traning report _central_electronic_limited_ (1)

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.

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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.

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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

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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.

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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.

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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.”

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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,

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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.

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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

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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

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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.

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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.

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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

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“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.

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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



5. Reset box

No.

-- RB – 257B 1

6. Track Device

Nos. Assembly

Nos.

TR – 556

Nos.

-- for a 2D system (ACS-55-2D) 2



7. Line verification box -- LV – 261 1

No.

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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

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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

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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.

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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”.

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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) :


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) :


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.

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(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.

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(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

29

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 :

30

(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.

31

(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.

32

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.

33

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.

34

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.

35

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

37

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)