A STUDY ON AUTOMATIC RAILWAY GATE CONTROL BY USING PLC

INTERNSHIP PROJECT SUBMITTED TO THE

NATIONAL SMALL INSUDTRIES CORPORATION

A REPORT SUBMITTED

IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY

IN

ELECTRICAL AND ELECTRONICS ENGINEERING

BY

.
Sl No. Roll no Name
01 19311A02A6 Mangali Vijaya Laxmi
02 20315A0226 Kammari Swetha
03 20315A0230 Nagireddy Prashanth Reddy
04 20315A0232 J Yashwanth

Under the guidance of

K SAMPATH KUMAR GOUD SIR (NSIC)
And
KAMARAJU SIR (NSIC)
 NATIONAL SMALL INSDUSTRIES CORPORATION
ECIL X ROAD, HYDERABAD

CERTIFICATE

This is to certify that the project report entitled study of AUTOMATIC

RAILWAY GATE CONTROL BY USING PLC has been carried by the team in
partial fulfillment the award of the degree of bachelor of technology under the
guidance of the Mr. K SAMPATH KUMAR GOUD SIR and KAMARAJU SIR
,and being submitted by

.
Sl No. Roll no Name
01 19311A02A6 Mangali vijaya laxmi
02 20315A0226 Kammari swetha
03 20315A0230 Nagireddy Prashanth Reddy
04 20315A0232 J Yashwanth
 ABSTRACT
The programmable logic controller (PLC) is the central controlling unit in the industry or a
process. The effective operation of the process and safety considerations if programmed
appropriately can meet the required objectives.

At present railway crossing gate control system is being operated manually thus many
accidents are being occurred if it is not done in proper time. So, it is needed to be automated to
reduce accidents. In this work an automatic railway crossing gate control system has been
develop using a PLC(programmable logic controller).The automatic control of railway gate
crossing deals with two aspects, firstly it deals with the reduction of time for which the gate is
being kept closed and secondly, to provide safety to the road users by reducing the accident.

The main aim of using PLC is to remove the manual work completely. It reduces the
errors and time of operation.PLC is used because of the fact that consists of timers which cannot
make the system bulk and complex. Programming is carried out on” SELPRO PLC”
programming software. Signaling light models are implemented using sensors and several output
devices i.e railway gates are operated using DC motors.
 ACKNOWLEDGEMENT

We are very thankful to our principal shivaReddy sir and our head of the
department barghava sir and entire electrical department for motivating us to do
internship with NSIC
It is always plesure to remind the fine people in the NATIONAL SMALL
INDUSTRIES CORPORATION for their sincere guidance we had received to
uphold my practical as well as theoretical skills in engineering.
We would like to thank THULASINGAM MUTHUKUMARAN SIR for
encouraging us to learn about PLC and maintaining friendly relation with us and
extending the friendship towards us and making a pleasure training environment in
NSIC.
We would like to thank KAMARAJU SIR for explaining basics of electrical
engineering and also explained components used in PLC and he cleared all doubts
regarding all.
We would like to thank K SAMPATH KUMAR SIR for the positive attitude
towards students .He explained about PLC and basics of PLC. He played a
fantastic role to complete the PLC and also he proposed one project for us
AUTOMATIC RAILWATY GATE CONTROL BY USING PLC
Finally we apologize all other unnamed who helped us in various ways to have a
good training
We thanks to one and all for their direct and indirect help at the various stages of
our project .
CHAPTER 1

1.1 Introduction about PLC

1.2 Block diagram
1.3 List of components used in block diagram
1.4 Programming languages and types
1.5 Scan cycle
1.6 Program instructions
1.7 Gates used in

1.71 OR Gate

1.72 AND Gate

1.73 NAND Gate

1.74 NOR Gate

1.75 EX-OR Gate

1.8 Counters

1.81 Up counter

1.82 Down counter

1.83 Up/ Down counter

1.9 Timers

2. CHAPTER

COMPONENTS USED:

2.0 IR sensor

2.1 Types of sensors

2.2 Gear motor

2.21 Types of gear motors

2.3 Relays

2.31 Types of relays

2.4 LED ( Light Emitting Diode)

3. CHAPTER

PROPOSED PROJECT

AUTOMATIC RAILWAY GATE CONTROL BY USING PLC

3.0 Introduction

3.1 diagram

3.2 components required in project

3.3 block diagram

3.4 Introduction to selpro 5.327

3.5 Details about how to create a ladder diagrams in selpro 5.327

4. CHAPTER

PROGRAM:

