Aug 2026· International journal of computer information systems and industrial management applications· Vol 18, pp. 488-498· 0 citations
Abstract
Railway level crossings remain a persistent source of accidents and fatalities on mixed road-rail networks, particularly where crossings are unmanned or rely on manual gate operation. This paper presents the design, structural validation, and prototype implementation of an automated railway barricade in which a Programmable Logic Controller (PLC) drives an underground rack-and-pinion mechanism to raise and lower a physical barrier in response to sensor-detected train movement. The underground placement minimizes visual obstruction relative to conventional above-ground boom barriers while a robust mechanical drive is intended to withstand repeated, high-cycle outdoor operation. A structural analysis using Finite Element Analysis (FEA) is used to validate the mechanical integrity of the rack-and-pinion drive under expected loading, and shaft design calculations confirm an adequate safety margin. A fabricated prototype demonstrates the automation cycle end-to-end, including a manual push-button override for fail-safe operation. To situate the contribution, a focused review of thirteen directly relevant studies retrieved from a bibliographic export is presented; it indicates that existing automated level-crossing work concentrates on sensing and control logic, while structurally validated mechanical actuator design for the barrier itself is comparatively under-addressed. The proposed system is offered as a scalable, low-cost step toward reducing manual dependency and human error at level crossings.
To address the secondary entrapment risk and the single-point protection defect of elevator power-off emergency devices, a multi-level safety protection system was designed based on a Programmable Logic Controller (PLC) and permanent magnet synchronous door machine star-sealing technology. The system is centered on the S7-200smart PLC and integrates the Auto Rescue Device (ARD) for elevator emergency leveling during power outages, establishing an active rescue-passive protection-fail-safe framework. Experimental verification shows that the system can achieve 100% emergency leveling rescue, with a braking torque of 15.2 Nꞏm, far exceeding the door-closing torque of 4.5 Nꞏm, completely eliminating secondary entrapment. The system operates reliably, providing an innovative solution for elevator safety.
Unknown authors· European Conference on Elect...· 0 citations
This study investigates the realization and verification of safety-related functions of the KZ-MPC-MA national modular microprocessor-based railway interlocking system for Kazakhstan. The work focuses on the realization stage of the IEC 61508 safety lifecycle and establishes traceability between station-specific safety requirements, interlocking algorithms, software implementation, hardware–software integration, and functional-safety assessment. The implemented interlocking logic incorporates 29 traffic safety conditions defined for the considered station configuration. A fail-safe control architecture based on central and distributed controller modules was implemented using certified safety-related industrial controllers and the SILworX development environment. A laboratory prototype was developed to verify route-setting functions, switch and signal control, and fail-safe system response under specified operational and failure conditions. Quantitative functional-safety assessment was performed using the probability of failure on demand (PFDavg) as a supplementary measure and the probability of dangerous failure per hour (PFH) as the governing criterion for continuous/high-demand operation within the defined assessment boundary and assumptions. The obtained PFH demonstrates that the investigated safety-related controller subsystem satisfies the specified SIL4 quantitative criterion. The study demonstrates the feasibility of realizing safety-related interlocking functions on the selected hardware–software platform and provides a basis for further system-level verification and validation.
Unknown authors· Applied System Innovation· 0 citations
The modernization of legacy industrial machines is a major challenge in intelligent automation, particularly when critical assets must be upgraded without replacing high-value mechanical and hydraulic infrastructure. This paper presents an industrial case study on the intelligent PLC-based retrofit of an obsolete Neyrpic Digipid speed governor installed in a Kaplan turbine. The proposed solution replaces a closed, vendor-dependent controller with an open Siemens ET 200SP architecture programmed in TIA Portal, integrating existing sensors, hydraulic actuators, redundant speed acquisition, sequential state-machine control, and a digital distributor–runner blade Cam Curve. A key technical contribution is the diagnosis and mitigation of hydraulic hunting in the distributor position loop. The instability was traced to the interaction between integral control action and the intrinsic integrating behavior of the hydraulic actuator, leading to the adoption of a proportional-only position tracking strategy. The system was validated through Factory Acceptance Tests (FATs) and Site Acceptance Tests (SATs), including signal verification, startup, synchronization, load acceptance and emergency load rejection. Quantitative results demonstrate that during initial commissioning of the new PLC-based PI position loop, the LVDT position error reached 41.59% peak-to-peak, with 351.2 servo-valve reversals per minute. Disabling the integral action reduced the peak-to-peak position error to below 1.5% and eliminated steady-state valve reversals under the tested operating conditions. Separately, the historical 0.966 V oscillation detected in the legacy analog-input chain was resolved during the retrofit. During no-load startup, the unit reached 97% of nominal speed in 49.4 s, with a maximum overshoot of 2.3% and a speed tracking standard deviation of 1.1%. The complete operational cycle was successfully validated under real industrial conditions, including a near-nominal load-rejection test (approximately 2.25 MW), during which the measured speed peaked at 126.4% of nominal speed and the shutdown sequence was completed without protection-system malfunction. The results show that open PLC-based retrofits can improve maintainability, diagnostics and operational reliability in safety-critical industrial machines, while establishing a foundation for future SCADA integration and condition-based maintenance.
