1

SUMMER
TRAINING REPORT

AXLE COUNTER FOR RAILWAYS SOLAR PHOTOVOLTAIC CELL

CENTRAL ELECTRONICS LIMITED

SAHIBABAD (U.P.) INDIA

BHAVYA KUMAR GAUTAM

B.TECH IIIrd –YEAR
ELCTRONICS &COMMUNICATION ENGG. (2507122)
UNIVERSITY INSTITUTE OF ENGINEERING & TECHNOLOGY
KURUKSHETRA UNIVERSITY,KURUKSHETRA

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1. Acknowledgement

2. 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 of Axle Counter System

6. Other products of CEL

7. New Products

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4
 8. Self Evaluation

CENTRAL ELECTRONICS LIMITED

A PROFILE

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ORGANISATION STRUCTURE OF CEL

CHAIRMAN &
MANAGING DIRECTOR

GENERAL GENERAL
MANAGER MANAGER
(CP & HRD) (PROJECT
MANAGEMENT)

Jt. GENERAL Jt. GENERAL

MANAGER MANAGER
(FINANCE) (MATERIALS
MANAGEMENT)

EXECUTIVE AGM
DIRECTOR (QUALITY
(OPERATIONS) ASSURANCE)

GENERAL Jt. GENERAL AGM

MANAGER MANAGER (FERRITE)
(SYSTEMS) (MICROWAVE)

GENERAL Jt. GENERAL Jt.GM

MANAGER MANAGER (CERAMICS)
(SPV) (R&D)

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 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 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 serve the industrial needs of Railway Signaling,
Microwave Repeaters, Defence 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, Solid State Interlocking System for Railways. The other products of this
division include Electronic Switching System, Cathodic Protection System for
underground pipelines and VSAT.

COMPONENTS GROUP:

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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, Sonars,
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.

PRODUCTS Of CEL

The organization manufactures different products that can be classified according to

the divisions of CEL as follows:

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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

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 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.

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

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.

INNOVATIVE ELECTRONIC SYSTEMS

Signalling & 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.

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 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.

QUALITY POLICY

The complete manufacturing operation, marketing and installation services of the

company is certified under ISO 9002 : 1994. The company has enunciated the
following quality policy 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

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 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 “UNIVERSAL AXLE COUNTER”.

NEED FOR AXLE COUNTERS :

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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, 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.
(iv) Block section monitoring (between stations) through axle counters using
multiplexers with cable or radio communication (18 GHz).
(v) Level crossing warning system.

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 FLOW CHART FOR MANUFACTURING OF AXLE
COUNTER

Fabrication Electronic Components

Raw Materials
PCB
COMPONENT MOUNTING
CABINET FABRICATION

INSPECTION
INSPECTION

Rejected Accepted
Rejected Accepted
WAVE SOLDERING

Mechanical
Components CLEANING
REWORK
MECHANICAL FITTING STATION

INSPECTION

Rejected Accepted
CABINET WIRING
CARD TESTING

LACQUERING

SYSTEM INTEGRATION

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 SYSTEM TESTING

INSPECTION

SHIPMENT

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

R1 R2 Railway Track R3 R4

T1 T2 T3 T4
Entry Point Track Section Exit Point

Signal Control
Relay Output

EVALUATOR

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Cable
Cable

BLOCK DIAGRAM OF AXLE COUNTER INSTALLATION

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.

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

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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

“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 :

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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.

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 / 544 1 No.
th
3. DC-DC converter -- (inside Evaluator only as 10 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 – 257B 1 No.

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

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

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

7. Line verification box -- LV – 261 1 No.

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 > 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%)

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 when reset key is
pressed)

Environmental Conditions :

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Relative Humidity 95 % - 98%
Non Condensing
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 DEPTH HEIGHT WEIGHT

(mm) (mm) (mm) (kg)
SINGLE 570 650 1065 70
RACK
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 515 330 170 15
ASSEMBLY

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LINE
VERIFICATION 150 135 80 1.20
BOX

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) :

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

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 wave rectifier. The output of each channel can be set precisely by means of a
lockable shaft potentiometer mounted at the front end of the PCB module. Typical
output is 300 mv (P-P) or 105-mv rms.

