Category: Transportation, None

Autocesta Zagreb-Macelj Ltd.

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Zagreb, Republic of Croatia

Zagreb-Macelj Motorway - part of a highway network in the Republic of Croatia located in the European traffic corridor of the Xa and Phyhrn motorway

Challenges

  • Need for centralized system – Required advanced SCADA to monitor traffic and maintenance from single point in Krapina, replacing existing fragmented systems.
  • Custom protocol integration – TLS2002 BASt protocol wasn't supported by standard industrial SCADA systems, requiring custom development solution
  • High availability requirements – System needed redundancy and scalability for critical traffic safety operations across 59.2km motorway with tunnels.

Results

  • Dramatic Cost Reduction – Backend development costs reduced 5x-7x, frontend costs reduced 2x-4x in workforce hours
  • Faster Implementation – Backend setup completed in weeks instead of months, rapidly accelerating deployment timeline
  • Enhanced Safety & Automation – Multiple automatic scenarios implemented including fire response, traffic flow regulation, and emergency protocols
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PrecisionX greatly improved our insight into the system and its crucial elements. It is comprehensive but intuitive.

— Operator in the Krapina Traffic Control and Highway Maintenance Center

About the Autocesta Zagreb-Macelj Ltd

The Autocesta Zagreb-Macelj Ltd. was established in March 2003 by government decision of the Republic of Croatia. The company’s purpose is to finance, build, operate, and maintain the Zagreb-Macelj Motorway and all related facilities.

Its mission is to maintain traffic safety at the highest level and to attract a larger number of travelers, thus creating economic as well as overall development in areas along the motorway. The mission also includes attaining environmental and energy sustainability and efficiency.

The company aims at maintaining proper management, maintenance, and modernization to provide the highest level of safety and comfort to make this highway attractive for the transport of both people and goods.

The Zagreb-Macelj Motorway is part of Croatia’s national highway network and lies within the European traffic corridor Xa and the Phyhrn motorway (Nürnberg-Graz-Maribor-Zagreb), connecting Croatian highways with the wider European network.

Key facts:

  • Starts at the Jankomir interchange on the Bregana-Zagreb-Lipovac motorway
  • Runs 59.2 kilometers through Zagreb and Krapina-Zagreb counties
  • Ends at Macelj, at the international border crossing with Slovenia
  • Includes 6 tunnels and 6 junctions
  • Operates a “closed” toll system with 2 frontal toll stations and 4 interchange toll stations
  • Recognized as one of the best highway connections between:
    • Central and Northern Europe
    • South and Southeast Europe
    • The Adriatic Sea
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PrecisionX greatly improved our insight into the system and its crucial elements. It is comprehensive but intuitive.

— Operator in the Krapina Traffic Control and Highway Maintenance Center
Autocesta Zagreb-Macelj Command Center Autocesta Zagreb-Macelj Command Center

Project Summary

The Autocesta Zagreb-Macelj required an advanced system to enhance its existing SCADA and enable centralized traffic monitoring, motorway management, and maintenance from the COKP Krapina control center.

Since the company preferred a .NET-based platform, it selected system integrator LED Elektronika Ltd.—a Zagreb-based R&D firm with proven expertise in intelligent transportation systems and custom .NET application development.

LED Elektronika conducted a market survey to identify the most suitable SCADA solution, focusing on key requirements:

  • Scalability for both small and large projects
  • High customization through open architecture
  • Redundancy to ensure high availability
  • Flexible UI/UX for fully customized designs and views

After in-depth analysis and testing of several options, the company chose GENESIS64 from Mitsubishi Electric Iconics Digital Solutions. The platform met all requirements and proved to be the strongest candidate for supporting reliable, future-ready operations.

Autocesta Zagreb-Macelj Command Center Autocesta Zagreb-Macelj Command Center

Software Deployed

Master Device View Master Device View
  • GENESIS64™
  • AlarmWorX™64
  • TrendWorX™64
  • GridWorX™
  • GraphWorX™64
  • ReportWorX™64
Master Device View Master Device View
PrecisionX Layout PrecisionX Layout

Realized Real-Time Benefits

Initially, LED Elektronika was using their PrecisionX SCADA system to collect, store, and process traffic data in real time and present it to operators in the Krapina Traffic Center. This capability resulted in reliable traffic surveillance and management, which are crucial for road safety.

To take these capabilities further, LED Elektronika enhanced its PrecisionX SCADA solution by building on top of the GENESIS64 platform. The result was a transportation-focused system designed specifically for tunnel and road automation. Setting up the backend (assets, data connections, and data collection/alarming) was completed in just a few weeks instead of months, significantly accelerating the implementation stage.

