensuring data transmission with a redundant 12-48Vdc power supply for greater reliability even in the demanding toll environment.
The engineering behind the efficiency
Improved data acquisition, precise counting of vehicles passing through each booth, and consequently better revenue were reported as a a direct benefit of the Altus solution through the integration and processing of data from track sensors.
Classification for toll purposes involves analyzing multiple criteria, such as vehicle type, height above the first axle, and the total number and type of axles. This demonstrates the advanced processing power of the XP300 and the ruggedness of its I/O system, evidencing the PLC's ability to handle complex and high-speed data flows from sensors, integrating the entire system into a precise and coherent control logic.
This improvement directly connects the technical precision of the PLCs and expansion modules — specifically their ability to process sensor data with accuracy — to a quantifiable financial benefit for Tecsidel. This highlights that the Altus solution, in addition to being a technical upgrade, is a direct contributor to the client's profitability and operational efficiency.
Another operational benefit was the ease of programming, a direct result of the intuitive interface of MasterTool IEC XE, its support for online changes, and simulation capabilities. This accelerates project completion and minimizes engineering overhead. Although it may seem like a direct benefit, its impact on a complex industrial project is profound. The ease of programming directly reduces work hours and speeds up the overall project completion schedule, a critical metric for companies operating under strict deadlines.
The value of Altus's technical support
The inestimable importance of Altus's technical support was a factor explicitly highlighted and praised by Evelyn Soares, Tecsidel's Project Manager, who stated that she received excellent service, both from our commercial team and the technical support team.
Altus's support team was called upon for field assistance and clarification of technical questions at the beginning of the project's lifecycle. This demonstrates Altus's commitment to proactive engagement, responsiveness, and a deep understanding of the client's needs throughout the entire implementation process. This rugged support network, combined with Altus's proven track record and long-standing market presence, inspires a high degree of confidence and represents a great strategic partnership in toll automation in Brazil. Altus demonstrated its ability to transform a critical operational challenge into a successful project, delivering under pressure and ensuring the continuity of Tecsidel's business.
By framing Altus's success in this expansive ITS context, the company demonstrates that its solutions contribute to a larger and transformative vision of connected and efficient transport networks with scalable and future-ready technologies, capable of being integrated into larger and more complex infrastructure projects.
Altus's forward-thinking approach and its strong alignment with the broader trends of Industry 4.0 and smart automation demonstrate its proven ability to provide solutions that meet the evolving demands of modern infrastructure. Furthermore, the XP300 and its expansion modules are designed with specific features for durability and compliance in aggressive environments. This includes rugged physical protections, such as tropicalization, and adherence to multiple international certifications for industrial use and even in hazardous locations, for example, cULus Class I Division II. This level of ruggedness is non-negotiable for applications where continuous operation and data integrity are paramount.
In summary, Altus reaffirms its commitment to delivering high added value, ensuring productivity, safety, and reliability for its clients who seek to modernize, optimize, and protect critical infrastructures in the transportation sector and beyond.
