axel counter summer training report

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A

SUMMER TRAIN ING REPORT

ON

AXEL COUNTER

AT

1



SUBMITTED BY:-MITIL KUMAR

0829021409

EEE, 4th - year

ABES IT GHAZIABAD

CONTENTS

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Certificate………………………………………………………………………….

Acknowledgement……………………………………………………

……………

Company

Profile………………………………………………………………….

The organization –

CEL…………………………………………………………

Divisions of

CEL………………………………………......

Products of

CEL……………………………………………

Nation’s Pioneer & World leader in

SPV……………….

Innovative Electronic

System……………………………..

Quality Policy of

CEL……………………………………..

Universal Axle

Counter………………………………………………………….

Introduction…………………………………………

……….

Flow chart of

manufacturing………………………………

Principle of

working………………………………………...

3



Brief

description……………………………………………..

Specifications………………………………………

…………

Description of various modules of Axle Counter

System………………......

Other products of

CEL………………………………………………………….

SPV

products……………………………………………….

Cathodic protectionsystem………………………………

Ferrite

Products……………………………………………

New

Products…………………………………………………………………

…

MediaGallery…………………………………………………………………

…

Self

Evalution………………………………………………………………

…….

4



ACKNOWLEDGEMENT

I am very thankful to Mr. ASHOK KOHLI (GM/ SPD) for providing

me the opportunity to undergo the practical training in the Systems

Production Division (SPD) of Central Electronics Limited under the

supervision of Mr. M. D. Mishra (CM). They all guided me from

time to time and gave me dynamic ideas and suggestions by

which I am able to complete my training successfully.

I also want to thank all the visible and non-visible hands, which

helped me to complete the practical training with great success.

MITIL KUMAR

5



INTRODUCTION :-

Central Electronics Limited is a public sector Enterprise under theDepartment of Scientific and Industrial Research (DSIR), Ministry of Science& Technology, Government of India. It was established in 1974 on 26th

june with an objective to commercially exploit the indigenous technologiesdeveloped by national laboratories and R & d Institutions in the country.CEL is one of the rare companies which utilized the homegrowntechnologies during all these years of its existence

CEL has developed a number of products for the first time in the countrythrough its own R&D efforts and in close association with the premierNational & International laboratories including Defense Laboratories. In

recognition of all these efforts, CEL has been awarded a number of timeswith prestigious awards including “NATIONAL AWARD for R&D by DSIR”.

CEL is pioneer in the country in the field of Solar Photovoltaic (SPV) and ithas developed state of the art technology with its own R&D efforts. Its solarproducts have been qualified to International Standards

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EC503/IEC1215 by the European Commission, joint Research center, andISPRA, ITALY

.CEL, pioneer in the field of Railways Safety & Signaling, has been identified

as a major indigenous agency for design an development of modernelectronic signaling and safety equipment by Indian Railways. Theequipment manufactured in CEL finds extreme usage in Railways in theform of Axle Counter, Axle Counter Block System and Train ApproachWarning devices. CEL’s Digital Axle Counter is approved as per EuropeanCENELEC safety level SIL-4 by RDSO(Research Design and StandardOrganization of Indian Railways )as an approved source in part-1 for variousrailway safety and signaling equipments for more than 25 years.

BRIEF HISTORY OF THE COMPANY ANDCOLLABORATING AGENCY

Central Electronics Ltd. is a public sector enterprise, under theadministrative control of the Deptt. Of Scientific & Industrial Research.

CEL is a pioneer in the field of solar Photovoltaic in the country and istoday ranked among the first few in the world in this area of activity. CEL isalso credited with many firsts in the country, professional Ferrites being oneof them.

CEL is presently engaged in the development, production and sale of

selected electronic components (Professional Ferrites, Electronics Ceramics

and Phase Shifters), selected electronic systems, solar photovoltaic cells,

modules and SPV systems and to take up engineering development &

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CEL IS A HIGH

TECHNOLOGY COMPANY



production based on indigenous technology developed through in house

efforts or know how from National Laboratories / Institutions.

The Operations of the company are divided into three Business

Groups. Solar Photovoltaic Group (SPVG), Systems Group (SG) and

Components Group (CG).

ORGANISATION STRUCTURE OF CEL

8

C

HAIRMAN &

MANAGING DIRECTOR

GENERAL

MANAGER

GENERAL

MANAGER(PROJECTMANAGEMENT)



9

Jt. GENERAL

MANAGER

(FINANCE)

EXECUTIVE

DIRECTOR AGM

(QUALITY

Jt. GENERAL

MANAGER(MATERIALSMANAGEMENT)

GENERAL

MANAGER

(SYSTEMS)

Jt. GENERAL

MANAGER

GENERALMANAGER

Jt.GM(CERAMICS)

Jt. GENERALMANAGER

AGM(FERRITE)



DIVISIONS OF CEL

Five business groups handle the total commercialoperations of the Company. These are as follows:

SOLAR PHOTOVOLTAIC GROUP (SPV):

CEL, backed by an integrated production facility, hasopened up new horizons in the field of Solar Photovoltaics.It fulfils the various demands from rural & urban areas,thus, harnessing the solar energy. The products of this

division are Solar Cells, Modules and systems, which servethe industrial needs of Railway Signaling, MicrowaveRepeaters, Defence equipments, Obstruction warninglights at airports, etc. and rural needs such as pumpingsystems for irrigation, street lighting systems, solarlanterns and rural telecommunications.

