Design of a PLC-Based Runway Guard Light Control System as a Learning Aid at the Makassar Aviation Polytechnic

Abstract

Runway Guard Light (RGL) is one of the essential components of the Airfield Lighting System (AFL), serving as a visual warning system for pilots and airside vehicle operators before entering an active runway, thereby enhancing aviation operational safety. However, the limited availability of learning media capable of realistically simulating the operation of the RGL system has become a challenge in the learning process at Makassar Aviation Polytechnic. Therefore, this study aims to design and develop a Programmable Logic Controller (PLC)-based Runway Guard Light control system as an instructional medium capable of simulating the operating principles of airport lighting systems. This study employed the Research and Development (R&D) method. The research stages included needs identification, hardware and software design, system assembly, PLC programming using CX-Programmer, Human Machine Interface (HMI) development using EasyBuilder Pro, and functional as well as performance testing of the developed system. The trainer kit consists of a solar panel, rechargeable battery, Omron CP1E-N20DT-D PLC, Weintek HMI, LDR sensor, MOSFET driver modules, Runway Guard Light lamps, DC Miniature Circuit Breaker (MCB), and a Digital Wattmeter, all integrated into a single instructional system. The results indicate that the developed system operates according to the intended design specifications. The PLC successfully controls the alternating flashing pattern of the Runway Guard Lights, supports both manual and automatic operating modes based on the LDR sensor input, and enables lamp brightness adjustment through the Pulse Width Modulation (PWM) method with five predefined intensity levels via the HMI. In addition, serial communication between the PLC and the HMI functions reliably, enabling real-time control and system monitoring. The separation of the 24 VDC control circuit and the 12 VDC load circuit using MOSFET driver modules also improves system stability. Therefore, the developed PLC-based Runway Guard Light trainer kit can be utilized as an effective learning medium to enhance cadets' knowledge and practical skills in industrial control systems, automation technology, and airport lighting systems.