Key Functionalities & Benefits
- Comprehensive PLC programming – Development of a complete traffic control and safety system on the Phoenix Contact PLC platform.
- High data capacity – Management of over 4,000 data points across subsystems (sensors, fans, lights, alarms, and control panels).
- Profinet network integration – Reliable real-time communication between PLC units and field devices.
- Redundant system architecture – Fault-tolerant design ensures continuous operation even in the case of hardware failure.
- Full-Scale simulation environment – Digital twin system built for software verification and automated test execution.
- Automated testing protocols – All control functions are thoroughly tested against formal test cases prior to live deployment.
- Optimised electrical plans – Collaboration with electrical engineers to refine schematics and ensure efficient wiring and layout.
- Safety & compliance – System designed to meet tunnel safety regulations for fire, smoke, and traffic control.
- Scalable design – Architecture enables future extensions or upgrades without requiring redesign of core systems.
Cross-Industry Opportunities
The methods and technologies applied in this tunnel project can be adapted to several industries requiring safety-critical automation and reliable process control, including:
- Transportation infrastructure – Railway and metro tunnel automation
- Energy and utilities – Power plant and substation control systems
- Industrial facilities – Ventilation, cooling, or safety control for manufacturing environments
- Smart buildings – Integrated fire safety and HVAC automation
- Water treatment plants – Process control with redundancy and remote monitoring
Door2World’s experience with large-scale PLC systems makes these solutions transferable to any sector that demands reliability, safety, and precise automation.
Building critical infrastructure demands precision and reliability.
Let’s develop your next PLC-based control system — designed for fault tolerance, safety, and long-term stability in demanding environments.
Technical Scope
- PLC Platform: Phoenix Contact
- Data Points: 4,000+
- Network Protocol: Profinet
- Architecture: Redundant and fault-tolerant PLC system
- Functions Controlled: Traffic management, smoke extraction, heat control, fire protection
- Simulation: Full-scale virtual model with automated test execution
- Testing: Automated functional testing per defined test cases
- Engineering Support: Electrical plan finalisation and optimisation
Results / Impact
- Achieved continuous system reliability through fault-tolerant control.
- Streamlined commissioning with automated testing and validated simulations.
- Improved safety assurance with verified control logic for fire and smoke extraction.
- Enhanced maintainability and long-term scalability for future system extensions.
Competitive Differentiators
- Proven expertise in critical infrastructure automation (transportation and safety systems).
- Redundant PLC design and automated test environment ensure unmatched reliability.
- Strong cross-disciplinary collaboration between software and electrical engineering.
- Capability to manage large-scale, multi-point automation projects with full lifecycle support.