Latest Building Automation Articles

Building automation system integrates electrical controls for HVAC, lighting, and power distribution, using BMS platforms, PLCs, BACnet/Modbus protocols, IoT sensors, and SCADA to optimize energy management, demand response, safety, and predictive maintenance.

What Is a Building Automation System?

An electrical control system automating HVAC, lighting, and power to improve efficiency, safety, reliability, and uptime.

✅ Integrates PLCs, sensors, VFDs, and switchgear controls

✅ Uses BACnet/Modbus for HVAC, lighting, and metering

✅ Enables energy analytics, demand response, fault diagnostics

In an era of rapidly evolving technology, smart buildings have become crucial to modern infrastructure. With the advent of the Internet of Things (IoT), facility managers are increasingly adopting advanced systems to monitor and control various parts of a building's performance. One such solution is the Building Automation System (BAS), which focuses on improving energy efficiency and occupant comfort and reducing maintenance costs. For an overview of foundational concepts, resources like what is building automation can help contextualize these systems for stakeholders.

The primary purpose of a building automation system is to streamline the operation and management of a building's critical subsystems, such as Heating, Ventilation, Air Conditioning (HVAC), lighting, security, and energy management. In addition, a centralized control platform enables facility managers to optimize resource utilization and respond to changing conditions more effectively. To understand device-level orchestration, guidance on energy management controls clarifies how setpoints and schedules are coordinated across platforms.

A typical BAS comprises three main components: input, controller, and output. Input devices like sensors to measure environmental parameters like temperature, humidity, and light levels. Controllers process this information and use pre-defined algorithms to determine the best action. Output devices, including actuators and relays, then implement these decisions by adjusting various systems, such as modifying the temperature in an HVAC system.

In practice, the data path often feeds into building energy management systems that aggregate trends for analytics and reporting.

There are numerous benefits to implementing a building automation system. First and foremost, it can significantly improve energy efficiency. By monitoring and controlling various systems, including HVAC, lighting, and energy management, a building automation system can ensure that resources are only used when necessary, leading to substantial cost savings. Moreover, intelligent building control system algorithms can identify inefficiencies and take corrective action, enhancing overall performance. When paired with disciplined energy management practices, these optimizations translate directly into measurable Key Performance Indicators.

In addition to improving energy efficiency, a BAS also enhances occupant comfort. By monitoring environmental factors like temperature, humidity, and air quality, the system can always maintain optimal conditions for occupants. Furthermore, many systems allow users to customize their preferences via a user interface, empowering them to create a comfortable environment suited to their needs. Organizations that formalize a energy management program often align comfort objectives with operational targets more consistently.

Another significant advantage of a BAS is its ability to integrate with IoT devices. As the IoT ecosystem expands, more devices and sensors are being developed, providing valuable data for building management. By incorporating this information into the building automation system, facility managers can gain deeper insights into building performance and make more informed decisions. This increasingly connected architecture enables advanced energy management workflows that leverage predictive models and fault detection for continuous improvement.

A wide range of building automation control systems is available on the market, catering to different needs and budgets. These include Energy Management Systems (EMS), which focus specifically on monitoring and controlling energy usage, and Building Management Systems (BMS), which offer a more comprehensive integration of various subsystems. In addition, some solutions provide systems integration capabilities, enabling facility managers to combine multiple systems under a user interface. Choosing among various energy management systems requires assessing scalability, interoperability, and cybersecurity posture for long-term success.

As technology continues to evolve, so will the capabilities of building automation systems. From advanced HVAC control to robust security systems and energy management solutions, a building automation system can potentially transform how buildings are managed and maintained. By implementing these systems, facility managers can achieve significant cost savings, improve occupant comfort, and contribute to a more sustainable future.

A building automation system is essential for modern facility management. They provide centralized control over various subsystems, improving energy savings and efficiency, occupant comfort, and reducing maintenance costs. Furthermore, as the IoT ecosystem expands, these systems are set to become even more powerful, offering deeper insights and more advanced control over building performance. So whether you are a facility manager looking to optimize your existing infrastructure or an architect designing the next generation of smart buildings, embracing the potential of building automation systems will undoubtedly lead to a more efficient and sustainable future.