By modeling equipment and data as assets within GENESIS64, LED Elektronika was able to take an object-oriented approach to the data model. This made it possible to transition quickly from custom-developed .NET applications to GENESIS64. As a result, workforce hours were reduced by 5x to 7x, cutting backend engineering and development costs while preserving system redundancy and scalability.

Additionally, the engineering and development costs of the front-end resulted in a 2x to 4x reduction in workforce hours along with a preservation of backward compatibility (presenting the GUI via web browsers). The GENESIS GUI layout design capabilities with panels and vector graphics provide high quality and responsive designs, and using the dynamics on the objects provides effects that meet user expectations.

Now, several levels of automatic scenarios and algorithms can be implemented in the system. In the field with local controllers, an automated workflow is implemented to ensure the regulation of traffic flow, depending on the data from the traffic detectors, fire sensors, cameras, and wind and air quality sensors.

In the Control Center, a global workflow is implemented, thus coordinating multiple field devices to ensure global traffic regulation and flow over the entire section of the road. In case of a fire, a fire response scenario is activated, bypassing all active algorithms to ensure smoke and fire localization (stratification and ventilation of tunnels) and to secure traffic regulation and traffic rerouting with the primary focus of saving human lives.

Operators can also initiate manual control of the system to directly control equipment in the field via an intuitive interface. And if needed, multiple commands can be sent simultaneously to individual devices or selected groups of devices.

To achieve optimal user experience and to ensure smooth performance of the system at the same time, LED Elektronika developed a wide range of custom features which include the following:

  • TAB CONTROL – inside every popup window there is a tab control created through custom design manipulation.
  • TOOL TIPS – every device has a custom tooltip control in which its position changes dynamically according to the position of the device.
  • MENU – a custom main menu can be triggered by hovering over a defined area and a context menu can be triggered by right-click, allowing the user to acknowledge an alarm on that specific device, open a popup on a specific tab, etc.
  • DYNAMIC POPUP – content is generated dynamically from assets. This capability drastically reduces the number of display files and enables high scalability of the user interface.
  • GROUP COMMANDS – users can configure custom batch commands via the interface.
  • GROUP COMMANDS PREVIEW – the custom-created group command can be previewed, allowing the user to confirm if set up is correct before triggering the command.
  • BUTTON – allows for dynamic change of a button color depending on different states, for example, mouse enter, mouse leave, and mouse down.
  • TREND VIEWER TIME SPAN – the time span on a viewer was set to allow the user to have multiple pop-ups open while changing time span only on one.
  • OBJECT POSITION – allows for dynamic change of an object’s position. Icon on a road sign dynamically changes position depending on its real-time location.
  • MASTER/SLAVE DEVICE – allows for visual preview of a master/slave device, where a dynamic object changes visual appearance (for example, border color).

LED Elektronika then decided to test the limits of just how extensible the GENESIS64 platform could be. While the TLS2002 BASt protocol had been mainstream in road traffic systems and the intelligent transportation system (ITS) industry for the last 40 years, it was not commonly found on the supported protocol list of any industrial automation SCADA system.

Now thanks to GENESIS' Extensibility ToolWorX training and some dedicated collaboration, LED Elektronika was able to develop a custom point manager that plugged seamlessly into the communication layer of the SCADA system. In addition, since redundancy is a relevant part of the system, client and server redundancy were implemented on site due to the high requirements of the overall system stability.

PrecisionX Layout PrecisionX Layout

Conclusion

The Autocesta Zagreb-Macelj and LED Elektronika teams have had an excellent overall experience in implementing the project. They are quite satisfied and impressed with the new application, especially with the modern user interface design combined with the system’s high-level of performance and impressive scalability. The enhanced system allows more data to be acquired with better representations (graphs, charts, etc.).

Additionally, with the more intuitive interface and in-depth view of equipment and overall system status, the number of actions needed to be completed by operators in everyday use has been significantly reduced. To add to this positive experience, Mitsubishi Electric Iconics Digital Solution proved to be exceptionally fast in responding to and solving problems.

Currently, the Autocesta Zagreb-Macelj and LED Elektronika are adding features to get a better overall user experience. In particular, the Autocesta Zagreb-Macelj plans to expand the PrecisionX SCADA system by adding one more traffic subsystem that will allow operators to monitor and manage traffic flow. They will have the option to manage more traffic signs and monitor relevant traffic data.

The next step is to integrate traffic devices such as traffic detectors and traffic lights. LED Elektronika also plans to add a screen recording feature in the SCADA system. In the near future, they would also like to extend the user interface with augmented reality (AR) features and are considering leveraging Hyper Historian for its more advanced, asset-centric data collection capabilities.