PLC Based Automated Traffic and Ramp Control for Railway Crossings

EE student graduation project

Title: PLC Based Automated Traffic and Ramp Control for Railway Crossings

Student: Haris Sadžak

Mentor: Assistant Professor Dr. Mohammad Al Samman

This project presents the development of a fully operational prototype of an automated railway crossing system, implemented using an ABB AC500 PM5630 PLC and a DA501 I/O module. The system integrates a custom 3D-printed traffic light and a NEMA 23 stepper-motor-driven ramp mechanism, coordinated through a ladder-logic control program developed in ABB Automation Builder. The control architecture manages all signaling phases—green blinking, yellow, and red—while synchronizing ramp motion based on a simulated tram-detection signal. Electrical schematics were designed in EPLAN, and the traffic light model was created in Autodesk AutoCAD and Inventor prior to fabrication. Real-time testing demonstrated reliable and consistent operation, highlighting the potential of PLC-based automation to enhance safety and efficiency compared to traditional timer-based systems. The prototype establishes a solid foundation for future extensions, including integration of real sensors and advanced safety diagnostics.