4.0 Circuit diagram (program) and working

5. CHAPTER

5.0 Circuit without simulation

5.1 Simulation results

6. CONCLUSION
1. INTRODUCTION:

1.1 PROGRAMMABLE LOGIC CONTROLLER

• Programmable logic controllers are often designed as miniature industrial

computer, to perform or to control the output by using logic function or
logic input.
• PLC consists of input element like push button, sensors, switches etc and
final elements (output element) like solenoid valve, contactors , relays,
actuators ,etc

1.2 BLOCK DIAGRAM OF PLC

POWER SUPPLY

SENSORS CPU VALVES

CONCTACTORS
SWITCHES MEMORY
MOTOR
PUSH COMMUNICATION
BUTTON

Upload download

PERSONAL
COMPUTER

1.3 COMPONENTS:

POWER SUPPLY
• 24V DC, 230V AC
• Inbuilt SMPS (Switch Mode Power Supply) PLC 230V
• 230V DC (CPU of PLC)
• 230V AC Personal computer of PLC
 • CPU is the heart of PLC. It is mainly useful for uploading and downloading
the application of program.
➢ Uploading is a process of taking a program from PLC to PC.
➢ Downloading is a process of giving program to PLC from PC.
➢ CPU is having communicating ports for communicating with PC and
other devices it some indications like RUN ,STOP ,ERROR ,FORCE,
ON, Force off, system fault ,breakdown fault etc..

MEMORY

For processing the program memory is divided into three types.

✓ System memory: system memory is for write the program.
✓ Load memory: To store the program.
✓ Work memory: To execute the program.

COMMUNICATION RS 232

Serial bus

RS 485

Ethernet bus (cable)

RS- recommended standard

I/O Devices:

Analog Digital

Analog i/p Analog o/p digital i/p digital o/p

1.4 PLC PROGRAMMING LANGUAGES:

1. Ladder logic diagram

2. Sequential function chart
3. Function block diagram
4. Structured text
5. Instruction text
Ladder logic diagram: Graphical type of PLC programming language. Ladder
diagram was originally modeled from relay logic which used physical
devices such as switches and mechanical relay to control.
Ladder diagram utilizes internal logic to replace all, except the physical
devices that need an electrical signal to activate them.
Ladder diagram is built in the form of horizontal rungs with two vertical
rails that represents the connection on relay logic schematics.
Sequential function chart: This decision based on timing a certain phase of
the process or physical state of the equipment.
Transitions are the instructions that you use to move from one step to
another step by the setting conditions of true or false.
Process can be broken into major steps that can make it faster and easier
trouble shooting.
Function block diagram: The function block diagram describes a function
between inputs and outputs that are connected in blocks by connection
lines.
Structured text: This language is a textual based language .structured text is
a high level language that is like basics, Pascal and C
You must write out each line of code and it uses functions such as FOR,
WHILE, IF, ELSE, IFELSE, AND, CASE.
Instruction list: The instruction list resembles assembly language when you
use this PLC programming language you will use mnemonic codes such as
LD (load), AND, OR, etc..
 1.5 SCAN CYCLE
I/P

Feed back

O/P LOGIC

The process of giving input and scanned total program and getting output from
PLC, It is called one scan cycle.

1.6 PROGRAM INSTRUCTIONS

Don’t connect two outputs coils in series.

Don’t connect two networks.

We can assign same network in any network.

We can assign same address in same network.

1.7 GATES:
1.71 OR GATE

1.72 AND GATE

Input A Input B Output

0 0 0

1 0 0

0 1 0

1 1 1
1.73 NAND GATE

1.74 NOR GATE

 1.75-OR GATE

1.8 COUNTERS:

1.81 UP COUNTER: When the output is ON for given counts (ex: 5 counts , 5 times
ON) if the CV and PV are equal output will ON.
IN ENO

R CV

PV

1.82 DOWN COUNTER: initially CV and PV will be equal when the input is high as
per PV value then the CV starts decreasing count by count ( maximum to
minimum)

When count i.e CV becomes zero then the output will be high.

IN ENO

R CV

PV
1.83 UP/ DOWN COUNTER: In up /down counter is a combination of an up
counter and down counter. It can count in both directions increasing as well as
decreasing.

CU ENO

CD QD

R CV

LD

PV

1.9 TIMERS:

ON TIME DELAY: When the input is input is high the output will be high after some
fixed delay.

In between if we OFF the input timer will run from starting (for every ON and OFF
timer is same)

IN ENO

PV CV

T#5S

When the output is high immediately output will ON. When we

OFF DELAY TIMER:
switch OFF the input, output will OFF after some fixed delay output will OFF.

