May 14, 2020

Case Study: Subway Control Systems With REGUL PLCs

The market of industrial automation has been continuously growing. The requirements for the equipment for automation are increasing and are becoming more complex with each year. The profitability of each company depends more and more on the quality of automation of its processes. It means that equipment has to be reliable, productive, ready for long-term use without failures.

Regul R600 Programmable Logic Controller

Image 1. Regul R600 PLC

GP Systems GmbH has been developing integrated products for industrial automation since 2014. First, were released programmable logic controllers REGUL, capable of being the backbone of a control system of any size.

Flagship products in this line of controllers, REGUL R600 and R500, are high-speed solutions for automation of complex technological objects. One of the crucial features of these series is a bi-directional redundant internal data bus. In 2016, we extended REGUL product line with series R400 and R200. They were designed for the use in local control systems and as remote terminal units (RTU) in most stringent operating conditions.

Since all the REGUL series operate on the same type of internal bus, it is possible to create a multitude of configurations of the control systems.

Supporting extended operating temperature range and having an increased level of protection, as well as high-performance specifications, controllers of the REGUL line are capable of solving any task given to them by customers. They are already in operation at the systems in the power industry, oil and gas, and industrial companies. Besides, REGUL RX00 controllers can be used in the transport industry. In particular, to control operation of the equipment and escalators in the subway facilities.

The modern subway system is a multi-level system that includes scheduling for trains, supply of power for all the equipment, ventilation, water and heating supply, operation of escalators, etc. Automation of the equipment and consolidation of control of these processes is a logical consequence to provide safety for passenger and punctuality of transportation.

In the subway control systems remote control is used historically. Operators on duty control processes remotely within their stations of responsibility, and along the adjacent tracks, while the operator of an escalator is responsible for local control of the equipment. Equipment for automation for the systems with such specifications requires continuous and reliable operation in harsh conditions: it includes 24/7 operation, lack of space for placement of the equipment, electromagnetic noise, etc. To all those requirements responds equipment made by GP Systems GmbH: the family of REGUL RX00 PLC satisfies entirely to the requirements control systems for subway automation.

For example, REGUL R500 PLC with full redundancy is used for the critical engineering facilities: tunnel ventilation and escalators. Full redundancy means that each CPU module controls its own set of the I/O modules, being a complete “mirror” of the second CPU.  Each module, central processor, a power supply, or an I/O, can be easily replaced in hot-swap, without interrupting power supply and without suspension of the technological process.

Regul R500 PLC - 100% Mirror Redundancy

Image 2. Example of “mirror” redundancy with Regul R500 PLC

For the automation of the waste-water and sewage systems are used REGUL R500 PLC with a non-redundant implementation, or even REGUL R200 PLC, in a compact housing, and capable of operation from -40 to +60 °C.

Choice of the controller does not impact integration between or among the controller systems, or configuration and programming. Each controller operates on the same type of Regul bus and is programmed in the Epsilon LD environment. Integration with third-party systems is done over the Modbus, OPC, or IEC protocols, built-in into the CPU modules by default.

Engineers of our group are continuing to expand the product line and types of modules for all the families, satisfying increasing complexity in requirements to the systems.

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