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1
SUMMER TRAINING REPORT
ON
UNIVERSAL AXLE COUNTER FOR RAILWAYS
CENTRAL ELECTRONICS LIMITED
SAHIBABAD (U.P.) INDIA
Submitted as partial fulfillment for the award of
BACHELOR OF TECHNOLOGY Degree In
Electronic & Communication Engineering
Department of Electronic & Communication Engineering
H.R INSTITUTE OF TECHNOLOGY GHAZIABAD (U.P) INDIA
Submitted To Submitted By
Mr. Rajesh Sir Ramakant Tyagi
& B.Tech, Ece, 4th year
Ms. Swati mam (1219431055)
(Asst. Professor) H.R institute of Technology
H.R institute of Technology
2
CONTENTS
1. Certificate
2. Acknowledgement
3. Company Profile (a) The organization – CEL (b) Divisions of CEL (c) Products of CEL (d) Nation’s Pioneer & World leader in SPV (e) Innovative Electronic System
(f) Quality Policy of CEL
4. Universal Axle Counter (a) Introduction (b) Flow chart of manufacturing (c) Principle of working
(d) Brief description
(e) Specifications
5. Description of various modules System
4. Other products of CEL (a) SPV products (b) Cathodic protection system
(c) Ferrite Products
5. New Products
6. Self Evaluation
of Axle Counter
3
ACKNOWLEDGEMENTS
I am extremely thankful and pay gratitude to Ms. Shraddha Sood (HOD, ECE
Department, Hrit) mam for giving me opportunity for training. I would like to thank my respected parents, who always encouraged me and taught me to think and workout innovatively what so ever be the field of life. My sincere thanks goes to Mr. Vikash singla (Sr. Engineer) for his prodigious guidance, persuasion, and painstaking attitude, reformative and prudential suggestion throughout my summer training schedule. Special thanks go to Mr.V.K.Joshi (Sr.Technician). Who helped me a lot in giving minute details of Axel Counter in Railways. Department and enlightened me with the knowledge of Universal Axel Counter and their working and how it used in Railways. Last but not the least, my sincere thanks to all the staff members and friends for instilling in me a sense of self-confidence.
NAME: RAMAKANT TYAGI
BRANCH: (ELECTRONICS & COMM. ENGG.)
Institute: H.R INSTITUTE OF TECHNOLOGY
4
CENTRAL ELECTRONICS LIMITED
A PROFILE
ORGANISATION STRUCTUREOF CEL
CHAIRMAN &
MANAGING DIRECTOR
EXECUTIVE
DIRECTOR (OPERATIONS)
GENERAL
MANAGER
(CP & HRD)
GENERAL
MANAGER (PROJECT
MANAGEMENT)
Jt. GENERAL
MANAGER
(FINANCE)
Jt. GENERAL
MANAGER (MATERIALS
MANAGEMENT)
GENERAL
MANAGER
(SYSTEMS)
Jt. GENERAL
MANAGER
(MICROWAVE)
AGM (QUALITY
ASSURANCE)
AGM
(FERRITE)
GENERAL
MANAGER
(SPV)
Jt. GENERAL
MANAGER
( R & D )
Jt.GM (CERAMICS)
5
DIVISIONS OF CEL
Five business groups handle the total commercial operations of the Company. These are as follows:
SOLAR PHOTOVOLTAIC GROUP (SPV):
CEL, backed by an integrated production facility, has opened
up new horizons in the field of Solar Photovoltaic’s. It fulfills
the various demands from rural & urban areas, thus,
harnessing the solar energy. The products of this division are
Solar Cells, Modules and systems, which serve the industrial
needs of Railway Signaling, Microwave Repeaters, Defense
equipments, Obstruction warning lights at airports, etc. and
rural needs such as pumping systems for irrigation, street
lighting systems, solar lanterns and rural telecommunications.
ELECTRONIC SYSTEMS GROUP (ESG):
The Company is a pioneer in manufacturing of Railway
Signaling and Safety Equipments. It manufactures Axle
Counters, Railway Level Crossing Warning System, and
Solid State Interlocking System for Railways. The other
products of this division include Electronic Switching
System, Cathodic Protection System for underground
pipelines and VSAT.
6
COMPONENTS GROUP:
A large range of products is manufactured here using state-
of-art technologies to meet the requirements of
communications, defense, consumer and industrial sectors.
It is divided into three sub departments. Their products and
applications are as follows:
(a) Professional Ferrites:
This department manufactures different types of ferrite
cores for high frequency applications. The different
types of cores manufactured are Pot cores, E, U, I, RM,
torroids etc. These are called professional because they
require highly sophisticated techniques for their
manufacture and give a superior performance. The
various applications of ferrite cores include TV sets,
Communication equipments, computers, electronic
ballasts, switch mode power supplies (SMPS) and
Microwave equipments.
(b) Electronic Ceramics:
This department manufactures piezo-electric transducer
elements, high temperature crucibles, high speed
bearings and other alumina products. These products are
used in Defense ammunitions, Ultrasonic cleaners,
Buzzers, Sonar’s, Gas Lighters, Automobiles, etc.
(c) Microwave Electronics: This department manufactures microwave components such as Phase Shifters used in Radars, Direction Finding Systems, Frequency Correlators, Antennas, etc.
7
PRODUCTS Of CEL
The organization manufactures different products that can be classified according to the divisions of CEL as follows:
Solar Photovoltaic Group :
Solar Cells/Modules
Solar Lantern
Street Light System
Home Light System
Water Pumping System
Electronic Systems Group :
Single / Multiple Entry / Exit Axle counters
Universal Axle counters
Block proving system
Railway Level Crossing Warning system
Solid State Interlocking System for Railways
Cathodic Protection system
Very Small Aperture Terminal (VSAT)
Electronic Switching Equipments
Components Group :
Different types of ferrite cores like Pot, RM, E, U, I, etc
Piezoelectric transducer elements
Special Bearings used in Heavy Water Plants
Microwave Ferrite Phase shifters
Direction Finding Systems
Frequency / Phase Correlators
8
NATION’S PIONEER & WORLD LEADER IN
SOLAR PHOTOVOLTAIC
In an era of growing energy needs and rising concern for
environment, solar energy, the abundant and pollution free
non-conventional energy source, offers the best alternative
solution.