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Industrial automation communication connects PLCs, sensors, drives, and SCADA via protocols like PROFINET, Modbus, OPC UA, and Ethernet/IP, enabling deterministic control, interoperability, diagnostics, safety, and IIoT data across electrical systems and networks.

What Is Industrial Automation Communication?

Networked real-time data exchange between PLCs, sensors, HMIs, and SCADA using standardized industrial protocols.

✅ Supports deterministic Ethernet (TSN) and legacy fieldbus integration

✅ Enables real-time control, diagnostics, and predictive maintenance

✅ Interoperates via PROFINET, Modbus, EtherNet/IP, and OPC UA

In the early 20th century, process control systems and the manufacturing systems were designed based primarily on the mechanical technology and with analog devices. After the period, the pneumatic control technology and the hydraulic power were introduced. The pneumatic control technology made it possible to control remote systems by a centralized control system. These technologies are still very common.

At the beginning of 1960, a digital computer was for the first time really applied as a digital controller. The term direct digital control (DDC) was used to emphasize that the computer directly controls the process. In the 1960s, the application of a minicomputer was still a fairly expensive solution for many control problems. In the meantime, programmable logic controller (PLC) was developed and it replaced the conventional, relay-based controller, having relatively limited control functions. In addition, many technologies were developed for machine tools and discrete production processes. The numerically controlled (NC) machine tool became to be controlled by computers and the robot was developed in this period.

With the more widespread use of digital computers and the associated technologies, industrial communication networks became to be developed with or converted to digital transmission. Proprietary digital communication networks for industrial use started in the 1960s as computers for automation systems were first linked together.

In mid 70s, the first distributed computer control system (DCCS) was announced by Honeywell as a hierarchical control system with a large number of microprocessors. Since its introduction in mid 1970s, the concept of the DCCS spread widely in many industrial automation systems such as power plant control systems, manufacturing systems, etc. The installation of distributed control systems in the newly planned plants or replacement of existing analogue or centralized control systems is presently a common decision of enterprise management. In sectors like power generation, advanced energy management strategies leverage DCS data to optimize load balancing and maintenance planning across units.

The use of local area networks to interconnect computers and automation devices within an industrial automation system has become popular since 1980. The high capacity low cost communication offered by local area networks has made distributed computing a reality, and many automation services. The 

As deployments expanded, many organizations realized that the benefits of industrial networks include lower downtime, scalable integration, and improved data visibility across operations.

industrial automation systems are often implemented as an open distributed architecture with communication over digital communication networks. Achieving high availability requires the right mix of industrial network components such as managed switches, protocol gateways, and ruggedized edge controllers.

It is now common for users connected to a local area network to communicate with computers or automation devices on other local area networks via gateways linked by a wide area network. Similar architectures now extend into transportation, where smart city automated level crossings depend on resilient networking to coordinate sensors, barriers, and central oversight.

As the industrial automation systems becomes large and the number of automation devices increases, it has become very important for industrial automation to provide standards which make it possible to interconnect many different automation devices in a standard way. Considerable international standardization efforts have been made in the area of local area networks. The Open Systems Interconnection (OSI) standards permit any pair of automation devices to communicate reliably regardless of the manufacturer. To plan these interoperable systems, designers often reference hierarchical levels in industrial networks to align plant-floor operations with supervisory and enterprise layers.

Industrial networks span many manufacturing applications. Standard industrial networks using digital communication technologies cover a wide range of manufacturing applications. In many applications, the types of devices and performance determine the type of network. Contrast the needs of two devices -- a proximity sensor used on a conveyor belt compared to a control valve used in a petroleum refinery. The proximity sensor has a single function - to transmit a Boolean on/off signal indicating the proximity of an object. We can accommodate this signal in a few bits of data. Diagnostic information from the sensor is probably limited to a single "health" indicator, which again requires very little data. However, we can expect the control valve to provide very sophisticated control functions and diagnostics, such as number of cycles since last servicing, packing friction, and ambient operating temperature. These parameters can be extremely critical in an environment such as a refinery -- failures can result in dangerous situations and costly downtime. Clearly, the proximity sensor and the control valve have different network requirements. Therefore, different types of industrial networks must address a variety of different needs. We must select the right network to address our specific application requirements.

