The challenge
At the loading docks of an international airport, there was no automated system for managing inbound and outbound freight traffic. Trucks entered the loading area without certainty of available dock spaces, leading to unnecessary waiting times and unsafe situations on the premises. Manual control was labor-intensive and prone to errors, especially during busy periods.
The client set concrete requirements: the system had to track in real-time how many loading docks were occupied, always give outgoing traffic priority, and stop incoming trucks as soon as no free loading dock was available. The entire system had to be scalable from 4 to 9 loading docks and remotely accessible for maintenance and monitoring.
The solution
Vision Partners developed the PLC software and supplied two identical control cabinets, each equipped with a 12-inch touchscreen HMI display. The software was written in TIA Portal and runs on a Siemens S7-1200 PLC — a platform with which Vision Partners has built extensive experience in industrial environments.
The system consists of:
- PLC software (Siemens S7-1200 / TIA Portal): Controls two traffic lights based on the real-time number of occupied charging docks; outgoing traffic always has priority and stops incoming traffic before outgoing gets a green light.
- Presence Detection Sensors count the number of trucks in the loading area; if there is a discrepancy with the number of occupied docks, the system automatically corrects it after an adjustable reset period.
- HMI touchscreen shows the current status of all docks in color; settings such as the maximum number of trucks and the reset timer are secured behind a login.
- Control cabinets two identical cabinets with connections for sensors, traffic lights, and power supply; suitable for at least 9 charging docks and 2 detection sensors.
- Remote access Both systems can be accessed remotely via a 4G connection (IXON module), enabling remote maintenance and diagnostics.
- Optional outdoor display: Extra visualization of the number of free docks directly at the traffic light at the entrance.
The result
The system went live at the international airport at the end of 2024. After a successful factory acceptance test (FAT) and a site acceptance test (SAT), the system was put into production. Since then, the traffic control system has ensured a smooth and safe flow of freight traffic: incoming traffic is automatically held back as long as no free docking bay is available, and outgoing traffic has priority at all times.
The HMI provides the dock manager with real-time insight into occupancy rates, and the system automatically corrects any counting discrepancies. Thanks to the 4G connection, Vision Partners can provide remote support without needing to be physically present.
Vision Partners managed the entire process: from software development and hardware delivery to FAT guidance, on-site SAT, and knowledge transfer to the operational organization.
Want to know more about custom automation solutions? Contact us via www.visionpartners.nl/contact.