CEL, with its commitment to harness the solar energy, has
opened up new vistas in the field of solar photovoltaic’s
CEL is the poignant and the largest producer of solar
photovoltaic’s.
Backed by an integrated production facility, CEL has made
accumulative supply of over 1.5 lakhs SPV systems (20 MW)
spread over 28 different types, covering both rural and
industrial applications. The company has not only given a
fillip to the Indian SPV market but also exported products to
Indonesia, Bhutan, Bangladesh, Egypt, Cuba, Nepal,
Mali, Columbia and Costa Rica.
CEL has successfully transferred technology for
manufacturing SPV Modules and Systems to Rajasthan
Electronics & Instruments Ltd. India in 1985 and very
recently to Scientific Studies and Research Center (SSRC),
Syria in May 1997. This is the first case of SPV Technology
Export from the Developing World.
CEL’s SPV Modules conform to the international specifications – JPL Block V and IEC specification no. CEI / IEC 61215. CEL SPV Modules were certified by European
Solar Test Installations (ESTI), JRC, Ispra, Italy.
9
INNOVATIVE ELECTRONIC SYSTEMS
Signaling & Safety Systems for the Indian Railways :-
CEL is the pioneer Public Sector Company supplying
Railway Signaling and Safety equipments to Indian
Railways.
CEL continually identifies new requirements of the Railways and develops / manufactures the same in association with Research, Design and Standards
Organization (RDSO) and Railway Board.
The Company is currently engaged in development of
Digital Axle Counter in association with RDSO and
Department of Scientific Industrial Research (DSIR).
The product is undergoing extensive field trials in different
zones of Indian Railways and software validation is under
progress. The product is expected to be deployed in Indian
Railway’s Signalling network in large numbers by the end
of year 2002.
Cathodic Protection Systems:-
CEL supplies Automatic Cathodic Protection Systems for the protection of oil / gas pipelines to organizations like Indian Oil Corporation, ONGC and GAIL.
The Company supplies different types of Cathodic
Protection Systems operating with solar photovoltaic or
thermoelectric power sources or operating on grid supply.
10
QUALITY POLICY
The complete manufacturing operation,
marketing and installation services of the
company are certified under ISO 9002: 1994.
The company
quality policy
has enunciated the following
to meet customer needs and
expectations through supply of quality products
and services.
“CEL is committed to strive for leadership in
the product marketed by the way of
continuous improvements in the quality of its
products and services and meeting the
consumers needs in time and every time at a
competitive price.
These shall be achieved through continuous
upgrading of technology and process
improvement by involving all the employees,
vendors, dealers and customers.
Quality is our basic business principle.”
11
UNIVERSAL AXLE COUNTER
FOR RAILWAYS
INTRODUCTION
Axle counters were developed as a substitute for track
circuiting. Initially axle counters were imported from
Germany to gain experience and to evaluate their suitability
for adoption on Indian Railways. Having gained acceptability
for introduction on a wide scale on Indian Railways, it was
considered to take up indigenous development of axle
counters, which was taken up in collaboration with IIT, Delhi
and DOE. Two models of axle counters known as single
entry/exit axle counter and multi entry/exit axle counters
emerged and after extensive laboratory and field trails under
various conditions, the design was finalized and
commercialized through private sector as well as public
sector.
Based on the feedback from field, a new axle counter has been developed by RDSO, known as “UNIVERSALAXLE COUNTER”.
NEED FOR AXLE COUNTERS :
The track circuits are considered as the vital components of
signaling system to achieve safety of train operations.
Various Accident Enquiry Committees have recommended to
bring more and more tracks under track circuiting to
safeguard against reception of trains on occupied lines. The
track circuiting could not achieve desired progress due to
virtual scarcity of wooden sleepers, prohibitive cost and
environmental consciousness in the country and the world at
large. Availability of concrete sleepers have solved the
problem to some extent but track circuiting on loop lines,
12
points and crossings still suffers for want of adequate supply and insertion of concrete sleepers.
ADVANTAGES:
The advantages of Axle Counter over a conventional track circuit are:
(i) It does not require wooden sleepers (where concrete sleepers are not available) except for short track circuits to suppress the counts due to movement of insulated trolleys.
(ii) An Axle Counter System can cover a very long section of upto 15 km as compared to 750 mtrs. of maximum length of operation of conventional track circuit.
(iii) It does not get affected either by flooding of track or poor maintenance of tracks unlike track circuits, which is highly susceptible to these conditions.
(iv) It does not require insulating joints, thus, rails can be continuously welded. This reduces track maintenance cost, lower wear and tear of tracks and vehicles and to increase traveling comfort.
APPLICATIONS :
Axle counters are finding more and more uses on modern
safety signaling systems in the railways. These are being used
presently for the following applications:
(i) Monitoring of berthing tracks in station areas and
yards.
(ii) Monitoring of point zones in station areas and
yards.
(iii) Automatic signaling systems.
13
WAVE SOLDERING
REWORK STATION
CLEANING
CABINET FABRICATION
INSPECTION
Accepted Rejected Accepted
PAINTING
MECHANICAL FITTING
CABINET WIRING
SYSTEM INTEGRATION
SYSTEM TESTING
INSPECTION
Mechanical
Components
CARD TESTING
LACQUERING
SHIPMENT
FLOW CHART FOR MANUFACTURING OF
AXLE COUNTER:-
Fabrication
Components Raw Materials
Electronic
INSPECTION Rejected Accepted
COMPONENT MOUNTING
INSPECTION
PCB
Rejected
14
R1 R4
R2 Railway Track R3
T1 T4
T2 T3
Entry Point Track Section Exit
Point
EJB 1
Cable
EVALUATOR
EJB 2
PRINCIPLE OF OPERATION:-
Signal aspect for train movement is controlled based on clear or
occupied status of the track section. If a train occupies the track
section, signal at the entry point of the section is made RED and the
next train is stopped from entering into the section. When the track
section is clear the signal is made GREEN and the train is allowed to
proceed into the section.