ELECTRONIC SYSTEMS GROUP (ESG):

The Company is a pioneer in manufacturing of RailwaySignaling and Safety Equipments. It manufactures Axle

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Counters, Railway Level Crossing Warning System, SolidState Interlocking System for Railways. The other productsof this division include Electronic Switching System,Cathodic Protection System for underground pipelines and

VSAT.

COMPONENTS GROUP:

A large range of products is manufactured here usingstate-of-art technologies to meet the requirements of communications, defense, consumer and industrialsectors.

It is divided into three sub departments. Their productsand applications are as follows:

(a)Professional Ferrites:

This department manufactures different types of ferrite cores for high frequency applications. Thedifferent types of cores manufactured are Pot cores,E, U, I, RM, torroids etc. These are called professionalbecause they require highly sophisticated techniques

for their manufacture and give a superiorperformance. The various applications of ferrite coresinclude TV sets, Communication equipments,computers, electronic ballasts, switch mode powersupplies (SMPS) and Microwave equipments.

11



(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, Sonars, Gas Lighters,Automobiles, etc.

(c) Microwave Electronics:

This department manufactures microwavecomponents such as

Phase Shifters used in Radars, Direction FindingSystems, Frequency Correlators, Antennas, etc.

PRODUCTS OF CEL

The organization manufactures different products thatcan be classified according to the divisions of CEL asfollows:

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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

13



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

NATION’S PIONEER & WORLD LEADERIN SOLAR PHOTOVOLTAIC

In an era of growing energy needs and rising concern forenvironment, solar energy, the abundant and pollutionfree non-conventional energy source, offers the bestalternative solution.

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CEL, with its commitment to harness the solar energy, hasopened up new vistas in the field of solar photovoltaics;CEL is the poignant and the largest producer of solarphotovoltaics.

Backed by an integrated production facility, CEL has madeaccumulative supply of over 1.5 lakhs SPV systems (20MW) spread over 28 different types, covering both ruraland industrial applications. The company has not onlygiven 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 formanufacturing SPV Modules and Systems to RajasthanElectronics & Instruments Ltd. India in 1985 and veryrecently 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 internationalspecifications – JPL Block V and IEC specification No.CEI / IEC 61215. CEL SPV Modules were certified byEuropean Solar Test Installations (ESTI), JRC, Ispra,Italy.

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INNOVATIVE ELECTRONIC SYSTEMS

Signalling & Safety Systems for the Indian

Railways :-

CEL is the pioneer Public Sector Company supplyingRailway Signaling and Safety equipments to Indian

Railways.

CEL continually identifies new requirements of theRailways and develops / manufactures the same inassociation with Research, Design and StandardsOrganization (RDSO) and Railway Board.

The Company is currently engaged in development of Digital Axle Counter in association with RDSO andDepartment of Scientific Industrial Research(DSIR).

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The product is undergoing extensive field trials indifferent zones of Indian Railways and softwarevalidation is under progress. The product is expected tobe 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 forthe protection of oil / gas pipelines to organizations likeIndian Oil Corporation, ONGC and GAIL.

The Company supplies different types of CathodicProtection Systems operating with solar photovoltaic orthermoelectric power sources or operating on grid

supply.

QUALITY POLICY

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The complete manufacturingoperation, marketing and installationservices of the company is certifiedunder ISO 9002 : 1994. The company hasenunciated the following quality policy tomeet customer needs and expectationsthrough supply of quality

products and services.

“CEL is committed to strive for leadership in the productmarketed by the way of continuous improvements in thequality of its products and services and meeting the

consumers needs in time and every time at a competitiveprice.

These shall be achieved through continuous upgrading of technology and process improvement by involving all theemployees, vendors, dealers and customers.

Quality is our basic business principle.”

Quality objective

• On time delivery of defect free products

• Providing effective customer support

• Continual improvement of processes

• Improvement of infrastructure

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• Development of human resources

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UNIVERSAL AXLECOUNTER

FOR

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INDIAN RAILWAYS

INTRODUCTION

Axle counters were developed as a substitute for trackcircuiting. Initially axle counters were imported fromGermany to gain experience and to evaluate theirsuitability for adoption on Indian Railways. Having gainedacceptability for introduction on a wide scale on IndianRailways, it was considered to take up indigenousdevelopment of axle counters, which was taken up incollaboration with IIT, Delhi and DOE. Two models of axlecounters known as single entry/exit axle counter and multientry/exit axle counters emerged and after extensivelaboratory and field trails under various conditions, thedesign was finalized and commercialized through privatesector as well as public sector.

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Based on the feedback from field, a new axle counter hasbeen developed by RDSO, known as “UNIVERSAL AXLECOUNTER”.

NEED FOR AXLE COUNTERS :

The track circuits are considered as the vital componentsof signaling system to achieve safety of train operations.Various Accident Enquiry Committees have recommendedto bring more and more tracks under track circuiting tosafeguard against reception of trains on occupied lines. The track circuiting could not achieve desired progressdue to virtual scarcity of wooden sleepers, prohibitive costand environmental consciousness in the country and theworld at large. Availability of concrete sleepers havesolved the problem to some extent but track circuiting onloop lines, points and crossings still suffers for want of adequate supply and insertion of concrete sleepers.

ADVANTAGES :

The advantages of Axle Counter over a conventional trackcircuit are:

(i) It does not require wooden sleepers (whereconcrete sleepers are not available) except forshort track circuits to suppress the counts due tomovement of insulated trolleys.

