At Germantown Academy (GA), the Senior Project program is more than a tradition; it’s a rite of passage. For over 50 years, it has allowed seniors to step outside the classroom and into the real world. This year, that opportunity took the shape of a traffic light.
Under the mentorship of Ed Brogan, Application Technology Specialist at Airline Hydraulics, and Mark Steffens, CEO of Airline and proud GA Class of 1988 alumnus, a group of students designed and built a fully functional, programmable traffic light intersection.
Their month-long project combined hands-on engineering and lessons in logic, design, and perseverance. Oh, the places you’ll go when education meets opportunity.
Keep reading to learn how their PLC programming project came to life, wires, logic, lights, and all.
🚦 Jump to the Video & See the Traffic Light Simulator in Action!
PLC Programming Through Real-World Projects
In a world driven by automation and smart systems, it’s never too early to start thinking like an engineer. And that’s exactly what these students did: during the last month of their senior year, they took on the challenge to build something technical and tangible. And with guidance from Ed, they brought their traffic light to life.
This wasn’t like LEGO® bricks. It was a real, working build. The students:
- Designed a custom metal frame (provided by Airline Hydraulics)
- Cut and fit plexiglass panels for the light housing
- Wired the electronics from scratchProgrammed a PLC (Programmable Logic Controller) using CX-Programmer One
The result? A professional-grade intersection simulator that reflects actual traffic signal logic and sequencing.
🚦 Watch the project in action:
See how these students engineered, programmed, and assembled the entire system from the ground up in our video below.
Video not loading? Watch on YouTube!
Where Curiosity Meets Code:
Students programmed the PLC to follow a precise timing sequence:
Green and red lights – 10 seconds
Yellow and red lights – 4 seconds
Red on both sides – 2 seconds
Each sequence mirrored real-world intersection timing. Every signal was coded, tested, and refined by the students themselves.
Before writing a single line of logic, they first had to understand core electrical engineering concepts: the difference between DC and AC power, how to safely wire and assemble circuits, and how to use timers to control output states.
This hands-on approach sparked curiosity, built confidence, and taught students what it feels like to bring a design to life and make it work.
Take the Next Step: Learn PLC Programming Yourself
Inspired by what these students built? You can do it, too.
Whether you're a student, educator, or industry professional, our PLC Programming Courses are designed to help you build real skills through real projects, just like this one.
👉 Click here to explore course outlines and request a class.
Basic PLC Programming Course |
Advanced PLC Programming Course |
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Perfect for beginners, this two-day course introduces you to the fundamentals of PLCs. You'll dive into:
You'll walk away with the confidence to program, debug, and modify your own logic.
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For those ready to level up, the advanced course explores:
Through instructor-led sessions and hands-on labs, you'll master complex functions and develop custom logic for real-world applications. |
Why This Matters
At Airline, we believe real learning happens through building. Projects like this traffic light simulator bring abstract concepts to life and show that learning isn’t confined to classrooms or textbooks.
We also know that industrial technology can be intimidating, but it doesn’t have to be. Our mission is to make complex systems accessible and approachable, especially for student learners. Through mentorship and hands-on experience, we help students develop real-world skills with real-world equipment.
And above all, we invest in the next generation of thinkers, makers, and problem solvers. These students aren’t just building circuits; they’re building confidence, creativity, and career potential. Every screw turned, and wire connected is a step toward becoming tomorrow’s innovators.
This project demonstrates what is possible when students are supported with mentorship and resources.
Let’s Keep Building
We’re proud to keep playing a part in this inspiring intersection of education and innovation. Because one day, the students who built this project may be the ones designing smarter cities, solving global challenges, or leading the next wave of automation.
Interested in learning more about how Airline Hydraulics supports STEM education and mentorship?
Check out some of our initiatives below or contact us to see how we’re helping shape the engineers of tomorrow.
- Our Tech Traveler is a mobile technology showcase that can come directly to your school or event, featuring live demos of cutting-edge automation tools.
- Demos and Training: How to Teach Cobots & Automation to Middle-Schoolers? | Lancaster Science Factory Field Trip
- Press Release: Philadelphia's La Salle Academy Celebrates Successful After-School STEM Program with Local Manufacturer, Airline Hydraulics
- Article: Airline Hydraulics Corporation's CEO, Mark Steffens, Recognized for Mentorship in Suburban Life Magazine
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