The clear or occupied condition of the track section is decided by Axle
Counter by counting the number of axles of train at entry and exit
points of the section. The axle counter compares the IN and OUT
counts and in case of count equality TRACK CLEAR signal is given.
In all other conditions TRACK OCCUPIED signal is given.
Signal Signal
Signal Control
Relay Output
Cable
BLOCK DIAGRAM OF AXLE COUNTER INSTALLATION
15
BRIEF DESCRIPTION
The Axle Counter is an electronic device and the complete system
consists of :
(i) Track mounting and trackside equipment.
(ii) Transmission media between trackside equipment and
central evaluator.
(iii) Central evaluator with EV relays and SUP relays as its
output.
(iv) Reset box.
(v) Line verification box.
Track mountings and track side equipments :
The track mounting equipment consists of a pair of transmitter and
receiver coils housed in specially designed housings, which are fixed
to flange of a rail section by means of suitable rail clamps using bolts
and nuts. Each detection point has two sets of such tracks devices
mounted on same rail with a fixed stagger between them. The two
transmitter coils of a detection point are connected in series to 5 kHz
oscillators housed in electronic junction box which is installed in a
location box by the side of the track. The output of two receiver coils
of a detection point serve as inputs to two receivers amplifiers housed
in the same electronic junction box through cables which are part of
the track mounting equipment. Electronic junction box is powered by
24 V DC supply.
Transmission media between trackside equipment
and central evaluator :
The connection between trackside equipment and central evaluator is
made using balanced twin twisted quad cables of specification IRS:
TC/41/90. The output of electronic junction box and input of central
evaluator are matched for an impedance of about 180 ohms at 5 kHz.
16
There is attenuation of signal from electronic junction box to central evaluator, which limits the length of the cable. Other media such as optic fiber and wireless system may also be used in place of cable by
incorporating appropriate interfacing equipment at transmitting and receiving ends.
Central evaluator with EV relay and SUP relay as
its output :
The signals received from electronic junction boxes are processed in
the central evaluator first by analog circuits and then by digital circuits
to produce suitable output in terms of picking up or dropping of EV
and SUP relays. The Dip’s generated by wheels as they pass over the
track
devices installed at detection points, after they get processed, generate
count pulses in a fail safe manner.
These pulses are identified as ‘IN COUNTS’ or ‘OUT COUNTS’
depending on the direction of movement of vehicles over the
monitored section. The counts are also displayed through the 7-
segment display on the front panel of the evaluator. The display unit is
useful in fault localization and initial and periodical adjustments.
The evaluator is provided with its own power supply unit known as
DC – DC converter mounted in the same rack and requires 24 V DC supply for its operation. The output of the EV and SUP relays are used
to indicate “TRACK CLEARED” or “TRACK OCCUPIED”
conditions.
Reset Box :
This equipment is installed in the station master’s room to enable
resetting of central evaluator in case of failure of system after
observing prescribed procedure. The reset unit consists of a RESET
key (which gets actuated after inserting, turning and pressing), the
counter and 3 LED indications (Red, Yellow and Green). This unit
requires 24 V DC supply for its operation. This unit functions in
conjunction with the line verification box.
17
Line Verification Box :
This box is required to be kept near monitored track portion outside
Station Master’s (SM) office for achieving co-operative feature. This
is a box consisting of a lock with a key fixed inside. The lock gets
actuated only when the key is inserted, turned and pressed. Whenever
there is a failure of axle counter, SM will depute his ASM/Switchman
to verify whether the track section controlled by axle counter is clear
or not. ASM/Switchman after verification of the track, if found clear,
will report to SM who in turn will handover the key of line verification
box for operation.
TYPE OF SYSTEMS :
There are four types of system used in the Indian Railways. They are
named below :
(i) One Device (1-D) System.
(ii) Two Device (2-D) System.
(iii) Three Device (3-D) System.
(iv) Four Device (4-D) System.
1-D System:
In this system, there is a common detection point at entry and exit
point of monitored section. This system is useful for monitoring the
berthing track of terminal yard. A train after passing the detection
point generates pulses equal to axles in it and these pulses are counted
and stored by the evaluator as ‘IN COUNTS’.
At the time of exit of train, the same detection point will be
encountered and it generates the same number of pulses as that during
the entry. These pulses are counted and recorded as ‘OUT COUNTS’
by the evaluator. When the IN COUNTS and OUT COUNTS are
equal, the system gives a
18
“Track clear” indication, otherwise it gives the “Track occupied”
indication.
2-D System :
The principle of working of this system is similar to 1-D System except that in this system there are two detection points, one at each
end of the monitored section. This system is useful for providing track circuiting on berthing track.
3-D System :
In this system, there are three detection points. The principle of
working of this system is similar to 2-D system. This system is useful
for providing track circuitry on points, crossings and sidings.
4-D System :
In this system, there are four detection points. The principle of
working of this system is similar to 2-D system. The system is useful
for providing track circuiting on branch lines, sidings and points and
diamond crossings.
The design of 4-D system is such that it can be converted into a 2-D
system or a 3-D system and vice–versa.
19
SPECIFICATIONS
Universal Axle Counter System mainly comprises of following
equipments : 1. Rack, ACS-55/56/57 -- (Common type for all models) 1 No.
2.Evaluator
No. 3. DC-DC converter No.
-- EV – 542 / 543 / 544 1
-- (inside Evaluator only as 10th Card) 1
4. Electronic Junction
Nos. box, JB-533
Nos.
Nos.
-- for 2D system (ACS-55-2D) 2
-- for 3D system (ACS-56-3D) 3
-- for 4D system (ACS-57-4D) 4
5. Reset box
No.
-- RB – 257B 1
6. Track Device
Nos. Assembly
Nos.
TR – 556
Nos.
-- for a 2D system (ACS-55-2D) 2
-- for a 3D system (ACS-56-3D) 3
-- for a 4D system (ACS-57-4D) 4
7. Line verification box -- LV – 261 1
No.