IN ENO

PV CV

T#5S
2 . COMOPONENTS USED
2.0 IR SENSOR:

Infrared frequencies are influenced by hard articles (for example dividers, entryways), smoke, dust, haze,
daylight and so on Thus it doesn't work through dividers or entryways. Infrared waves at high force can harm
eyes. In screen and control application, it can control just a single gadget at one time.

Advantages of Infrared sensor

Following are the advantages of Infrared sensor:

➨It provides secured communication due to line of sight or point-to-point mode of communication.

➨The battery used in infrared devices last for long duration due to lower power consumption.

➨Infrared motion sensors detect motion in daytime and nighttime reliably.

➨The sensor does not require any contact with the product to be sensed. The infrared devices are

more appropriate for targets which are close than 10 mm.

Disadvantages of Infrared sensor

Following are the disadvantages of Infrared sensor:

➨Infrared frequencies are affected by hard objects (e.g. walls, doors) , smoke, dust, fog, sunlight

etc. Hence it does not work through walls or doors.

➨Infrared waves at high power can damage eyes.

➨In monitor & control application, it can control only one device at one time. Moreover it is difficult to

control things which are not in LOS (Line of Sight). It requires line of sight between transmitter and

receiver to communication.
 2.1 TYPEDS OF SENSORS:
• Push buttons.
• Selector Switch.
• Limit Switches.
• Factors in choosing sensors.
• Two types of sensors: Analog and Discrete.
• Proximity Sensor.
• Inductive Proximity Sensor.
• Capacitive Proximity Sensor.

2.12 GEAR MOTOR

The two most common geared motor types are right angle geared motor and inline geared motor.

• Right-angle geared motor use worm, bevel or hypoid gearing.

• Inline geared motor typically use spur gears, helical or planetary gear sets.
• Parallel shaft geared motors type helical gears

The Different Types of Gear Motors

There are a variety of gear motor types, each with special functions.

• Right-angle geared motors - These are electric motors coupled with a gear reducer. Right-angled
gear motors are commonly used in automation equipment for food services, agriculture, and medicine
because of their compact nature.
• Inline geared motors - Inline geared motors are formed from one body piece, which reduces the
potential for wear and deformation. These are ideal for rugged applications for industries like cement
manufacturing, power, shipping, and more.
• Parallel shaft geared motors - These use high-quality gears to reduce the speed of a machine's
operation. Parallel shaft geared motors are often used in stirring machines that mix large vats of
liquids.
• Planetary Gear Motors - Planetary Gearboxes are used on high precision motion control applications
that require a high torque, high torsional stiffness and low backlash. Ideal for motors whose optimal
efficiency is at higher speeds.

Importance of Gear Motors

A gear motor is a component of a much larger motor. It's used to adjust the whole mechanism's speed. This is
important for various applications, like controlling conveyor belts or the speed of stirring mechanisms. As such,
it's important to choose a high-quality and durable gear motor.
2.3 RELAYS:

Relay is a type of Switch which can switched ON or OFF with the help of a signal or a pulse of electricity.
For example, if you want to turn ON or OFF and LED using a Microcontroller, you can probably connect
the LED directly to the IO pin of the Microcontroller (with a current limiting resistor) and send a signal to,
well, turn the LED ON or OFF.

But what if you want to turn ON or OFF a 10W mains powered LED Bulb using a Microcontroller? As the
LED is a tiny device with small voltage and current requirements (which are reasonable for the
Microcontroller), it is connected directly to the IO Pin of the Microcontroller.

2.31Types of Relays
There are different types of relays like:

• Electromagnetic Relays
• Latching Relays
• Electronic Relays
• Non-Latching Relays
• Reed Relays
• High-Voltage Relays
• Small Signal Relays
• Time Delay Relays
• Multi-Dimensional Relays
• Thermal Relays
 • Differential Relays
• Distance Relays
• Automotive Relays
• Frequency Relays
• Polarized Relays
• Rotary Relays
• Sequence Relays
• Moving Coil Relays
• Buchholz Relays
• Safety Relays
• Supervision relays
• Ground Fault Relays
All these and many other relays are classified based on their function, application type, configuration or
structural features, etc. Now, let us take a look at various types of relays, which are more popularly used
in many applications.

Latching Relays
A Latching Relay is a relay which maintains its state after being actuated. That is why these types of
relays are also called as Impulse Relays or Keep Relays or Stay Relays. In applications, where there is a
need to limit the power consumption and dissipation, a latching relay is best suitable.

There is an internal magnet in a latching relay. When the current is supplied to the coil, it (internal
magnet) holds the contact position and hence it requires no power to maintain its position. So, even after
being actuated, removal of drive current to the coil cannot move the contact position but remains in its last
position. Thus, considerable energy is saved by these relays.
Latching relays can be made with one or two coils and these coils are responsible for the position of the
armature of the relay. Hence, latching relays don’t have any default position as shown in above figure.