What is an Industrial Network? By definition, an industrial network requires geographical distribution of the physical measurement I/O and sensors or functional distribution of applications. Most industrial networks transfer bits of information serially. Serial data transfer has the advantage of requiring only a limited number of wires to exchange data between devices. With fewer wires, we can send information over greater distances. Because industrial networks work with several devices on the same line, it is easier to add a new device to existing systems. Comparing fieldbus, Ethernet, and wireless backbones, understanding transmission methods in industrial networks helps engineers match latency, bandwidth, and environmental constraints.

To make all this work, our network must define a set of rules -- a communication protocol -- to determine how information flows on the network of devices, controllers, PCs, and so on. With improved communication protocols, it is now possible to reduce the time needed for the transfer, ensure better data protection, and guarantee time synchronization, and real-time deterministic response in some applications. Industrial networks also ensure that the system sends information reliably without errors and securely between nodes on the network.

For the lower level communication network for industrial automation, the industrial local area network solutions such as MAP are too expensive and/or do not reach the required short response times, depending on the application. The fieldbuses have been, therefore, developed to meet these requirements, and many efforts are now being made to make fieldbus standards for industrial automation applications. The same field-level connectivity principles underpin a modern building automation system where HVAC, lighting, and security integrate reliably across facilities.

Read More: Hierarchical Levels in Industrial Communication Networks

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Industrial network components enable reliable Ethernet, fieldbus, and IIoT connectivity across PLCs, HMIs, drives, and sensors, using managed switches, routers, protocol gateways, and cybersecurity firewalls for real-time control, redundancy, and deterministic data.

What Are Industrial Network Components?

Hardware like switches, routers, gateways, and I/O modules that link PLCs and sensors for secure, deterministic control.

✅ Managed Ethernet switches enforce VLANs, QoS, and ring redundancy

✅ Gateways bridge Modbus, PROFIBUS, and PROFINET protocols

✅ Industrial routers add VPN, firewall, and IEC 62443 security

Industrial Network Components

In larger industrial and factory networks, a single cable is not enough to connect all the network nodes together. We must define network topologies and design networks to provide isolation and meet performance requirements. In many cases, because applications must communicate across dissimilar networks, we need additional network equipment. The following are various types of network components and topologies:

For an overview of how devices exchange data across varied protocols, see the guide on industrial automation communication best practices for plant networks.

• Repeaters -- a repeater, or amplifier, is a device that enhances electrical signals so they can travel greater distances between nodes. With this device, we can connect a larger number of nodes to the network. In addition, we can adapt different physical media to each other, such as coaxial cable to an optical fiber.
• Router -- a router switches the communication packets between different network segments, defining the path.
• Bridge -- with a bridge, the connection between two different network sections can have different electrical characteristics and protocols. A bridge can join two dissimilar networks and applications can distribute information across them.
• Gateway -- a gateway, similar to a bridge, provides interoperability between buses of different types and protocols, and applications can communicate through the gateway.

In planning placement of routers, bridges, and gateways, it's useful to map the hierarchical levels of industrial networks across field, control, and enterprise layers.

Network Topology

Industrial systems usually consist of two or more devices. As industrial systems get larger, we must consider the topology of the network. The most common network topologies are the bus, star, or a hybrid network that combines both. Three principal topologies are employed for industrial communication networks: star, bus, and ring as shown in Figure 3. Understanding media choices and signaling options is essential, and the overview of transmission methods for industrial networks explains tradeoffs between copper, fiber, and wireless.

A star configuration contains a central controller, to which all nodes are directly connected. This allows easy connection for small networks, but additional controllers must be added once a maximum number of nodes are reached. The failure of a node in a star configuration does not affect other nodes. The star topology has a central hub and one or more network segment connections that radiate from the central hub. With the star topology, we can easily add further nodes without interrupting the network. Another benefit is that failure of one device does not impair communications between any other devices in the network; however, failure of the central hub causes the entire network to fail. These design choices tie directly to the benefits of industrial networks that improve scalability and resilience.