20
PARAMETER
SPECIFICATIONS
1. No. of Detection Points ACS-55 / 56 / 57 2 / 3 / 4
2. Maximum Train Speed 200 kmph
3. Counting Capacity 1023
4. Max. Line Attenuation (over cable) 20 dB
5. Signal Input (5 KHz) sinusoidal Min. 150 mv.rms
Max. 1500 mv.rms
6. Relay Drive Voltage for 1000 ohm
Shelf type 4F / 4B relay or Q Style
Plug in Relay 1000 ohm, 4F / 4B
Power Requirement :
> 10 V
Powers required by various units are as follows :
DC – DC Converter 1.5 Amp max.
24 V (-10% to +20%)
Evaluator 24 V 1.5 Amps (21.6 – 28.8 V DC)
Junction Box 24 V < 250 mA
(21.6 – 28.8 V DC)
Reset Box 24 V
(21.6 – 28.8 V DC)
Environmental Conditions :
500 mA
(only when reset key is
pressed)
Relative Humidity 95 % - 98% Non Condensing
21
Temperature range :
Universal Evaluator 0 to + 60 C
Junction Box & Track Devices 0 to + 70 C
PHYSICAL CHARACTERISTICS :
The approximate dimensions and weights of various units of Universal
Axle Counter are given as follows :
Name of UNIT
WIDTH
(mm)
DEPTH
(mm)
HEIGHT
(mm)
WEIGHT
(kg)
RACK SINGLE 570 650 1065 70
DOUBLE 600 650 1460 100
EVALUATOR 482 439 310 21
JUNCTION BOX 208 280 170 5
RESET BOX 255 175 115 2.3
TRACK DEVICE ASSEMBLY
515 330 170 15
LINE
VERIFICATION
BOX
150
135
80
1.20
22
Colour :
The rack is painted in a combination of light and dark grey colours.
Evaluator, Junction box and Reset box are also painted in the same
colour combination. The track devices are painted in black colour.
IDENTIFICATION :
Rack :
The identification label of the rack is put at the left hand top on the front side of the rack with inscription.
a) For a 2D system Universal axle Counter, ACS – 55 with EV – 542 Evaluator.
b) For a 3D Universal Axle Counter System, ACS – 56 with EV – 543 Evaluator.
c) For a 4D Universal Axle Counter System, ACS – 57 with EV - 544 Evaluator.
The serial no. label is mounted on the right hand top side of
the rack at the back.
Evaluator :
The label “Evaluator, EV - 542”, “EV - 543” or “EV - 544”,
for a 2D, 3D or a 4D system respectively is marked on the
front side of the evaluator. The serial no. label is on the back
side.
Junction Box :
On the top (front) of the Junction Box the label “JUNCTION
BOX, (JB-533)” given whiles the serial no. label is on the
back plate.
23
Reset Box :
The label “RB – 257B” is given on the front side. The Sr. No. label is on the back side.
Line Verification Box :
The label “LINE VERIFICATION BOX, LV - 261” is put on
the front side and the Sr. No. label is on the right side cover.
Track Devices :
Labels indicating the Tx and Rx coil of the Track Devices are
given on each track transducer.
DC – DC Converter :
It is the 10th Card Module inside the Evaluator and it is marked as “POWER SUPPLY”.
24
DESCRIPTION OF VARIOUS MODULES
OF AXLE COUNTER SYSTEM :
1. EVALUATOR :
The Evaluator consists of 10 PCB modules. The interconnections
between the various PCB cards are made with the help of a
motherboard. The polarization arrangement (to avoid wrong
insertion of modules) is provided on the aluminum modular sheets
in each. Hence it is important to ensure correct fitting of modular
shield in each card. In the Universal Axle Counter System
manufactured by Central Electronics Limited , relevant card
number has been number punched for easy identification to ensure
correct fitting of modular shields. A brief description of each P.C.
assembly is given below.
(a) Attenuator/Amplifier & Rectifier Card (Card no. 1) :
This is a double sided PCB (Size: 225mm X 275mm). It contains
four identical channels , each comprising of a 5 kHz high pass filter , a
line
matching transformer, attenuator pads, a two stage amplifier and a
full wave rectifier. The output of each channel can be set precisely by
means of a lockable shaft potentiometer mounted at the front end
of the PCB module. Typical output is 300 mv (P-P) or 105-mv rms.
(b) Attenuator/Amplifier & Rectifier Card (Card no. 2) :
This is a double sided PCB (Size: 225mm X 275mm). It contains
four identical channels , each comprising of a 5 kHz high pass filter , a
line matching transformer, attenuator pads, a two stage amplifier and a
25
full wave rectifier. The output of each channel can be set precisely by
means of a lockable shaft potentiometer mounted at the front end of
the PCB module. Typical output is 300 mv (P-P) or 105-mv rms.
For 1D and 2D Systems, there will be one such card (Card no. 1)
while for 3D and 4D Systems, the evaluator will have two nos. of such
cards (Card nos. 1 & 2).
(c) Pulse Shaper Card (Card no. 3) :
This is a double sided PCB (Size: 225mm X 275mm). It contains four
identical channels, each consisting of a low pass filter, a Schmitt
trigger, an impulse time filter and a 10 V to 5 V level converter. The
outputs of these channels are TTL compatible. In addition to above,
each channel comprises of a Trolley Suppression Circuit.
(d) Pulse Shaper Card (Card no. 4) :
This is a double sided PCB (Size: 225mm X 275mm). It contains
four identical channels, each consisting of a low pass filter, a Schmitt
trigger, an impulse time filter and a 10 V to 5 V level converter. The
outputs of these channels are TTL compatible. In addition to above,
each channel comprises of a Trolley Suppression Circuit.
For 1D and 2D Systems, there will be one such card (Card no. 3)
while for 3D and 4D Systems, the evaluator will have two nos. of such
cards (Card nos. 3 & 4).