Jorge Manuel Araújo Teixeira, Filipe Pereira· Applied Sciences· 0 citations
The implementation of the ground deceleration function in civil aircraft represents a critically complex process that deeply relies on the seamless collaboration of multiple onboard systems, including but not limited to braking, thrust reversal, spoiler, and steering systems. The operational logic governing these systems is highly intricate, characterized by tightly coupled interactions, stringent safety requirements, and a vast array of diverse physical and logical interfaces. This inherent complexity makes it exceptionally difficult to gain a thorough, system-level understanding of the implementation mechanisms and collaborative principles solely through traditional means of examining extensive, yet often fragmented, design documentation. The limitations of document-based analysis frequently lead to unforeseen integration conflicts, which are typically discovered late in the development cycle, resulting in substantial rework costs and project delays. To address this pervasive industry challenge, this paper selects the aircraft ground deceleration function as a representative case study and proposes an innovative, simulation-based validation methodology. This approach systematically utilizes model state machines to create a dynamic digital representation of the system-of-systems, enabling rigorous validation of aircraft deceleration requirements under various operational scenarios. By adopting this model-based systems engineering (MBSE) paradigm for mechanism representation, our approach effectively captures the nuanced coordination, timing dependencies, and dynamic interactions within the multi-system operational logic. It thereby facilitates the intuitive identification, analysis, and resolution of potential design flaws, including logical conflicts, deadlocks, race conditions, and uncovered or ambiguous requirements. Consequently, the method not only provides a robust framework for validating the aircraft’s function-related design requirements with greater confidence but also offers crucial, data-driven support for the iterative optimization and evolution of the overall functional architecture. The fundamental value proposition of this research lies in its transformative capability to convert implicit design knowledge and assumptions—originally scattered across voluminous documents, specifications, and expert minds—into an integrated set of executable, observable, and analyzable formal models. This digital thread enables systems engineers and designers to identify deep-seated integration and coordination issues proactively during the early conceptual and detailed design stages, rather than relying on discovery during the late, costly integration and testing phases. By shifting validation left in the development V-cycle, this approach significantly reduces the risk of major design changes and associated cost overruns later in the project lifecycle. Ultimately, it effectively enhances the overall maturity, safety, certifiability, and operational reliability of complex aircraft function development, paving the way for more efficient and predictable engineering processes.
Mingqian Wang, Q. Yu, Miao Yu et al.· SAE technical paper series· 0 citations
The disassembly and collection of railway fasteners are critical components of track maintenance, directly influencing the efficiency, safety, and sustainability of railway operations. Currently, manual operations are hindered by high labour intensity and safety risks, while semi-automatic equipment remains limited by its reliance on manual positioning. Specialized machinery often suffers from low collection rates and poor compatibility across diverse fastener types. Although various robotic disassembly technologies have been proposed, existing solutions face significant challenges, including coaxiality deviations between the end-effector and the nut assembly, and insufficient compensation for angular and positional misalignments during high-speed execution. To address these issues, this paper proposes a novel fully automated railway fastener disassembly and collection system. The system integrates a specialized pneumatic end-effector with a universal joint limiting mechanism designed for angular deviation compensation and high-speed swing suppression. Furthermore, a modular mechanical architecture comprising six core functional modules is developed to realize a continuous material handling sequence from disassembly to centralized storage. A test platform simulating realistic railway operating conditions was constructed to conduct comparative experiments under varying lateral offsets. The results demonstrate that the proposed configuration achieves a 100% operational success rate under lateral deviations of 0–2.0 mm and maintains an 80% success rate at a maximum deviation of 3.0 mm, significantly outperforming conventional configurations. These findings provide a robust technical reference for the intelligent transformation of railway maintenance by enhancing operational reliability and reducing manual intervention.
Jianglong Guo, Chen Li, Zhijie Wang et al.· Proceedings of the Instituti...· 0 citations
Manual operation of barriers at access points can increase operator workload and may delay vehicular movement. This study designed, constructed, and evaluated a remote-controlled gate cross bar intended to provide a low-cost wireless alternative for automated access control. The system integrated an Arduino Uno microcontroller based on the ATmega328P, a 433 MHz radio-frequency transmitter and receiver, a 12 V DC geared motor, a motor-driver module, limit switches, relay control, status indicators, and a mechanical barrier arm. The control program processed remote commands, activated bidirectional motor movement, and used limit-switch feedback to stop the barrier at the fully open and closed positions. Performance was evaluated under outdoor conditions using 20 opening-and-closing cycles. The measured parameters included response time, opening time, closing time, remote operating range, and operational consistency. The system recorded a mean response time of 0.61 ± 0.05 s, a mean opening time of 2.43 ± 0.08 s, and a mean closing time of 2.48 ± 0.07 s. Stable RF communication was maintained over an average distance of 25 ± 1.2 m. Temporary electromagnetic interference, metallic obstacles, reinforced-concrete walls, and minor power-supply fluctuations affected signal reception or motor speed during some observations. No mechanical failure, motor overheating, excessive vibration, or structural deformation was reported during testing. The developed prototype demonstrated the practical integration of locally available mechanical and electronic components for wireless gate operation, although further evaluation under broader field conditions is required.
M. E. Ishaje, N. Akonjom, E. O. Obi et al.· Physical Science Internation...· 0 citations
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