In the bus topology, each node is directly attached to a common communication channel. Messages transmitted on the bus are received by every node. If a node fails, the rest of the network continues in operation as long as the failed node does not affect the media. This shared medium approach is often integrated under a facility's building automation system where distributed controllers share status and control signals.

In the ring topology, the cable forms a loop and the nodes are attached at intervals around the loop. Messages are transmitted around the ring passing the nodes attached to it. If a single node fails, the entire network could stop unless a recovery mechanism is not implemented.

In transportation settings like automated level crossings environments, deterministic performance and failover are crucial for safety.

For most networks used for industrial applications, we can use hybrid combinations of both the bus and star topologies to create larger networks consisting of hundreds, even thousands of devices. We can configure many popular industrial networks such as Ethernet, FOUNDATION Fieldbus, DeviceNet, Profibus, and CAN using hybrid bus and star topologies depending on application requirements. Hybrid networks offer advantages and disadvantages of both the bus and star topologies. We can configure them so failure of one device does not put the other devices out of service. We can also add to the network without impacting other nodes in the network. Hybrid architectures also support advanced energy management strategies that balance load and reduce downtime during maintenance.

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PLC training courses build automation skills in ladder logic, SCADA, HMI, and motion control, with hands-on programming on Siemens and Allen-Bradley platforms, diagnostics, IEC 61131-3 standards, safety, and commissioning best practices.

What Are PLC Training Courses?

Programs teaching PLC programming, SCADA, HMI, and industrial automation with hands-on labs and commissioning.

✅ Ladder logic, function blocks, and IEC 61131-3 programming

✅ Siemens TIA Portal and Allen-Bradley RSLogix labs

✅ Fault finding, I/O wiring, safety, and commissioning

Our PLC training courses are designed to help students keep abreast of the latest PLC technologies and techniques available for industrial automation. These courses offer an excellent opportunity for students to ask specific questions and exchange ideas relating to their own applications. For context on modern plant connectivity, see the overview of industrial automation communication standards used in training.

Our PLC training courses are intended for experienced users and will give them greater knowledge of enhanced PLC functionality. Participants also review the benefits of industry networks to understand how network design impacts reliability.

We have three PLC training courses:

Before selecting a pathway, it helps to understand the hierarchical levels of industrial networks that underpin PLC architectures.

PLC Basics Training

PLC Training Basic - Our 12-Hour (2-Day) live online instructor-led industrial automation course is designed to instruct electrical control professionals on how to successfully integrate a PLCs into actual day-to-day industrial electrical processes. The course not only deals with the hardware and software, but all the surrounding systems that must be compatible to achieve a safe and reliable control system. This PLC Training Basic course is generic in nature and applies to all PLC types and manufacturers. We also examine key industrial network components so attendees can better integrate field devices.

PLC Training - Intermediate

PLC Training - Intermediate - Our 12-Hour (2-Day) live online instructor-led industrial automation course is designed to instruct electrical control professionals on how to successfully integrate a PLC into actual day-to-day industrial electrical processes. It not only deals with the hardware and software, but all the surrounding systems that must be compatible to achieve a safe and reliable control system.  The curriculum compares common transmission methods in industrial networks to guide protocol selection.

PLC Training Course - Advanced

In the advanced module, we connect control strategies to advanced energy management concepts for measurable performance gains.

Our 12-Hour (2-Day )Advanced PLC Training Course is designed to give students a basic understanding of Programmable Logic Controllers and how PLCs function. This Advanced PLC training course will not make students PLC experts but rather give them a basic understanding of the PLC, the PLC’s functionality and limitations. The PLC training seminar is generic in nature and applies to all types and manufacturers. Case studies include applications like smart city automated level crossings where safety and uptime are critical.

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Energy Management Program optimizes electrical loads via SCADA, submetering, and analytics, driving energy efficiency, demand response, peak shaving, load forecasting, and power factor correction to reduce kWh, cut OPEX, and improve power quality and reliability.

What Is an Energy Management Program?