(e) Logic – I (Card no. 5) :
This is a double sided PCB (Size: 225mm X 275mm). This card
generates ‘IN COUNTS’ and ‘OUT COUNTS’, depending upon the
direction of the train movement, due to the dips caused form the track
transducers E, F, G, H. In addition to main count pulses, duplicate
incount and outcount pulses are also generated here for supervision
purpose. The ‘IN COUNT’, ‘OUT COUNT’, ‘Duplicate In count’ and
‘Duplicate Out count’ pulses are fed separately to different combiner
gates housed in card 6 (Logic II) and thereafter fed to the counter card
(Card 7) for further processing.
As E, F, G, H channel inputs are used only in case of 3D or 4D
Systems, card 5 will be used only with the 3D and 4D Evaluators.
26
(f) Logic – II (Card no. 6) :
This is also a double sided PCB (Size: 225mm X 275mm). This card
houses the logic circuitry to generate ‘IN COUNTS’, ‘OUT
COUNTS’, ‘DUPLICATE IN COUNTS’ and ‘DUPLICATE OUT
COUNTS’ due to the dips caused from channel inputs from the track
detection points A, B, C and D. It also has combiner gates, which
combine the count pulses generated from all the detection points AB,
CD, EF and GH. The outputs of these gates are fed to the counter card
(Card no. 7) for counting and counts supervision.
Card 6 also has an ‘INTERROGATOR’ circuit. This generates four
clock pulse trains. All these four pulse trains are staggered in phase,
with each of these pulse trains having a phase difference of 25 µ secs.
As compared to the subsequent one.
The interrogator ensures that even if more than one incount or more
than one outcount are fed simultaneously from different detection point, the final count pulses fed to the counter card get staggered and thus counts are not missed.
In addition to above, this PCB also houses the IN/OUT supervision
circuits, both counter checking each other. In case of any malfunction
the system latches to failure condition. This card also houses the 1st
outcount inhibit circuit which ensures latching up of the system in the
event of 1st count getting registered being an ‘OUT COUNT’ instead
of an ‘IN COUNT’.
(g) Counter Comparator (Card no.7) :
This is a double sided PCB (Size: 225mm X 275mm). This card
houses two 10 stage digital counters. One for counting the ‘IN
COUNTS’ and the other for ‘OUT COUNTS’. It also has count super-
vision circuits, both for in counts as well as the out counts, to check
the integrity of the counters. In addition, there are two comparators;
one being a duplicate of the other, to compare the counts from the two
counters the ‘IN COUNTER’ and the ‘OUT COUNTER’.
The outputs of the comparators are further compared with EX-OR
chain to ensure integrity of the comparators.
27
(h) General Supervision Card (Card no. 8) :
This is a double sided PCB (Size: 225mm X 275mm). It houses the
following evaluator circuits : (i) Comparator Supervision.
(ii) Pulse Shaper (Card no. 3 and 4) supervision for all the eight
channels. (iii) Failure Supervision.
(j) Relay Driver (Card no. 9) :
This is a double sided PCB (Size: 225mm X 275mm) and it houses the
following circuits :
(i) Level detector circuits for all the 8 channel inputs to
ensure the presence of proper channel input levels.
(ii) The ‘VOLTAGE MONITOR’, which serves as, a
‘WATCH DOG’ for the +5V power supply to the
Evaluator.
(iii) Relay driver outputs for driving the EV relay and the
supervisory relay.
(k) Counts Display Card :
This is a double sided PCB (Size: 225mm X 275mm) containing four
seven segment LED’s for ‘IN COUNTS’ and four seven segment
LED’s for ‘OUT COUNTS’ and it can count upto 1023 counts in both
the display. This card is mounted on front panel of evaluator and
counts are recorded in decimal system.
(l) EV & SUP Relay Indication LEDs :
The output of the Evaluator is used to drive two 12 Volts DC, 4F/4B shelf type relays or 12 Volts DC, Q-style 4F/4B plug-in relays which
are used to indicate the track clear or track occupied indications to control signal aspects. Two 10 mm dia. LEDs (Green and Red) have
been provided in the front side of the Axle Counter Rack in a metallic
28
strip for locally displaying the position of the above relays. These
LEDs have to be suitably wired at the time of installation as per
requirements from the terminal strip connections provided at the rear
side of the Axle Counter Rack.
(m) Mother Board :
This is a double sided PCB (Size: 420 mm X 260 mm) mounted at the
back of the Evaluator. The PCB is mounted at right angles to the other 10 PC Cards and serves the purpose of providing various interconnections between them. The female parts of the Euro
Connectors are mounted on this PCB and corresponding male parts which are mounted on the PCBs (Cards 1 to 10) mate with them when
the card modules are inserted in the unit. The mother board also provides access, through MS Couplers, to feed various inputs like
channel inputs from the tracks, power supply and trolley protection and to feed outputs to the EV and the Supervisory Relays kept in the rack.
(n) Reset Relay :
This is mounted at the back of the Evaluator on the motherboard. A
67DP-24-4C3 OEN Relay is mounted on this PCB with a mounting
socket. This Relay resets the System whenever required to do so.
2. ELECTRONIC JUNCTION BOX (EJB) :
The Electronic Junction Box houses PCB modules which are inter-
connected through motherboard. All the incoming / outgoing signals
are terminated on the MS Couplers (7 pin) mounted at the back of the
junction box. Two types of outputs are available from the EJB. The
output of the EJB is sent to the Evaluator either through a 4 wire or a
2-wire system.
(a) 4-Wire System :
In a 4-Wire System, two pairs of under ground cable are required to
send transition signal to evaluator for counting the dips. In this
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system there are three PCBs consisting of common oscillator
feeding to two transmitter coils in series and two number of receiver amplifiers, one for each receiver coil. The sequence of
cards is, regulator and oscillator in first position, first amplifier in 2nd position and second amplifier in the 3rd position from left to
right.
Detail of individual cards :
CARD No. 1 :
Regulator / Oscillator Card. (Size : 200 mm X 110 mm)
This is a single sided PCB (size : 200mm X 110 mm), which
generates 5 KHz ±20 Hz sinusoidal signal which is fed to the
transmitter coils in series. The output voltage is 60 V ± 10% (rms)
and current supplied is 420 mA ± 10% in the coils in series.