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(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 conventionaltrack circuit.

(iii) It does not get affected either by flooding of trackor poor maintenance of tracks unlike track circuits,which is highly susceptible to these conditions.

(iv) It does not require insulating joints, thus, rails canbe continuously welded. This reduces track

maintenance cost, lower wear and tear of tracksand vehicles and to increase traveling comfort.

APPLICATIONS :

Axle counters are finding more and more uses on modernsafety signaling systems in the railways. These are beingused presently for the following applications:

(i) Monitoring of berthing tracks in station areas andyards.

(ii) Monitoring of point zones in station areas andyards.

(iii) Automatic signaling systems.

(iv) Block section monitoring (between stations)through axle counters using multiplexers withcable or radio communication (18 GHz).

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(v) Level crossing warning system.

FLOW CHART FOR MANUFACTURING OFAXLE COUNTER

FabricationElectronic Components

Raw Materials

PCB

24

INSPECTIO

COMPONENT

INSPECTIO

CABINET



Rejected Accepted

Rejected Accepted

Mechanical

Components

RejectedAccepted

25

WAVE

CLEANING

INSPECTION

INTING

MECHANICAL FITTING

INSPECTIO

CARD TESTING

SYSTEM TESTING

REWORK

LACQUERING

CABINET WIRING

SYSTEM INTEGRATION



PRINCIPLE OF OPERATION

Signal aspect for train movement is controlled based onclear or occupied status of the track section. If a trainoccupies the track section, signal at the entry point of thesection is made RED and the next train is stopped fromentering into the section. When the track section is clearthe signal is made GREEN and the train is allowed toproceed into the section.

The clear or occupied condition of the track section isdecided by Axle Counter by counting the number of axlesof train at entry and exit points of the section. The axlecounter compares the IN and OUT counts and in case of count equality TRACK CLEAR signal is given. In all otherconditions TRACK OCCUPIED signal is given.

SignalSignal

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SHIPMENT



R1 R2 Railway TrackR3 R4

T1 T3 T4

Entry Point Track SectionExit Point

Signal Control

Relay Output

Cable

Cable

BLOCK DIAGRAM OF AXLE COUNTERINSTALLATION

27

EJB 1

EJB 2

E

VALUATOR



BRIEF DESCRIPTION

The Axle Counter is an electronic device and the completesystem consists of :

(i) Track mounting and trackside equipment.

(ii) Transmission media between trackside equipmentand central evaluator.

(iii) Central evaluator with EV relays and SUP relays asits 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 designedhousings, which are fixed to flange of a rail section bymeans of suitable rail clamps using bolts and nuts. Eachdetection point has two sets of such tracks devicesmounted on same rail with a fixed stagger between them. The two transmitter coils of a detection point are

28



connected in series to 5 kHz oscillators housed inelectronic junction box which is installed in a location boxby 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 boxthrough cables which are part of the track mountingequipment. Electronic junction box is powered by 24 V DCsupply.

Transmission media between trackside equipmentand central evaluator :

The connection between trackside equipment and centralevaluator is made using balanced twin twisted quadcables of specification IRS: TC/41/90. The output of electronic junction box and input of central evaluator arematched for an impedance of about 180 ohms at 5 kHz.

There is attenuation of signal from electronic junction boxto central evaluator, which limits the length of the cable.Other media such as optic fiber and wireless system mayalso be used in place of cable by incorporatingappropriate interfacing equipment at transmitting andreceiving ends.

Central evaluator with EV relay and SUP relay as its

output :

The signals received from electronic junction boxes areprocessed in the central evaluator first by analog circuitsand then by digital circuits to produce suitable output in

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terms of picking up or dropping of EV and SUP relays. TheDip’s generated by wheels as they pass over the track

devices installed at detection points, after they getprocessed, generate count pulses in a fail safe manner.

These pulses are identified as ‘IN COUNTS’ or ‘OUTCOUNTS’ depending on the direction of movement of vehicles over the monitored section. The counts are also

displayed through the 7-segment display on the frontpanel of the evaluator. The display unit is useful in faultlocalization and initial and periodical adjustments.

The evaluator is provided with its own power supply unitknown as DC – DC converter mounted in the same rackand requires 24 V DC supply for its operation. The outputof 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 toenable resetting of central evaluator in case of failure of system after observing prescribed procedure. The resetunit consists of a RESET key (which gets actuated afterinserting, turning and pressing), the counter and 3 LEDindications (Red, Yellow and Green). This unit requires 24V DC supply for its operation. This unit functions inconjunction with the line verification box.

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Line Verification Box :

This box is required to be kept near monitored trackportion outside Station Master’s (SM) office for achievingco-operative feature. This is a box consisting of a lock witha key fixed inside. The lock gets actuated only when thekey is inserted, turned and pressed. Whenever there is afailure of axle counter, SM will depute his ASM/Switchmanto verify whether the track section controlled by axle

counter is clear or not. ASM/Switchman after verificationof the track, if found clear, will report to SM who in turnwill handover the key of line verification box for operation.

TYPE OF SYSTEMS :

There are four types of system used in the IndianRailways. They are named below :

(i) One Device (1-D) System.

(ii) Two Device (2-D) System.

(iii) Three Device (3-D) System.

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(iv) Four Device (4-D) System.