An engineered method to monitor and control electrical loads, boosting efficiency, reliability, and cutting costs.

✅ Integrates SCADA, submeters, and IoT sensors for real-time visibility

✅ Implements ISO 50001, KPIs, and M&V for continuous optimization

✅ Enables demand response, peak shaving, and power factor correction

An energy management program is increasingly important in industrial, commercial, and institutional power systems due to growing concerns about energy efficiency, costs, and environmental impact. Implementing an effective energy management program (EMP) can help businesses save money, reduce their carbon footprint, and achieve sustainability goals. This article will delve into the key components of an energy management program and discuss how it can benefit businesses in various sectors. To understand the broader scope of best practices, resources on energy management provide context for implementation across sectors.

An effective EMP typically includes energy efficiency measures, energy audits, energy conservation strategies, building automation, energy monitoring, demand response initiatives, sustainable energy policies, and the implementation of EM systems. Facility management plays a crucial role in ensuring the success of such programs. For teams new to these concepts, a concise primer on what is building automation can help align terminology and roles.

One of the primary goals of an energy management program is to increase energy efficiency. This can be achieved by identifying areas where energy is wasted and implementing measures to reduce energy consumption. For instance, energy-efficient lighting, heating, and cooling systems can significantly reduce energy usage in commercial and institutional buildings. Incorporating energy management controls enables precise scheduling and setpoint optimization for measurable savings.

Energy audits are a vital component of an EMP, as they help identify areas of energy waste and provide recommendations for improving energy efficiency. These audits involve a thorough assessment of a facility's energy consumption patterns and equipment performance, which can lead to the implementation of cost-effective energy-saving measures. Audit findings are often operationalized through energy management systems that track KPIs and verify results.

Energy conservation strategies are another crucial aspect of an energy management program. These strategies aim to minimize energy consumption without compromising operational efficiency. Examples of energy conservation measures include optimizing equipment performance, implementing energy-saving operational procedures, and promoting energy-conscious behavior among employees. Modern analytics and automation in advanced energy management support continuous improvement in conservation programs.

Building automation systems play a significant role in energy management programs by allowing for the centralized control and monitoring of various building systems, such as HVAC, lighting, and security. These systems can help optimize energy usage by automatically adjusting settings based on factors like occupancy, time of day, and weather conditions. Selecting an open-protocol building automation system improves interoperability with meters and sub-systems for broader control.

Energy monitoring is essential for tracking the effectiveness of an energy management program. By continuously measuring and analyzing energy consumption data, businesses can identify trends, pinpoint inefficiencies, and implement corrective measures to optimize energy use further. Many organizations centralize this function within building energy management systems to visualize trends and trigger alerts.

Demand response initiatives can help businesses in industrial, commercial, and institutional power systems participate in energy markets by adjusting their energy consumption in response to market signals, such as electricity price fluctuations or grid reliability issues. This can help businesses reduce energy costs and support grid stability.

Sustainable energy policies guide businesses in adopting cleaner energy sources and reducing their reliance on fossil fuels, such as oil and gas. Examples of sustainable energy sources include solar, wind, and hydroelectric power. Integrating these sources into a facility's energy mix can help reduce greenhouse gas emissions and promote long-term sustainability.

EM systems support energy management programs by providing a platform for monitoring, controlling, and optimizing energy usage across a facility. These systems can help businesses identify opportunities for energy savings, improve equipment performance, and reduce energy costs.

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Smart city automated level crossings integrate IoT sensors, AI, and V2X to optimize traffic management, enhance rail safety, enable predictive maintenance, and deliver real-time monitoring via 5G, edge computing, and SCADA platforms.

What Are Smart City Automated Level Crossings?

Systems using IoT, AI, and sensors to automate rail-road gates, boost safety, reduce delays, and optimize city traffic.

✅ Adaptive control via AI, V2X, and edge analytics

✅ Integrated SCADA with remote monitoring and diagnostics

✅ Fail-safe design with SIL-rated controllers and redundant sensors

Around the world, railway tracks pass through villages, towns, cities and metropolises which creates the problem of ubiquitous Level Crossings as they transect roads, highways, etc. The real-time train data, collected through Global Positioning System (GPS) satellites can be used to calculate critical distance to a level crossing. A sensor (receiver) keeps polling the approaching train data and actuates a motor that closes the gate of an unmanned LC.