CARD No. 2 :
Receiver Amplifier-1. (Size : 200 mm X 110 mm)
This is a single sided PCB of size same as that of card 1 and it
rejects any noise over riding in the signal by means of a two stage
tuned amplifier. The output of the receiver coil (1) is fed to the
input of the amplifier. The output of the amplifier is connected to
the Evaluator and voltage is more than 1.2 V (rms).
CARD No. 3 : Receiver Amplifier-2. (Size : 200 mm X 110 mm)
This card is exactly similar to card no. 2 and is used for receiver
coil(2).
(b) 2-Wire System :
In 2-wire system, a 4th card is inserted in the EJB, which converts
the frequency of the second receiver amplifier signal to 3.5 KHz
with the use of converters. Thus, 2-wire system is having output on
2-wire and consists of 4 cards, namely the regulator / oscillator
card, the receiver amplifier card-1, the receiver amplifier card-2
and 4W / 2W card. This is used in block working at Advance
starters only.
The sequence of cards is :
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(i) Regulator / Oscillator Card. (ii) Receiver Amplifier Card-1. (iii) Receiver Amplifier Card-2. (iv) 4W / 2W Converter Card.
3. RESET BOX :
This box houses one 12 way PIRI terminal strip for terminating IN
/ OUT signals. The indication LEDs of the reset box are fitted in
LED holders and projected to the front for indication. Green and
Red indications are given for track clear and track occupied
conditions. The Yellow LED indicates co-operative permission for
resetting the Axle Counter.
4. TRACK DEVICE ASSEMBLY :
The Single Rail Track Device Assembly consists of two transmitter
and two receiver coils assembly, which are fitted with suitable
mounting arrangements on the rail camp, which in turn is fitted to
the rails. The two transmitter coils at each of the detection point are
fed in series by a 5 KHz sinusoidal signal from the junction box,
which forms an electromagnetic field across the receiver coils. The
receiver coil in turn generates induced voltage. The induced
voltage drops to a minimum whenever there is an axle between the
transmitter and the receiver coils.
(a) Track Device Transmitter :
The transmitter coil is placed in a FRP housing and it is potted in place by m-seal compound. It is fixed on the rail clamp on
the outer side of the rail. Each transmitter coil will be provided with a 10 meter, 24 / 0.2 PVC cable.
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(b) Track Device Receiver:
The receiver coil is housed in a composite aluminium fiber glass
housing and is potted in place by the means of an m-seal
compound. The receiver housing is fixed on the base clamp on the
inner side of the rail. Each receiver coil will be powered with a 10
meter, 24 / 0.2 PVC cable.
5. POWER SUPPLY :
The Power Supply, to the Evaluator is fed by a DC–DC Convertor.
The various output voltage of the DC–DC Convertor are as follows
:
+ 5 V@ 5Amp. with ± 0.1% line & load regulation.
+ 5 V@ 5Amp. with ± 0.1% line & load regulation.
+ 10 V isolated @500 mA.
The DC-DC Convertor in turn derives its power from a + 24 V dc
source i.e. a battery bank.
The Junction Box (JB - 531) and the Reset Box (RB – 257B) are
also powered from + 24 V dc battery bank.
All the supplies have over current protection while 5V supply has
additional crow bar protection at 6.2 volts.
PRODUCTION TESTING & TEST PROCEDURE :
The semi – conductor devices like diodes and transistors used are of
high reliability type. The other vital components like ICs mostly are
the commercial grade ICs which will undergo burn in at 60°C with dc
power ‘ON’ for 72 hours.
This will eliminate the failure of critical components after the
assembly of the PCB.
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WAVE SOLDERING :
All the PCB’s assembly will be wave soldered for good reliability and
also coated with lacquer to withstand climatic conditions.
INSPECTION :
Each unit will be examined for proper workmanship, fitness, finish
and proper markings. Also each unit will be tested thoroughly as per the test schedules mentioned in the test report before the final
shipment.
SPECIAL FEATURES
The Universal Axle Counter has the following special features :
PCB LAYOUT :
Better PCB layouts to have supply feeding and decoupling for better
noise immunity.
MOTHER BOARD :
The use of mother board gives extra noise immunity as compared to
back panel wiring.
RACK :
The Evaluator is housed in a rack fabricated out of M.S. sheet. This
gives good noise immunity against electromagnetic interference.
SHIELDING :
The Rack is well shielded for better noise immunity. All the metallic
frames of the rack are interconnected to the main frame by means of
34 / 0.3 wire. Shielded cables will be used in system, shield of which
is connected to the back panel of the Evaluator.
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CARD INSERTION :
Each Card alongwith a module is guided separately.
CARD MODULES :
Each Card is provided with a module alongwith the identification
label.
CARD POLARISATION :
Polarizing holes on the card modules and guiding pins from the
Mother Board side are used to provide card polarization to ensure
correct card slotting.
MODULE TIGHTENING SCREWS AND CARD HANDLES :
Module tightening screws are provided to fix the cards along with the module in the unit smoothly. By loosening, the cards can be removed
from the unit. Two card handles are provided on each module. The modules can be taken out with the help of these handles.
COUNTS DISPLAY :
The Counts display is given on a PCB and mounted on the front panel
inside and is viewed through display viewing plate at the front panel
of the Evaluator.
EVALUATOR MARKINGS :
In each unit input /output labels, the supply, channel markings and
trolley protection A / B, C / D are marked.
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OTHER PRODUCTS
OTHER PRODUCTS OF CEL
SOLAR WATER PUMPING SYSTEMS :
A Solar Photovoltaic Water Pumping System essentially consists of an
SPV panel or array directly powering a water pump. Water pumped
during the day can be stored in the storage tanks for use during the
night.
CEL offers SPV Water Pumping Systems for both shallow as well as
deep well conditions. Such systems have been deployed all over the country. The system has also been exported to many developing
countries.
The generated electricity from the SPV array is fed to the pump
through a switch. Normally low storage batteries are provided, as the
water can be stored in the storage tanks if required.