1-D System:

In this system, there is a common detection point at entryand exit point of monitored section. This system is usefulfor monitoring the berthing track of terminal yard. A trainafter passing the detection point generates pulses equalto axles in it and these pulses are counted and stored bythe evaluator as ‘IN COUNTS’.

At the time of exit of train, the same detection point willbe encountered and it generates the same number of pulses as that during the entry. These pulses are countedand recorded as ‘OUT COUNTS’ by the evaluator. Whenthe IN COUNTS and OUT COUNTS are equal, the systemgives a

“Track clear” indication, otherwise it gives the “Track occupied” indication.

2-D System :

The principle of working of this system is similar to 1-DSystem except that in this system there are two detectionpoints, one at each end of the monitored section. Thissystem is useful for providing track circuiting on berthingtrack.

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3-D System :

In this system, there are three detection points. Theprinciple of working of this system is similar to 2-Dsystem. This system is useful for providing track circuitryon points, crossings and sidings.

4-D System :

In this system, there are four detection points. Theprinciple of working of this system is similar to 2-Dsystem. The system is useful for providing track circuitingon branch lines, sidings and points and diamondcrossings.

The design of 4-D system is such that it can be convertedinto a 2-D system or a 3-D system and vice–versa.

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 -- EV – 542 / 543 / 5441 No.

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3. DC-DC converter -- (inside Evaluator only as 10th

Card) 1 No.

4. Electronic Junction -- for 2D system (ACS-55-2D)2 Nos.

box , JB-533 -- for 3D system (ACS-56-3D)3 Nos.

-- for 4D system (ACS-57-4D)4 Nos.

5. Reset box -- RB – 257B1 No.

6. Track Device -- for a 2D system (ACS-55-2D)2 Nos.

Assembly -- for a 3D system (ACS-56-3D)3 Nos.

TR – 556 -- for a 4D system (ACS-57-4D)4 Nos.

7. Line verification box -- LV – 2611 No.

PARAMETER

SPECIFICATIONS

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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. 150mv.rms

Max. 1500mv.rms

6. Relay Drive Voltage for 1000 ohm

Shelf type 4F / 4B relay or Q Style > 10 V

Plug in Relay 1000 ohm, 4F / 4B

Power Requirement :

Powers required by various units are as follows :

DC – DC Converter 1.5 Amp max.

24 V (-10% to +20%)

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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 500 mA

(21.6 – 28.8 V DC) (only whenreset key is

pressed)

Environmental Conditions :

Relative Humidity 95 % - 98%

NonCondensing

Temperature range :

Universal Evaluator 0 to + 60˚C

Junction Box & Track Devices 0 to + 70 ˚C

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PHYSICAL CHARACTERISTICS :

The approximate dimensions and weights of various unitsof Universal Axle Counter are given as follows :

Name of UNIT WIDT

H

(mm

)

DEPT

H

(mm

)

HEIGH

T

(mm)

WEIGH

T

(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

LINEVERIFICATION

BOX

150

135 80 1.20

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Colour :

The rack is painted in a combination of light and dark greycolours. Evaluator, Junction box and Reset box are alsopainted in the same colour combination. The track devicesare painted in black colour.

IDENTIFICATION :

Rack :

The identification label of the rack is put at the left handtop on the front side of the rack with inscription.

a) For a 2D system Universal axle Counter, ACS – 55with EV – 542 Evaluator.

b) For a 3D Universal Axle Counter System, ACS – 56with EV – 543 Evaluator.

c) For a 4D Universal Axle Counter System, ACS – 57with EV - 544 Evaluator.

The serial no. label is mounted on the right hand top sideof the rack at the back.

Evaluator :

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The label “Evaluator, EV - 542”, “EV - 543” or “EV - 544”,for a 2D, 3D or a 4D system respectively is marked on thefront side of the evaluator. The serial no. label is on theback side.

Junction Box :

On the top (front) of the Junction Box the label “JUNCTIONBOX, (JB-533)” given whiles the serial no. label is on the

back plate.

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 thefront side and the Sr. No. label is on the right side cover.

Track Devices :

Labels indicating the Tx and Rx coil of the Track Devicesare given on each track transducer.

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DC – DC Converter :

It is the 10th Card Module inside the Evaluator and it ismarked as “POWER SUPPLY”.

DESCRIPTION OF VARIOUSMODULES OF AXLE COUNTER

SYSTEM :

1.EVALUATOR :

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The Evaluator consists of 10 PCB modules. Theinterconnections between the various PCB cards are madewith the help of a motherboard. The polarization

arrangement (to avoid wrong insertion of modules) isprovided on the aluminum modular sheets in each. Henceit is important to ensure correct fitting of modular shield ineach card. In the Universal Axle Counter Systemmanufactured by Central Electronics Limited , relevantcard number has been number punched for easyidentification 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). Itcontains four

identical channels , each comprising of a 5 kHz highpass filter , a line

matching transformer, attenuator pads, a two stageamplifier and a full

wave rectifier. The output of each channel can be setprecisely by means of a lockable shaft potentiometer

41



mounted at the front end of the PCB module. Typicaloutput is 300 mv (P-P) or 105-mv rms.

(b) Attenuator/Amplifier & Rectifier Card (Card no.2) :


identical channels , each comprising of a 5 kHz highpass filter , a line

matching transformer, attenuator pads, a two stageamplifier and a full

wave rectifier. The output of each channel can be setprecisely by means of a lockable shaft potentiometermounted at the front end of the PCB module. Typicaloutput 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 evaluatorwill have two nos. of such cards (Card nos. 1 & 2).

