GANI MANUFACTURING + ENGINEERING — SERIESTürkiye · Denmark

Signalling and maintenance electronics for six major crossings

Electronic units for lane signalling, the under-deck maintenance units and the cable cars that carry inspection crews along the main cables — on the 15 Temmuz Şehitler, Fatih Sultan Mehmet, Yavuz Sultan Selim, Osman Gazi and 1915 Çanakkale crossings, and in Scandinavia on the Stord and Bømla crossings in Norway and a further crossing in Denmark. Built and tested by GANI Manufacturing, specified and programmed by GANI Engineering, for a globally known technology group and a public authority — both named on request.

PROGRAM PROFILE

Delivery geography: Türkiye & Denmark
Variants in scope: 6 crossings, 4 unit types
Program duration: Multi-year programme with repeat batches
Responsibility level: Series
Standards applied: IEC 60068 environmental test practice · IPC-A-610 Class 2 as practice · Operator functional specification

THE BUILDING

Schematic elevation drawn by GANI to locate the scope — not an architectural document.

THE CHALLENGE

A bridge is a machine that is never switched off. Lane signals tell traffic what a closed lane means; the maintenance gantries under the deck carry people over open water while inspection work is done. Both need electronics that survive salt air, vibration and a temperature swing from a Marmara winter to an August afternoon — and that can be serviced years later without a specialist flying in. The equipment is also spread across two climates: five Turkish crossings and a Danish one, where the same electronics meet North Sea damp, road salt and icing — different builders, different vintages, one discipline.

STARTING CONDITION

Functional requirements and interface definitions came from the operators and equipment builders. The electronics, their production and the embedded programming were ours to define and deliver.

CUSTOMER PROVIDED

Functional and interface specifications per crossing
Environmental requirements: salt, humidity, vibration, temperature range
Safety and interlock requirements for maintenance movement
Existing equipment documentation for the older crossings
Cold-climate, icing and de-icing requirements for the Danish crossing
Maintenance and spare-part expectations for a multi-decade asset

GANI OWNED

Electronic design review, component selection and derating for the marine environment
Production of the control and signalling electronics with conformal-coated assemblies
Drive, position and safety electronics for the maintenance cable cars, including the emergency-stop chain
Embedded programming, parameter sets and commissioning software
Functional test on a fixture that reproduces the field interfaces
Serialized units with a build and test record retained for the asset lifetime
Spares and repeat batches supplied from the same documented build

OUTCOME

What the program delivers.

One electronics family serving five crossings instead of five one-off solutions
Units serialized and traceable, so a replacement matches what is already installed
Programming and parameters versioned with the hardware, not kept in someone’s laptop
Repeat batches and spares produced years later from the same released documentation

THE PROGRAM, PART BY PART

Three scopes, kept apart.

Lane signalling electronics

The signals over the deck are the only thing standing between a closed lane and a driver at speed. The electronics that drive them are built to be boring: they show what the operator commanded, they say so back, and they fail in a way the control room sees.

Drive electronics for the signal heads on the deck gantries
Status feedback per head, reported back to the operator system
Position, limit and safety input handling
Local diagnostics and fault indication for the maintenance crews

Under-deck maintenance unit

The unit travels its rail under the deck with people on board, over open water. Its control is an interlock problem before it is a motion problem: nothing moves unless every condition for moving is true.

Travel drive control along the under-deck rail
Interlock chain: no motion without every permissive true
End-of-travel limits and emergency stop wiring
Operating panel with clear state for the crew on board

Maintenance cable car

The cable car carries the inspection crew along the main cable, from deck level to the tower top. Drive control, travel limits and the emergency-stop chain are the whole product; the cabin is the easy part.