SOLAR PHOTOVOLTAIC LIGHTING SYSTEMS :
CEL’s Solar Photovoltaic Lighting Systems are ideal sources for
providing indoor/outdoor illumination in remote and unelectrified
settlements/ villages. The SPV Lighting System essentially consists of
an SPV panel battery, a charge controller and lights. The SPV panel
converts the sunlight incident on it directly to DC electricity that can
be stored in the battery and used to energize the lights when required.
The charge controller prevents the overcharging and deep discharge of
the battery.
SPV INDOOR LIGHTING SYSTEMS :
Two types of indoor lighting systems are available (DLS-02 and DLS- 4) depending on the lighting requirements. DLS-02 has two numbers
of 9W luminous efficiency lamps with wall mounting fittings. DLS-04
has four such lamps. Each lamp can give the output of 60-watt
incandescent lamp.
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SPV OUTDOORS LIGHTING SYSTEMS :
These systems use a weather proof 18-watt or 20-watt fluorescent tube light fittings. Two models SLS-03 and SLS-06 are available depending on hours of operation in day. Switching ON at dusk and OFF after
specified hours of operation is automatic. The SPV panel, battery and the tube-light fittings are mounted on a 4M long pole.
SOLAR LANTERNS :
CEL Solar Lantern is a versatile and a reliable source of lighting. It
consists of a lantern, a SPV module and a connecting cable. The SPV
module when exposed to light charges the battery in the lantern. This
stored energy in the battery is used to operate the lamp when required.
SPV MODULE :-
A number of high-grade crystalline silicon solar cells, interconnected
in series combination and hermetically sealed with a toughened glass
cover, form a SPV module.
SALIENT FEATURES :-
ENVIRONMENTAL FRIENDLY
PORTABLE
RUGGED AND DEPENDABLE
APPLICATIONS :-
EMERGENCY LIGHTING SOURCE
LIGHTING SOURCE IN REMOTE VILLAGES
LIGHTING AT PICNIC SPOTS AND FARM HOUSES
GARDEN LIGHTING
MILESTONES OF SPV SYSTEMS
DEVELOPMENT AT CEL
SPV operated Radio set in Jammu & Kashmir - 1978
SPV Irrigation Water Pumping System installed at Kalyani, West Bengal – 1979
SPV Pumping System for drinking water near Jaipur – 1980
36
SPV Community Lighting Systems installed at SOS children’s
village, Leh, Ladakh, J&K – 1980 SPV Community Television Systems installed at Kalyani,
West Bengal – 1980
Special SPV Power Pack for the first Indian scientific
expedition to Antarctica – 1981 First SPV Power System for unmanned off-shore oil well
platform of ONGC – 1982
SPV operated Diesel Dispensing Pump – 1982
Export of SPV Water Pumping and other System – 1983
First SPV powered stand-alone Street Lighting System in
Salojipali, Andhra Pradesh – 1983 SPV foldable modules for Everest-84 Expedition – 1984
SPV systems for Direct Reception community TV sets of
Doordarshan – 1985 SPV Systems for Cathodic Protection of oil pipelines – 1985
SPV systems for Vaccine Refrigeration in village Health
Centers –1985 Design and supply of first SPV Systems for very low powered
unmanned TV transmitter (VLPT) & TV Receiver Only
(from INSAT) (TVRO) terminals of Doordarshan - 1986 Supply of SPV Power System for weather monitoring, lighting
and entertainment at an Avalanche Study Station at Rohtang Pass (ALT : 3600 mtrs/12000 ft.) in the Himalayas – 1986
SPV powered Lighting and Television System for army at
Siachin (ALT : 3600 – 5500 mtrs / 12000 ft.) in the Himalayas – 1987
Supply of first 2 KW power SPV Village Power Pack – 1987
SPV systems for warning signals at Unmanned Railway Level
Crossings – 1988 SPV Rural Deep well Water Pumping Systems for National
Drinking Water Mission - 1989
SPV Power System for Rural Telecommunication
transmission and switching equipments – 1989
Supply and installation of SPV Systems in village Hitam-ulu,
Sumatra, Indonesia – 1990 SPV Lighting Systems for Adult Education under National
Literacy Mission – 1990
Supply and installation of 6 KW Power Plant at Kariawali
village in U.P. – 1990
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Supply and installation of Asia’s first 100 KW SPV Power
Plant at Kalyanpur village near Aligarh, U.P. – 1992 10 KW Power Generator for M.S. Swaminathan Foundation
at Taramani, Madras – 1993
Supply of Foldable Lightweight SPV modules for powering
Man pack Communication – 1993 Equipments for the defense services to operate in the
temperature range from –30°C to +55°C.
CATHODIC PROTECTION SYSTEM
INTRODUCTION :
M/s Indian Oil Corporation Limited is presently laying 18” dia., 437
Km. long pipe line in 2 segments for augmenting the capacity of existing OD 498 Km. long Haldia-Barauni Crude Oil pipeline from
Haldia to Barauni.
Owner intends to provide permanent cathodic protection system
consisting of 13 nos. of impressed current cathodic protection station to cathodically protect the underground coated pipeline for a design
life of 35 years.
BASIS IN BRIEF :
Permanent CP System has been designed for CTE coating having
coating resistance of 7000 ohm / m factor of safety as 1.3. Designed
life of anode bed is 35 years and that of the CP system is 20 years.
SUMMARY OF PERMANENT CP SYSTEMS :
Designed current density considered for design mts. Total no. of CP stations
Total designed current for entire span
Max. design current of CP station
Total no. of 22 Kg high silicone chrome anode
: 125 microA/sq.
: 13 Nos.
: 103.8 A
: 10 A
: 250
38
PROJECT INFORMATION :
The Haldia – Barauni Augmentation pipeline is starting from Haldia
and it terminates approximately 473 Km. away at HBPCL near
Barauni.
Coating Details :
The pipelines shall have yard coated coal for tar coating with
fiberglass reinforcement. The coating resistance in normal soil shall be
7000 Ω/m.