(c) Pulse Shaper Card (Card no. 3) :


42



identical channels, each consisting of a low pass filter, aSchmitt trigger, an impulse time filter and a 10 V to 5 Vlevel converter. The outputs of these channels are TTLcompatible. In addition to above, each channel

comprises of a Trolley Suppression Circuit.

(d) Pulse Shaper Card (Card no. 4) :


identical channels, each consisting of a low pass filter, aSchmitt trigger, an impulse time filter and a 10 V to 5 Vlevel converter. The outputs of these channels are TTLcompatible. In addition to above, each channelcomprises 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 incountand outcount pulses are also generated here forsupervision purpose. The ‘IN COUNT’, ‘OUT COUNT’,‘Duplicate In count’ and ‘Duplicate Out count’ pulsesare fed separately to different combiner gates housed

43



in card 6 (Logic II) and thereafter fed to the countercard (Card 7) for further processing.

As E, F, G, H channel inputs are used only in case of 3Dor 4D Systems, card 5 will be used only with the 3D and4D Evaluators.

(f) Logic – II (Card no. 6) :

This is also a double sided PCB (Size: 225mm X275mm). This card houses the logic circuitry togenerate ‘IN COUNTS’, ‘OUT COUNTS’, ‘DUPLICATE INCOUNTS’ and ‘DUPLICATE OUT COUNTS’ due to the dipscaused from channel inputs from the track detectionpoints A, B, C and D. It also has combiner gates, whichcombine the count pulses generated from all thedetection 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. Thisgenerates four clock pulse trains. All these four pulsetrains are staggered in phase, with each of these pulsetrains having a phase difference of 25 µ secs. Ascompared to the subsequent one.

The interrogator ensures that even if more than oneincount or more than one outcount are fedsimultaneously from different detection point, the finalcount pulses fed to the counter card get staggered andthus counts are not missed.

44



In addition to above, this PCB also houses the IN/OUTsupervision circuits, both counter checking each other.In case of any malfunction the system latches to failurecondition. This card also houses the 1st outcount inhibitcircuit which ensures latching up of the system in theevent of 1st count getting registered being an ‘OUTCOUNT’ 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. Onefor counting the ‘IN COUNTS’ and the other for ‘OUTCOUNTS’. It also has count supervision circuits, bothfor in counts as well as the out counts, to check theintegrity of the counters. In addition, there are twocomparators; one being a duplicate of the other, tocompare the counts from the two counters the ‘IN

COUNTER’ and the ‘OUT COUNTER’.

The outputs of the comparators are further comparedwith EX-OR chain to ensure integrity of thecomparators.

(h) General Supervision Card (Card no. 8 ) :

This is a double sided PCB (Size: 225mm X 275mm). Ithouses the following evaluator circuits :

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(i) Comparator Supervision.

(ii) A series of monoshots forming a chain for static

supervision i.e. to prove the effectiveness of anumber of DC levels of the system and a fewground points.

(iii) Pulse Shaper (Card no. 3 and 4) supervision forall the eight

channels.

(iv) Failure Supervision.

(j)Relay Driver (Card no. 9) :

This is a double sided PCB (Size: 225mm X 275mm) andit houses the following circuits :

(i) Level detector circuits for all the 8 channelinputs to ensure the presence of properchannel input levels.

(ii) The ‘VOLTAGE MONITOR’, which serves as, a‘WATCH DOG’ for the +5V power supply to theEvaluator.

(iii) Relay driver outputs for driving the EV relayand the supervisory relay.

(k) Counts Display Card :

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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 itcan count upto 1023 counts in both the display. Thiscard is mounted on front panel of evaluator and countsare recorded in decimal system.

(l)EV & SUP Relay Indication LEDs :

The output of the Evaluator is used to drive two 12Volts DC, 4F/4B shelf type relays or 12 Volts DC, Q-style4F/4B plug-in relays which are used to indicate thetrack clear or track occupied indications to controlsignal aspects. Two 10 mm dia. LEDs (Green and Red)have been provided in the front side of the AxleCounter Rack in a metallic strip for locally displayingthe position of the above relays. These LEDs have to besuitably wired at the time of installation as perrequirements from the terminal strip connectionsprovided 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 ismounted at right angles to the other 10 PC Cards andserves the purpose of providing variousinterconnections between them. The female parts of the Euro Connectors are mounted on this PCB andcorresponding male parts which are mounted on the

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PCBs (Cards 1 to 10) mate with them when the cardmodules are inserted in the unit. The mother board alsoprovides access, through MS Couplers, to feed variousinputs like channel inputs from the tracks, power supply

and trolley protection and to feed outputs to the EV andthe Supervisory Relays kept in the rack.

(n) Reset Relay :

This is mounted at the back of the Evaluator on themotherboard. A 67DP-24-4C3 OEN Relay is mounted on

this PCB with a mounting socket. This Relay resets theSystem whenever required to do so.

2. ELECTRONIC JUNCTION BOX (EJB) :

The Electronic Junction Box houses PCB modules whichare interconnected through motherboard. All theincoming / outgoing signals

are terminated on the MS Couplers (7 pin) mounted atthe back of the junction box. Two types of outputs areavailable from the EJB. The output of the EJB is sent tothe Evaluator either through a 4 wire or a 2-wiresystem.