In one coil type relay, the armature position is determined by the direction of current flow in the coil,
whereas in case of two coil type, the position of the armature is dependent on the coil in which current
flows. These relays can maintain their position once they are actuated but their reset position depends on
the control circuitry.

2.4 LIGHT-EMITTING DIODE (LED)

A light-emitting diode (LED) is a two-lead semiconductor light source. It is a p–n

junction diode that emits light when activated. When a suitable current is applied to the leads,
electrons are able to recombine with electron holes within the device, releasing energy in the
form of photons. This effect is called electroluminescence, and the colour of the light
(corresponding to the energy of the photon) is determined by the energy band gap of the
semiconductor. LEDs are typically small (less than 1 mm2) and integrated optical components
may be used to shape the radiation pattern appearing as practical electronic components in 1962,
the earliest LEDs emitted low-intensity infrared light. Infrared LEDs are still frequently used as
transmitting elements in remote-control circuits, such as those in remote controls for a wide
variety of consumer electronics. The first visible-light LEDs were of low intensity and limited to
red. Modern LEDs are available across the visible, ultraviolet, and infrared wavelengths, with
very high brightness.
Early LEDs were often used as indicator lamps for electronic devices, replacing small
incandescent bulbs. They were soon packaged into numeric readouts in the form of seven-
segment displays and were commonly seen in digital clocks. Recent developments have
produced LEDs suitable for environmental and task lighting. LEDs have led to new displays and
sensors, while their high switching rates are useful in advanced communications technology.
LEDs have many advantages over incandescent light sources, including lower energy
consumption, longer lifetime, improved physical robustness, smaller size, and faster switching.
Light-emitting diodes are used in applications as diverse as aviation lighting, automotive
headlamps, advertising, general lighting, traffic signals, camera flashes, lighted wallpaper and
medical devices. They are also significantly more energy efficient and, arguably, have fewer
environmental concerns linked to their disposal.
Unlike a laser, the colour of light emitted from an LED is neither coherent nor monochromatic,
but the spectrum is narrow with respect to human vision, and for most purposes the light from a
simple diode element can be regarded as functionally monochromatic.
 3. CHAPTER

AUTOMATIC RAILWAY GATE CONTROL BY USING PLC

3.0 Introduction:

When it involves public and private safety, it is always desirable to improve the signaling system
and the way people are warned about potentially dangerous situations. The existing conventional
signaling system most of the times rely on the oral communication through telephonic and
telegraphic conversation as input for the decision making in track allocation for trains. There is a
large scope for miscommunication of the information or communication gap due to the higher
human interference in the system [1]. This may cause the wrong allocation of the track for trains
that ultimately results in the train collision. The statistics within the developing country showing
that most of worst collisions occurred thus far are because of either human errors or incorrect
decision making through miscommunication in signaling and its implementation. At railway
crossing, the traditional railway system uses the warning lights and human controlled gates to
alert the people about an oncoming train. When the train leaves the station, the station agent
informs the gatekeeper regarding the arrival of the train using the telephone and telegraph. The
gatekeeper closes the gate depending on the timing at which the train arrives. Hence, if the train
is late because of certain reasons, then gate stay closed for an extended time inflicting traffic near
the gates [2]. By victimization, the automatic railway gate control at the railway crossing the
arrival of the train is detected by the sensing element placed on the track at a precise distance
from the gate. This sensing element detects the approaching train and consequently controls the
operation of the gate. When the wheels of the train moving over the track there will be position
switch and it will send the signal to PLC to indicate train arrival. This reduces the time that gate
is closed as compared to the gates operated manually. In addition, this also reduces the human
labor. This sort of automatic railway gate system is employed in associate unmanned gate
crossing where the probabilities of accidents are higher and reliable operation is needed.

A programmable logic controller (PLC) or programmable controller is an industrial digital

computer which has been ruggedized and adapted for the control of manufacturing processes,
such as assembly lines, or robotic devices, or any activity that requires high reliability control
and ease of programming and process fault diagnosis.
They were first developed in the automobile manufacturing industry to provide flexible,
ruggedized and easily programmable controllers to replace hard-wired relays, timers and
sequencers. Since then they have been widely adopted as high-reliability automation controllers
suitable for harsh environments. A PLC is an example of a "hard" real-time system since output
results must be produced in response to input conditions within a limited time, otherwise
 3.1 DIAGRAM

For automatic railway gate opening and closing system, PLC takes the reference of train position sensors. If
the train is closer to the level crossing, PLC activates its output and sends the close command through a relay
to gear motors which are coupled to the railway gate assembly.