Case Study – Indian Railways and problems with its LCs

Since the past few years, Indian Railways (IR) has been making strides in the realm of digital technology. Being the largest employer in the world, means managing a mammoth workforce and movement of passengers every day, equal to the population of Australia. Unfortunately, this includes running trains and transporting goods on a stagnated infrastructure of railroads. Both manned and unmanned Level Crossings, cause several accidents. The manned LCs, that have an operator, to pull the gate, are unreliable and often lead to delays for public, that wants to get from one side of the railway track to another.

Solution - Data from satellites

Taking advantages of advancements made in the field of satellite communications technology, Indian Railways has started using Global Positioning System data for running its trains. It collects the actual data as received from the satellites and links it to mobile phone applications and its web portal where travelers can find the running status of a train, they are interested in. This gives any user, information, such as speed, last station passed, time to reach the selected destination (approx.) and whether if the train is running late or at the right time.

Building Blocks of the proposed system – PLC and its FBD

A Programmable Logic Controller, or PLC, Fig. 1, is like a mini computer used for industrial automation everywhere around us. These controllers can automate a specific process, machine function, or even an entire production line. They can be made to calculate positions and take actions based on the status. The PLC receives information from connected sensors or input devices (thru the Input Modules), processes the data (in its Processor), and triggers outputs (connected to the Output Module) based on pre-programmed parameters. Depending on the inputs and outputs, a PLC can monitor and record run-time data, automatically start and stop processes, generate alarms if a machine malfunctions, and more. Programmable Logic Controllers are a flexible and robust control solution, adaptable to almost any application. For field deployments, reliable controller-network interoperability relies on industrial automation communication standards that govern data exchange between sensors, PLCs, and supervisory systems.

Fig. 1 - A Programmable Logic Controller consisting of a Power Supply, CPU and input and output modules.

Modern PLCs are programmed using Functional Block Diagram (FBD). They were introduced by IEC 61131-3 to overcome the weaknesses associated with textual programming and ladder diagrams. An FBD network, Fig. 2, primarily comprises interconnected functions and function blocks to express system behavior. Function blocks were introduced to address the need to reuse common tasks such as AND gate, OR gate, counters, and timers at different parts of an application or in different projects. A function block is a packaged element of software that describes the behavior of data, a data structure and an external interface defined as a set of input and output parameters. A function block is depicted as a rectangular block with inputs entering from the left and outputs exiting on the right. Key features of function blocks are data preservation between executions, encapsulation, and information hiding. Engineering teams can accelerate safe commissioning by leveraging PLC training courses that focus on FBD practices, diagnostics, and lifecycle maintenance.

An FBD is a program constructed by connecting multiple functions and function blocks resulting in one block that becomes the input for the next. Unlike textual programming, no variables are necessary to pass data from one subroutine to another because the wires connecting different blocks automatically encapsulate and transfer data.

A function block is not evaluated unless all inputs that come from other elements are available. When a function block executes, it evaluates all its variables, including input and internal variables as well as output variables. During its execution, the algorithm creates new values for the output and internal variables. Outputs of function blocks are updated because of function block evaluations. Changes of signal states and values therefore naturally propagate from left to right across the FBD network.

Fig. 2 - Functional Block Diagram (FBD) used to program a PLC. Complex mathematic operations are performed by simple functions in steps, deriving outputs from one or multiple inputs.

Automated LCs

The GPS data collected from satellites can be used for supplementary applications using simple systems integration technologies to improve a city’s infrastructure. In municipal deployments, integrating these feeds with a building automation system enables coordinated signaling, energy use, and roadway messaging across adjacent facilities.