(a) 4-Wire System :

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In a 4-Wire System, two pairs of under ground cable arerequired to send transition signal to evaluator forcounting the dips. In this system there are three PCBsconsisting of common oscillator feeding to twotransmitter coils in series and two number of receiveramplifiers, one for each receiver coil. The sequence of cards is, regulator and oscillator in first position, firstamplifier 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 whichis fed to the transmitter coils in series. The outputvoltage is 60 V ± 10% (rms) and current supplied is 420mA ± 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 1and it rejects any noise over riding in the signal bymeans of a two stage tuned amplifier. The output of thereceiver coil (1) is fed to the input of the amplifier. The

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output of the amplifier is connected to the Evaluatorand 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 forreceiver coil(2).

(b)2-Wire System :

In 2-wire system, a 4th card is inserted in the EJB, whichconverts the frequency of the second receiver amplifiersignal to 3.5 KHz with the use of converters. Thus, 2-wire system is having output on 2-wire and consists of 4cards, namely the regulator / oscillator card, thereceiver amplifier card-1, the receiver amplifier card-2and 4W / 2W card. This is used in block working at

Advance starters only.

The sequence of cards is :

(i) Regulator / Oscillator Card.

(ii) Receiver Amplifier Card-1.

(iii) Receiver Amplifier Card-2.

(iv) 4W / 2W Converter Card.

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3. RESET BOX :

This box houses one 12 way PIRI terminal strip for

terminating IN / OUT signals. The indication LEDs of thereset box are fitted in LED holders and projected to thefront for indication. Green and Red indications are givenfor track clear and track occupied conditions. The Yellow LED indicates co-operative permission forresetting the Axle Counter.

4. TRACK DEVICE ASSEMBLY :

The Single Rail Track Device Assembly consists of twotransmitter and two receiver coils assembly, which arefitted with suitable mounting arrangements on the railcamp, which in turn is fitted to the rails. The two

transmitter coils at each of the detection point are fedin series by a 5 KHz sinusoidal signal from the junctionbox, which forms an electromagnetic field across thereceiver coils. The receiver coil in turn generatesinduced voltage. The induced voltage drops to aminimum whenever there is an axle between thetransmitter and the receiver coils.

(a) Track Device Transmitter :

The transmitter coil is placed in a FRP housing andit is potted in place by m-seal compound. It is fixedon the rail clamp on the outer side of the rail. Each

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transmitter coil will be provided with a 10 meter, 24/ 0.2 PVC cable.

(b) Track Device Receiver :

The receiver coil is housed in a compositealuminium fiber glass housing and is potted in placeby the means of an m-seal compound. The receiverhousing is fixed on the base clamp on the inner sideof the rail. Each receiver coil will be powered with a10 meter, 24 / 0.2 PVC cable.

5. POWER SUPPLY :

The Power Supply, to the Evaluator is fed by a DC–DCConvertor. The various output voltage of the DC–DCConvertor 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.

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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 5Vsupply has additional crow bar protection at 6.2 volts.

PRODUCTION TESTING & TEST PROCEDURE :

The semi – conductor devices like diodes and transistorsused are of high reliability type. The other vitalcomponents like ICs mostly are the commercial grade ICswhich will undergo burn in at 60°C with dc power ‘ON’ for

72 hours.

This will eliminate the failure of critical components afterthe assembly of the PCB.

WAVE SOLDERING :

All the PCB’s assembly will be wave soldered for goodreliability and also coated with lacquer to withstandclimatic conditions.

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INSPECTION :

Each unit will be examined for proper workmanship,

fitness, finish and proper markings. Also each unit will betested thoroughly as per the test schedules mentioned inthe test report before the final shipment.

SPECIAL FEATURES

The Universal Axle Counter has the following specialfeatures :

PCB LAYOUT :

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Better PCB layouts to have supply feeding and decouplingfor better noise immunity.

MOTHER BOARD :

The use of mother board gives extra noise immunity ascompared to back panel wiring.

RACK :

The Evaluator is housed in a rack fabricated out of M.S.sheet. This gives good noise immunity againstelectromagnetic interference.

SHIELDING :

The Rack is well shielded for better noise immunity. All themetallic frames of the rack are interconnected to the mainframe by means of 34 / 0.3 wire. Shielded cables will beused in system, shield of which is connected to the backpanel of the Evaluator.

CARD INSERTION :

Each Card alongwith a module is guided separately.

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CARD MODULES :

Each Card is provided with a module alongwith the

identification label.

CARD POLARISATION :

Polarizing holes on the card modules and guiding pinsfrom the Mother Board side are used to provide cardpolarization to ensure correct card slotting.

MODULE TIGHTENING SCREWS AND CARDHANDLES :

Module tightening screws are provided to fix the cardsalong with the module in the unit smoothly. By loosening,the cards can be removed from the unit. Two card handlesare 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 thefront panel inside and is viewed through display viewing

plate at the front panel of the Evaluator.

EVALUATOR MARKINGS :

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In each unit input /output labels, the supply, channelmarkings and trolley protection A / B, C / D are marked.

OTHER PRODUCTS OF CEL

SOLAR WATER PUMPING SYSTEMS :

A Solar Photovoltaic Water Pumping System essentiallyconsists of an SPV panel or array directly powering awater pump. Water pumped during the day can be storedin the storage tanks for use during the night.

CEL offers SPV Water Pumping Systems for both shallowas well as deep well conditions. Such systems have been

deployed all over the country. The system has also beenexported to many developing countries.