3.2 COMPONENTS REQUIRED:

• PLC
• Gear motor
• Vibration sensor
• Led lights
• Traffic lights
3.3 BLOCK DIAGRAM:

SENSOR MOTOR
PLC

MONITORING AREA

FOR UNI -DIRECTIONAL CONTROL

PLC ladder diagram plays as important role here without it no function is possible. Here PLC
diagram means the program for the PLC which is stored in it to do the function according to
the diagram.

X0- Arriving train input of Sensor 1 for UP track. X1- departure train input of Sensor 2
for UP track. Y0-Operation of motor to closing gate.
Y2-for buzzer sounds.
Y1-Operation of motor for opening gate TMR- Time delay for motor
operation.
M1 to M9-These are memory bits used for avoiding repetition of above instructions.
This is the ladder diagram to control the gate with the help of input signal from the sensor.
This diagram shows the control ladder for unidirectional passage of train.

3.4 Introduction to SELPRO Version 5.3 SELPRO:

SELPRO is a user friendly Windows based software which
enables a user to draw and simulate ladder diagrams. We can configure HMI for PLCs with built
in HMI Supports Downloading of application in the PLC and Uploading of application from the
PLC.
Features of SELPRO Version 5.3

• User-friendly software based on IEC61131-3.

• On-line and Off-line Simulation modes ·
• Built in interface for configuration of HMI ·
 • Selective 8, 16 ,32 bit data type support for variables ·
• Selective retention of variable ·
• Auto-Save after preset time ·
• Auto-Read file at start up ·
• Selective Print operations for printing ladder diagrams ·
• Password protection for ladder file ·
• Facility of uploading project.
• Serial Printing facility.
• Master communication through Customize

Protocol Programming Language supported:

Ladder Diagram Data types supported: BOOL, SINT,INT, DINT, UINT, USINT,UDINT,
TIME, DATE, TOD, WORD, DWORD, REAL (FLOAT), LREAL(DOUBLE)

Maximum No. of ladder representations that can be made is 5000 Rungs. It also depends
on the product memory capacity.

Platform: Windows XP, Windows VISTA, Windows-7, Windows-8 RAM – 512 MB or

above Processor- Minimum 166 MHz

To start with SELPRO 5.3:

There are 2 ways of starting SELPRO 5.3

1. From the Start menu

Start>All programs>Selpro 5.3
2. Double Click on Shortcut on Desktop

3.5 How to create a ladder diagram in selpro soft ware:

➢ File
➢ New
➢ Project name
➢ Patch-drives
➢ PLC model (based on our requirement)
➢ Ok
➢ Write the program
➢ Save the program
➢ Go to simulation
➢ RUN(offline or online)
➢ Stop
 4.CHAPTER

PROGRAM
 Input devices Output devices
Switch-1 Gate-1
Sensor -1 Relay
Sensor -2 Red and green LEDs
Set Reset
Switch-2 Gate-2

Input switches:

• Normally opened
• Normally closed
Outputs:

• Coil (lamp or LED)

4.1 WORKING:
• Firstly switched is manually operated.
• Set is automatically sensed by the vibration sensor.
• As soon as the sensor senses the signal then red light is ON.
• Then automatically for certain time gates will be closed.
• When gate closes train will run along the track for certain time
• One more vibration sensor senses the signal then green light is ON then automatically the
red light will OFF.
• After few minutes gates will be opened.
• To continue this process we need to reset the whole process by clicking the resets input
button.
• Then automatically this process will continue when number of train occurs.
 5. CHAPTER
5.1 SIMULATION RESULTS:
Circuit diagram without simulation:
Simulation on 1
Simulation 2
Simulation on 3
Simulation on 4
Simulation 5
Simulation OFF:
 6. CHAPTER

CONCLUSION:
The accidents are avoided at places where there is no person to manage the railway crossing
gates .Here we use the DC motor to open and close the gates automatically when it rotates
clockwise or anticlockwise direction to operate the gate automatically .When the train arrives
in a particular direction the sensor senses and generates appropriate signal, then at the same
time the PLC provides certain output signal to the DC motor to function. When the signal from
PLC is sent to the Gear motor rotates to function open/closes the gate according to the signal
output from sensor. Nowadays the railway protection system can be done either by manual
process (or) by semi-automatic process using embedded system technology. The intention of the
proposed idea is to provide gate control using single PLC. It will remove the manual work and
makes the whole system fully automated. This system provides a remarkable change in railway
system for protection purpose with affordable cost.