Depth of pipeline :
Generally the HBPCL has proposed the pipeline to be laid at
minimum depth of 1 mt. from the ground level. Depth may increase to
9 mts. or more depending on the soil.
High silicon-chrome anode and anode beds :
The anodes shall be High Silicon Chromium cast iron, cylindrical
type. Anodes shall be provided with encapsulated heads and heat sink
caps connected at top.
The technical data of the Hi-Si-Cr-Fe anodes assembly shall be as
under. ANODE TYPE DIMENSIONS
WEIGHT
COMPOSITION: -
: Hi-Si-Cr-Fe Anode : 65 mm. Dia. & 1 mt. long
: 22 Kg.
Si : 4 % to 15.5 %
Mn : 0.8 %
C : 1.4 %
Cr : 4.5 %
Fe : remaining
PROFESSIONAL FERRITES
INTRODUCTION TO FERRITES :-
Ferrites are dense homogeneous ceramic structures having a general
molecular formula MFe2O4 where M is an oxide of a divalent metal.
When M has more than one metal than it is called Mixed Ferrite.
39
Ferrite has a process flexibility, which permits easy
and economic moulding into much different geometry.
Besides there, Ferrites are advantageous because they
have high electrical resistivity resulting in some eddy
current loses over a wide frequency range, high
permeability and time and temperature stability as
compared to other metallic magnetic materials such as
silicon steels.
The ferrites are used in Transformers,
Telecommunications, TV industry, Antennas, Defense
Equipments, etc.
Application of different types of Ferrite cores :-
The ferrite cores that are produced
available in different sizes and their
follows :
a) Pot cores & RM cores :
in CEL are
uses are as
These are used in stable low loss Filters,
Inductors requiring high Q, Chokes, Proximity
switches, R.F. Transformers,
Converters & Inverters
low power
etc. for
Telecommunications, Axle Counter System for
Railways and other
applications.
Professional electronic
40
b) Toroids :
They are used in Pulse Transformers, Delay lines,
Chokes, Converter / Inverter Transformers, Wide Band Transformers, Transformers, etc.
c) Blocks :
Impedance matching
They are used for Transmitter and Receiver
application of Axle Counters. They can also be
used as building blocks for making high power
transmitters.
d) E, EI, ETD & EC Cores :
These types of cores are used in the
Inverter/Converter Filters, Chokes, Inverters for
Fluorescent Lamps and Flash Light Inverters,
Switch Mode Power Supply for Television and
Computers, etc.
e) U & UI Cores :
These cores are used in Insulation Testers, DC-to-
DC Converters, DC halogen lamp Inverters,
Ultrasonic Cleaners and high voltage Inverters. By stacking of transformers in
manufactured.
these cores, high power Kilowatt range can be
41
Batch
Mixing
CALCINATION
(PREFIRING)
PRESSING
GRANULATION
(SPRAY DRYING)
MILLING
PRODUCTION
TESTING SINTERING LAPPING
AIR GAP
ADJUSTMENT PRINTING
QUALITY
ASSURANCE
BINDER LUBRICANT
STORES
AND
DESPATCH
FERRITE PROCESS FLOW CHART
Iron Oxide
Zinc Oxide
Manganese
Oxide
42
NEW PRODUCTS
SINGLE SECTION DIGITAL AXLE
COUNTER
A state-of-the-art Digital Axle Counter has been developed
by CEL for track monitoring of single section in railways.
The system is designed with :
High frequency track coils.
Track side electronic counting unit including vital relay
drive.
The system has two detection points for monitoring either
end of the section. When the train is entering the section the
wheel counts are registered and stored in the 1st SSDAC unit.
When the train is entering the section the wheel counts are
registered and stored in the 2nd SSDAC unit. After exchange
of counts stored in both SSDAC1 and SSDAC2 units, the
section is declared as ‘CLEAR’ in case the counts are equal.
Otherwise the section is shown as ‘OCCUPIED’.
The health of SSDAC1 and SSDAC2 units are continuously
monitored and proved in vital relay drive circuits.
The vital relay drive is available independently at either end
of the section from SSDAC1 and SSDAC2 units.
43
SOLID STATE INTERLOCKING
Solid State Interlocking (SSI) is Signaling System to
select and operate the routes in station for guiding the
movement of the trains. The system replaces the
conventional Route Relay Interlocking. The system is
designed with “2 out of 2” Microprocessor with hot
standby. The system has software redundancy.
The operator panel is used to control and command and
display the status of SSI.
FEATURES :
System capacity: 450 Input, 72 Output.
Dual Microprocessor Based (2 out of 2) Fail-safe
design.
Hot standby for High System Availability.
On Line self-diagnostic facility.
Data Logging with Time Stamping of all SSI Inputs
and Outputs for Off-line analysis.
Opto Isolated Inputs and Outputs.
Modular design for easy maintenance and expansion.
44
SOLAR POWERED RAILWAY LEVEL
CROSSING RADIO WARNING SYSTEM
(SOLARGUARD ™)
CEL has developed this system, in association with
Research, Designs and Standards Organization
(RDSO) for providing early warning of a train /
locomotive approaching unmanned level crossing, to
the people and road traffic crossing the Railway line.
SYSTEM OPERATION:
A track device actuated solar powered VHF
transmitter located 3-4 Kms, from the level crossing
(i.e. Far End) sends a coded radio signal towards the
level crossing when an approaching train crosses the
Far End. The radio signal is received by solar powered
receiver located at the level crossing (Gate End) which
after decoding the signal actuates an Audio- Visual
Alarm for forewarning the traffic. The system is ideal
for remote railway level crossings. The ruggedized
system is under extensive field trials.
45
SELF EVALUATION
These 30 days Industrial Training has led me to
understand the various designing, assembling and the
manufacturing processes of equipments in the
industry, CEL.
It has also enhanced my knowledge about the
functioning and management of an industry, which I
am sure, will be beneficial to me in my career.
Ramakant Tyagi B.TECH 4th Year (1219431055)
(Electronics & Communication Engg. )
H.R Institute of Technology (194),
Morta, Ghaziabad (U.P)