The generated electricity from the SPV array is fed to thepump through a switch. Normally low storage batteriesare provided, as the water can be stored in the storagetanks if required.

SOLAR PHOTOVOLTAIC LIGHTING SYSTEMS :

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CEL’s Solar Photovoltaic Lighting Systems are idealsources for providing indoor/outdoor illumination inremote and unelectrified settlements/ villages. The SPVLighting System essentially consists of an SPV panel

battery, a charge controller and lights. The SPV panelconverts the sunlight incident on it directly to DCelectricity that can be stored in the battery and used toenergize the lights when required. The charge controllerprevents the overcharging and deep discharge of thebattery.

SPV INDOOR LIGHTING SYSTEMS :

Two types of indoor lighting systems are available (DLS-02and DLS-04) depending on the lighting requirements. DLS-02 has two numbers of 9W luminous efficiency lamps withwall mounting fittings. DLS-04 has four such lamps. Eachlamp can give the output of 60-watt incandescent lamp.

SPV OUTDOORS LIGHTING SYSTEMS :

These systems use a weather proof 18-watt or 20-wattfluorescent tube light fittings. Two models SLS-03 andSLS-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 thetube-light fittings are mounted on a 4M long pole.

SOLAR LANTERNS :

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CEL Solar Lantern is a versatile and a reliable source of lighting. It consists of a lantern, a SPV module and aconnecting cable. The SPV module when exposed to lightcharges the battery in the lantern. This stored energy inthe 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

SILENT OPERATION

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APPLICATIONS :-

EMERGENCY LIGHTING SOURCE

LIGHTING SOURCE IN REMOTE VILLAGES

LIGHTING AT PICNIC SPOTS AND FARM HOUSES

GARDEN LIGHTING

LIGHTING AT MILITARY OUTPOSTS

MILESTONES OF SPV SYSTEMS

DEVELOPMENT AT CEL

SPV operated Radio set in Jammu & Kashmir - 1978

SPV Irrigation Water Pumping System installed atKalyani, West Bengal – 1979

SPV Pumping System for drinking water near Jaipur –1980

SPV Community Lighting Systems installed at SOSchildren’s village, Leh, Ladakh, J&K – 1980

SPV Community Television Systems installed atKalyani, West Bengal – 1980

Special SPV Power Pack for the first Indianscientific expedition to Antarctica – 1981

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First SPV Power System for unmanned off-shoreoil 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 LightingSystem 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 villageHealth Centers –1985

Design and supply of first SPV Systems for very lowpowered unmanned TV transmitter (VLPT) & TVReceiver Only (from INSAT) (TVRO) terminals of Doordarshan - 1986

Supply of SPV Power System for weather monitoring,lighting and entertainment at an Avalanche StudyStation at Rohtang Pass (ALT : 3600 mtrs/12000ft.) in the Himalayas – 1986

SPV powered Lighting and Television System for

army at Siachin (ALT : 3600 – 5500 mtrs / 12000ft.) in the Himalayas – 1987

Supply of first 2 KW power SPV Village Power Pack –1987

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SPV systems for warning signals at UnmannedRailway Level Crossings – 1988

SPV Rural Deep well Water Pumping Systems forNational Drinking Water Mission - 1989

SPV Power System for Rural Telecommunicationtransmission and switching equipments – 1989

Supply and installation of SPV Systems in villageHitam-ulu, Sumatra, Indonesia – 1990

SPV Lighting Systems for Adult Education under

National Literacy Mission – 1990

Supply and installation of 6 KW Power Plant atKariawali village in U.P. – 1990

Supply and installation of Asia’s first 100 KW SPVPower 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 forpowering Man pack Communication – 199.

Equipments for the defense services to operate inthe temperature range from –30°C to +55°C.

CATHODIC PROTECTION SYSTEM

INTRODUCTION :

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M/s Indian Oil Corporation Limited is presently laying 18”dia., 437 Km. long pipe line in 2 segments for augmentingthe capacity of existing OD 498 Km. long Haldia-BarauniCrude Oil pipeline from Haldia to Barauni.

Owner intends to provide permanent cathodic protectionsystem consisting of 13 nos. of impressed currentcathodic protection station to cathodically protect theunderground coated pipeline for a design life of 35 years.

BASIS IN BRIEF :

Permanent CP System has been designed for CTE coatinghaving coating resistance of 7000 ohm / m factor of safetyas 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 : 125microA/sq. mts.

Total no. of CP stations : 13

Nos. Total designed current for entire span : 103.8A

Max. design current of CP station : 10 A

Total no. of 22 Kg high silicone chrome anode : 250

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PROJECT INFORMATION :

The Haldia – Barauni Augmentation pipeline is startingfrom Haldia and it terminates approximately 473 Km.away at HBPCL near Barauni.

Coating Details :

The pipelines shall have yard coated coal for tar coatingwith fiberglass reinforcement. The coating resistance innormal soil shall be 7000 /m.Ω

Depth of pipeline :

Generally the HBPCL has proposed the pipeline to be laidat minimum depth of 1 mt. from the ground level. Depthmay 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 withencapsulated heads and heat sink caps connected at top.

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The technical data of the Hi-Si-Cr-Fe anodes assemblyshall be as under.

ANODE TYPE : Hi-Si-Cr-FeAnode

DIMENSIONS : 65 mm. Dia. &1 mt. long

WEIGHT : 22 Kg.

