Workplace Safety FAQs
Do I have to have a working internet connection for the system to work?
No. The solution is completely Edge based. All of the image capture, analysis of human entry in the red zone and output of that signal to mill control systems (PLC) is done within an Axis camera (Axis.com).
Is there a subscription charge for the onboard camera software that detects the presence of humans in the red zone?
No. Red zone detection is included in the Axis camera cost.
Is there an interposing Ethernet or software requirement between the camera and the mill PLC to communicate a human detect condition?
No. Onboard I/O sends red zone status directly to the PLC. Options exist for Modbus or Ethernet/IP but this can add complexity and multiple failure points.
Is there a single point of failure?
No. Each camera communicates independently. Video and review dashboard applications are typically hosted on a mill (or ECS) virtualized server. Server failure does not affect detection and direct wire communication to the PLC.
What happens when a camera fails?
Stakeholders are notified. A spare camera is installed and per camera configuration is confirmed. Other health conditions are monitored with email alerts and responded with ECS 365/24/7 Sustain Support.
Can the cameras constantly store video and display live video?
Yes. Full 24/7 video is stored with human detection and unsafe events listed in the dashboard. Live video with red zone overly can be displayed on the machine floor or on any monitor in the mill via the local network.
Can machine floor enunciators (sirens and lights) be energized when the red zones have human detection?
Yes. Local sirens and lights can activate when operators enter red zones.
How does the system protect the operator in present time and determine unwanted human/machine interaction to minimize future safety risks?
Our camera based safety solution is designed to stop both the immediate harm to the operator while also understanding and identifying all human interactions that may turn into future life-changing and life-ending events. It is the ECS Safety Dashboard that develops the foundation of collecting and analyzing all human and machine interactions.
What is the smallest system footprint and timeline for installation?
One camera installs in hours by power over Ethernet (POE), onboard camera I/O and SD video storage. Expandable to unlimited cameras across multiple PLCs.
If PLC communication is required does ECS program the PLC for machine control?
No. Mill programs the PLC to define unsafe conditions and machine responses for interlock and permissive controls.
What resolution and frame rate does the human detection AI engine process? Does it skip frames and lower the native resolution of the camera output?
AI processes every frame at full resolution, 1920x1080, 30 fps. Cloud solutions reduce resolution and frame rate to 5 to 10 fps at 720 x 1080, losing critical lifesaving information.
Is video constantly being stored or only a small portion when the AI engine detects a human in the red zone?
The ECS solution is a full featured Video Management System that stores every frame of the video regardless of human detection or not. In contrast, cloud-based solutions typically only store a small portion of video around a human detection. If the cloud-based solution does not correctly identify a human in the red zone, no video is saved.
No, you don't need specialized servers or hardware to install the ECS edge-based system. The system operates directly at the camera level, processing data and includes input and output ports to communicate directly to machine PLCs.
Do I need specialized server or hardware to install the system?
The ECS solution is completely edge based – there are no interposing steps to alarm the PLC of red zone intrusions. Cloud based systems have several steps for PLC alarming: compress low frame rate video at a centralized server, internet connection for additional cloud-based processing and feedback to the local server and finally software (example – Modbus or OPC) communication to the PLC for alarming. On average, cloud-based solutions provide a 10x slower response time. This renders such solutions unusable for high-speed machine safety solutions.
What is the human detection time of the ECS system and how does this compare to cloud-based solutions?
General FAQs
What is ECS’s cancellation policy?
In the event that a scheduled service visit needs to be cancelled or rescheduled, all requests must be made by contacting the Service Manager, Robert Cornette, at 704-625-8812 ext. 202. It is the responsibility of the site receiving service to ensure ECS has received the cancellation or rescheduling request.
All service visits are considered final when a PO is issued.
All cancellations and reschedules will be assessed a fee based on time and cost as necessary.
Rescheduling on Behalf of ECS:
In the event that ECS needs to reschedule a service visit, the service manager will reach out to the primary point of contact to communicate what has happened, and what will need to happen to fulfill the agreement.
What’s the fastest way I can order spare parts from ECS?
There are many ways to make a quote request. You can either:
Use our drop-down Quote Request Form here
Email your request to Quotes@ecsuptime.com
Talk to your ECS point of contact
Does ECS have training classes for technicians?
Yes, we do have mill-specific training available. We host an Advanced Training Class once a season to refresh those who want to be proficient with ECS Software.
If you are interested in signing up for our next Advanced Training Class, click on the button and fill out the form.
Should I call my contact or the ECS Support Line first?
You should call the support line first, as technical issues are entered in as a ticket and tracked through our system. Your local service technician may be in a mill, and not able to respond timely.
Also, the ECS Support Line are the only ones who can remote into a system.
You can contact the ECS Support Line at: 704-519-5053
How fast will my parts arrive?
If the parts are in stock, and no set-up time is required, many times the order will be shipped out same-day, if the order is received by 10am EST.
ECS offers an expediting fee, if your order supersedes the standard production/delivery schedule.
Standard shipping is UPS Ground.
If two-day or overnight shipping is required, ensure that this is noted within your quote request.
Call ECS to confirm lead time.
What if I need parts over the weekend/after business hours?
Orders & Quote Requests received after business hours/over the weekend/on holidays will be processed the next business day.
Please reference the above question for details about delivery.
What if I need support over the weekend or after business hours?
The ECS Support team is on call 24/7. If you reach the after hours voice mailbox, make sure that you leave a way to contact you back. We do not outsource our incoming calls to a call center - you’re speaking directly to ECS employees about your issue.
Make sure to provide the ECS Support Team:
Minimum
Name
Corporation
Mill Location
Asset/Machine
Contact Info (if your shift will end, who can be reached next?)
Also helpful…
Description of the issue
When the issue first appeared
What camera(s)/computer(s) are affected?
Has this issue happened before?
Specific time/circumstances surrounding the issue (screenshots are SUPER helpful)
How do I request a quote/schedule a time for follow-up training for my ECS System?
Submit a quote request here, or call us during business hours at 704-519-5053.
ECS hosts quarterly training sessions at our ECS Headquarters here in Charlotte, NC. You can find the sign-up link here.
We’re also happy to host training at your facility, and gear it towards:
Basic operator training
Advanced operator training
Maintenance or E&I Groups