The LC has a sensor (receiver) which keeps polling the approaching train data continuously from the satellites. The receiver sends this information to a Programmable Logic Controller, which calculates the "critical distance to the crossing" (difference, based on coordinates) The FBD can be designed using a comparator that compares real time position input to a pre-set value (say 300 ft.). It shall then proceed to calculate the difference of these 2 values. If this value is zero, then the output should become 1, which means that the train is now in the crossing envelope and the gates need to be shut. This output feeds the motor starting circuit. An important thing to note here are the factors influencing this calculation such as, the speed of the train and its distance away from the crossing envelope. Another parameter affecting this calculation is the width of the road, across the railway track. For wider roads, crossing envelope is more, on both sides of the road, which leads to the crossing envelope’s pre-set value to be more (than 300 ft.). While for narrow roads the crossing envelope pre-set value can be set to a lesser margin (less than 300 ft).

Making use of the several digital outputs available at the output module of the PLC, extra functionalities that can be added to the PLC circuit may include a horn sound, to alert the public near the crossing and a stop (RED) or go (GREEN) light. The power supply for this system is derived from Uninterruptible Power Supply (UPS) system with a battery unit, See Fig. 3. Integrating the UPS and load profiles into an advanced energy management strategy can optimize battery sizing, charging windows, and lifecycle costs.

Fig. 3 – GPS based Automated Level Crossing for Railroads

As the train, approaches the crossing, the gate will be closed, stopping the traffic on the road, until the train has moved away from the crossing envelope on the other side of the road.

When the train has gone out of the critical distance, using real time polling from GPS, the PLC will run its FBD again. The FBD will now not have a zero output but a positive value as the difference of the pre-set value (300 ft. in our example) and the current coordinates of the train is a positive number. After running this sequence for 2 minutes, and finding a positive number in the output of the FBD, it can open the gate by reversing the motor. This restores movement of road traffic.

Have more data? Use it for automation

The PLC can be programmed to detect and transmit alarms for faults in cases such as when the Motor does not start or the Battery units are low on the charge and need replacement. During such situations, PLC can send this information thru a wireless signal to the nearest control center, Fig.3. A Rail Infrastructure Operations & Maintenance (O&M) app or website could collect all this data and send out maintenance personnel to look after the equipment periodically thereby enhancing the life of the LC unit. A Central Control Operator (CCO) screen, Fig. 4, can display erroneous behavior of any equipment. The development of interface between the PLC and CCO requires detailed engineering and sound knowledge of communications. Choice of media and protocols should consider the available transmission methods in industrial networks to balance latency, range, and resiliency.

Fig. 4 – A sample Central Control operator screen shows the health of all the equipment. It is very important to keep monitoring the real-time status of critical infrastructure so necessary action can be taken subsequently.

At the control-center side, architects should map data paths to the hierarchical levels of industrial networks so alarms, control, and historian traffic are segregated appropriately.

Advantages aplenty

Railway Operators have a responsibility towards everyone, from the travelers on the trains and stations to people using its infrastructure elsewhere. Automated LCs will prevent accidents. This system is faster, as often guards at LC tend to shut the gates 10 to 15 minutes before the approach of the train, causing loss of valuable time of the public. Being a satellite based system, it is bound to be very precise and accurate. It will also save money as the need for guards to be present at such crossings will be eliminated. Beyond safety, standardized connectivity delivers measurable ROI through the benefits of industry networks such as improved uptime, easier scaling, and vendor interoperability.

Way forward

As various Railway Operators around the globe, look for ways to keep themselves functional and profitable, all railway crossings should be converted to automatic type, removing the need for a guard to be present 24x7. This solution can be a lynchpin to a digital revolution. Within a city’s limits, such automated LCs will enable transition towards a smart city and smart transport initiatives. Railway Operators must realize the importance of the data that they generate and put it to several innovative uses that makes people’s life easy.

Kshitij Saxena received his BTech in electrical and electronics engineering from Vellore Institute of Technology (2008) and MS in electrical engineering from University of Southern California (2010).

                He is currently working as a Senior Traction Power Engineer at WSP Oakland, USA. Previously he has worked with Bombardier Transportation and Pennsylvania Transformer Tech Inc.

                Mr. Saxena is an Engineer in Training from Pennsylvania and is a PMP. He’s passionate about Mass Transit & Renewable Energy.

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