COMPOSITION: -

Si : 4 % to 15.5 %Mn : 0.8 %

C : 1.4 %

Cr : 4.5 %

Fe : remaining

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PROFESSIONAL FERRITES

INTRODUCTION TO FERRITES :-

Ferrites are dense homogeneous ceramic structureshaving a general molecular formula MFe2O4 where M is

an oxide of a divalent metal. When M has more than onemetal than it is called Mixed Ferrite.

Ferrite has a process flexibility, which permits easy andeconomic moulding into much different geometry. Besidesthere, Ferrites are advantageous because they have highelectrical resistivity resulting in some eddy current losesover a wide frequency range, high permeability and time

and temperature stability as compared to other metallicmagnetic materials such as silicon steels.

The ferrites are used in Transformers, Telecommunications, TV industry, Antennas, DefenseEquipments, etc.

Application of different types of Ferritecores :-

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The ferrite cores that are produced in CEL are available indifferent sizes and their uses are as follows :

a) Pot cores & RM cores :

These are used in stable low loss Filters, Inductorsrequiring high Q, Chokes, Proximity switches, R.F. Transformers, low power Converters & Inverters etc.for Telecommunications, Axle Counter System for

Railways and other Professional electronicapplications.

b) Toroids :

They are used in Pulse Transformers, Delay lines,Chokes, Converter / Inverter Transformers, WideBand Transformers, Impedance matching Transformers, etc.

c) Blocks : They are used for Transmitter andReceiver application of Axle Counters. They can alsobe used as building blocks for making high powertransmitters.

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d)E, EI, ETD & EC Cores :

These types of cores are used in theInverter/Converter Filters, Chokes, Inverters forFluorescent Lamps and Flash Light Inverters, SwitchMode Power Supply for Television and Computers,etc.

e)U & UI Cores :

These cores are used in Insulation Testers, DC-to-DCConverters, DC halogen lamp Inverters, UltrasonicCleaners and high voltage Inverters. By stacking of these cores, high power transformers in Kilowattrange can be manufactured.

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FERRITE PROCESS FLOW CHART

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Mangane

Batch

Mixin

CALCINATION

(PREFIRING)

MILLING

GRANULATION

BINDERLUBRICANT

PRESSIN

LAPPING

PRODUCTIONTESTING



NEW PRODUCTSSINGLE SECTION DIGITAL AXLECOUNTER

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AIR GAP

ADJUSTMENPRINTIN

QUALITY ASSURANC

STORES

ANDDESPATCH



A state-of-the-art Digital Axle Counter has been developedby 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 relaydrive.

The system has two detection points for monitoring eitherend of the section. When the train is entering the sectionthe wheel counts are registered and stored in the 1st

SSDAC unit. When the train is entering the section thewheel counts are registered and stored in the 2nd SSDACunit. After exchange of counts stored in both SSDAC1 andSSDAC2 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 continuouslymonitored 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.

SOLID STATE INTERLOCKING

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Solid State Interlocking (SSI) is Signaling System to selectand operate the routes in station for guiding the

movement of the trains. The system replaces theconventional Route Relay Interlocking. The system isdesigned with “2 out of 2” Microprocessor with hotstandby. The system has software redundancy.

The operator panel is used to control and command anddisplay 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 andOutputs for Off-line analysis.

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• Opto Isolated Inputs and Outputs.

• Modular design for easy maintenance and expansion.

SOLAR POWERED RAILWAY LEVEL

CROSSING RADIO WARNING SYSTEM

(SOLARGUARD ™)

CEL has developed this system, in association withResearch, Designs and Standards Organization(RDSO) for providing early warning of a train / locomotive

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approaching unmanned level crossing, to the people androad traffic crossing the Railway line.

SYSTEM OPERATION :

A track device actuated solar powered VHF transmitterlocated 3-4 Kms, from the level crossing (i.e. Far End)sends a coded radio signal towards the level crossingwhen an approaching train crosses the Far End. The radiosignal is received by solar powered receiver located at thelevel crossing (Gate End) which after decoding the signalactuates an Audio- Visual Alarm for forewarning thetraffic. The system is ideal for remote railway levelcrossings. The ruggedized system is under extensive fieldtrials.

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MEDIA GALLERY

CEL has been in news headlines ever since it started its operations owing to

various technological breakthroughs and achievements. Here are some of the clippings on what the media says about us..

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PHOTO GALLERY

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http://www.celsolar.com/consec/photo_14.jpg



Former PM of India Narsimha Rao

at CEL facility

His Excellency Dr. Sam Nujoma, President of Namibia walking on CEL's Photovoltaic

module to check the strength of the module

Gen.Md. Nooruddin Khan.

Min. Of Science & Technology

Goverment Of Bangaldesh

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http://www.celsolar.com/consec/guestbig.jpg



Hon' ble Members of Parliament

(Rajya Sabha)

Dr. Ri Kwang Ho

Minister Of Science Academy,

DRP-Korea

SELF EVALUATION

This 30 days Industrial Training has led me to understandthe various designing, assembling and the manufacturingprocesses of equipments in the industry, CEL.

It has also enhanced my knowledge about the functioningand management of an industry, which I am sure, will bebeneficial to me in my career.

Regards,

Mitil kumar

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0829021408

IVth - Year

(Electrical & Electronics Engg.)

ABES INSTITUTE OF TECHNOLOGY

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axel counter summer training report

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