Retrofit Project for Railway Water Station
Challenge
The modernization of the fresh water station had to meet several critical requirements. The system needed to prevent staff from simultaneously connecting drinking water and wastewater hoses. After 24 hours of inactivity, an automatic hygiene flush should occur. To minimize downtime, the system needed to report malfunctions to the control center in real-time and enable service technicians to resolve issues remotely. Comprehensive logging was required to document legally mandated functional tests and detect leaks early.
erminas, a system integrator and product developer from Oldenburg, specializes in Industrial IoT. The company supports production processes and product digitalization.
Solution
erminas integrated a Revolution Pi system with the RevPi Core and the digital I/O expansion module, RevPi DIO, as the central control unit. The system controls electrical locks, buttons, LEDs, heaters, water meters, and magnetic ball valves. A DIN rail router connects the system to the internet, allowing it to retrieve weather data and automatically regulate the heaters.
Implementation
The Revolution Pi system continuously monitors all station components. It communicates with the I/O modules via Modbus TCP and forwards fault messages directly to the Siemens control center system. Service technicians automatically receive SMS and email notifications for malfunctions and can control the system remotely. The system logs all operational data for functional tests required by the Federal Railway Authority.
Technologies used:
- RevPi Core as central control
- RevPi DIO for digital inputs and outputs
- Modbus TCP communication
- DIN rail router for internet connection
- Connection to Siemens control system
- SMS and email notification system
Results & Outlook
The system reliably controls the station and enables efficient remote maintenance. The automatic fault detection and notification minimizes downtime. The detailed logging fulfills all legal requirements and helps detect leaks early.
Featured Products
COMPACT CONTROL SYSTEM
REVPI CORE
- Compact and cost-efficient
- Perfect for limited space in the switch cabinet
- Expandable with I/Os and gateways
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