For 1D and 2D Systems, there will be one such card (Card no. 1) while for 3D and
4D Systems, the evaluator will have two nos. of such cards (Card nos. 1 & 2).

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

This is a double sided PCB (Size: 225mm X 275mm). It contains four

identical channels, each consisting of a low pass filter, a Schmitt trigger, an
impulse time filter and a 10 V to 5 V level converter. The outputs of these channels
are TTL compatible. In addition to above, each channel comprises of a Trolley
Suppression Circuit.

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

This is a double sided PCB (Size: 225mm X 275mm). It contains four

identical channels, each consisting of a low pass filter, a Schmitt trigger, an
impulse time filter and a 10 V to 5 V level converter. The outputs of these channels
are TTL compatible. In addition to above, each channel comprises of a Trolley
Suppression Circuit.

For 1D and 2D Systems, there will be one such card (Card no. 3) while for 3D and
4D Systems, the evaluator will have two nos. of such cards (Card nos. 3 & 4).

(e) Logic – I (Card no. 5) :

This is a double sided PCB (Size: 225mm X 275mm). This card generates ‘IN
COUNTS’ and ‘OUT COUNTS’, depending upon the direction of the train
movement, due to the dips caused form the track transducers E, F, G, H. In
addition to main count pulses, duplicate incount and outcount pulses are also
generated here for supervision purpose. The ‘IN COUNT’, ‘OUT COUNT’,
‘Duplicate In count’ and ‘Duplicate Out count’ pulses are fed separately to
different combiner gates housed in card 6 (Logic II) and thereafter fed to the
counter card (Card 7) for further processing.

As E, F, G, H channel inputs are used only in case of 3D or 4D Systems, card 5

will be used only with the 3D and 4D Evaluators.

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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.

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

This is a double sided PCB (Size: 225mm X 275mm). It houses 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 a number of DC levels of the system and a few
ground points.
(iii) Pulse Shaper (Card no. 3 and 4) supervision for all the eight
channels.
(iv) 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 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 :

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 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 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)

29
 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 :

(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.

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 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.

(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.

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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.

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.

32
 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.

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 :

33
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.

35
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-04) 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.

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.

36
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

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 at Kalyani, West Bengal –
1979
 SPV Pumping System for drinking water near Jaipur – 1980
 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

37
 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
 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.

38
 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 :

39
Designed current density considered for design : 125 microA/sq. mts.
Total no. of CP stations : 13 Nos.
Total designed current for entire span : 103.8 A
Max. design current of CP station : 10 A
Total no. of 22 Kg high silicone chrome anode : 250

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 : Hi-Si-Cr-Fe Anode
 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

40
 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.

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 in CEL are available in different sizes and their
uses are as follows :

a) Pot cores & RM cores :

These are used in stable low loss Filters, Inductors requiring high Q, Chokes,
Proximity switches, R.F. Transformers, low power Converters & Inverters etc.
for Telecommunications, Axle Counter System for Railways and other
Professional electronic applications.

41
 b) Toroids :

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

c) Blocks :

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
these cores, high power transformers in Kilowatt range can be manufactured.

42
 FERRITE PROCESS FLOW CHART

Iron Oxide
Batch CALCINATION
Zinc Oxide (PREFIRING)
Mixing

Manganese
Oxide

LUBRICANT BINDER

GRANULATION
PRESSING MILLING
(SPRAY DRYING)

PRODUCTION
SINTERING LAPPING TESTING

AIR GAP
PRINTING
ADJUSTMENT

STORES
QUALITY
AND
ASSURANCE
DESPATCH

43
 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.

44
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.

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.

45
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.

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 :

46
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.

SELF EVALUATION

This 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.

Vijay Krishna
IIIrd Year
(Mechanical Engg.)
Marathwada Institute of Technology, Delhi

47
48