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Summer Training Report On Central Electronics Limited AXEL COUNTER
Summer Training Report On Central Electronics Limited AXEL COUNTER
SUBMITED BY:
KIRAN NAUTIYAL
III-Year
(ELECTRONICS AND COMMUNICATION
ENGINEERING)
HINDUSTAN INSTIUTE OF TECHNOLOGY
1
GREATER NOIDA.
CONTENTS
1. Certificate
2. Acknowledgement
3. Company Profile
(a) The organization CEL
(b) Divisions of CEL
(c) Products of CEL
(d) Nations 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
(a) SPV products
(b) Cathodic protection system
(c) Ferrite Products
7. New Products
8. Self Evaluation
PROFILE
ORGANISATION STRUCTURE OF CEL
CHAIRMAN &
MANAGING DIRECTOR
GENERAL
MANAGER
(CP & HRD)
GENERAL
MANAGER
Jt. GENERAL
MANAGER
(FINANCE)
Jt. GENERAL
MANAGER
(PROJECT
MANAGEMENT)
(MATERIALS
MANAGEMENT)
EXECUTIVE
DIRECTOR
AGM
(QUALITY
ASSURANCE)
(OPERATIONS)
GENERAL
MANAGER
(SYSTEMS)
Jt. GENERAL
MANAGER
(MICROWAVE)
GENERAL
MANAGER
(SPV)
Jt. GENERAL
MANAGER
(R&D)
4
AGM
(FERRITE)
Jt.GM
(CERAMICS)
DIVISIONS OF CEL
Five business groups handle the total commercial operations of the
Company. These are as follows:
COMPONENTS GROUP:
A large range of products is manufactured here using state-of-art
technologies to meet the requirements of communications, defense,
consumer and industrial sectors.
It is divided into three sub departments. Their products and applications
are as follows:
(a) Professional Ferrites:
This department manufactures different types of ferrite cores for
high frequency applications. The different types of cores
manufactured are Pot cores, E, U, I, RM, torroids etc. These are
called professional because they require highly sophisticated
techniques for their manufacture and give a superior performance.
The various applications of ferrite cores include TV sets,
Communication equipments, computers, electronic ballasts, switch
mode power supplies (SMPS) and Microwave equipments.
(b) Electronic Ceramics:
This department manufactures piezo-electric transducer elements,
high temperature crucibles, high speed bearings and other alumina
products. These products are used in Defense ammunitions,
Ultrasonic cleaners, Buzzers, 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:
Solar Photovoltaic Group :
Solar Cells/Modules
Solar Lantern
Street Light System
Home Light System
Water Pumping System
Components Group :
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.
10
UNIVERSAL
AXLE COUNTER
FOR RAILWAYS
11
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.
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.
12
(ii)
(iii)
(iv)
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)
(ii)
(iii)
(iv)
(v)
13
Electronic Components
PCB
COMPONENT MOUNTING
CABINET FABRICATION
INSPECTION
INSPECTION
Rejected
Rejected
Accepted
Accepted
WAVE SOLDERING
Mechanical
Components
CLEANING
REWORK
STATION
MECHANICAL FITTING
INSPECTION
Rejected
CABINET WIRING
Accepted
CARD TESTING
LACQUERING
SYSTEM
INTEGRATION
SYSTEM TESTING
INSPECTION
SHIPMENT
14
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
R1
R2
T1
T2
Signal
Railway Track
Entry Point
Track Section
R3
R4
T3
T4
Exit Point
Signal Control
Relay Output
Cable
EVALUATOR
Cable
15
BRIEF DESCRIPTION
The Axle Counter is an electronic device and the complete system
consists of :
(i)
(ii)
(iii)
(iv)
Reset box.
(v)
16
17
TYPE OF SYSTEMS :
There are four types of system used in the Indian Railways. They are
named below :
(i)
(ii)
(iii)
(iv)
1-D System:
In this system, there is a common detection point at entry and exit point
of monitored section. This system is useful for monitoring the berthing
track of terminal yard. A train after passing the detection point generates
pulses equal to axles in it and these pulses are counted and stored by the
evaluator as IN COUNTS.
At the time of exit of train, the same detection point will be encountered
and it generates the same number of pulses as that during the entry. These
pulses are counted and recorded as OUT COUNTS by the evaluator.
When the IN COUNTS and OUT COUNTS are equal, the system gives a
18
19
SPECIFICATIONS
Universal Axle Counter System mainly comprises of following
equipments :
1. Rack, ACS-55/56/57 -- (Common type for all models)
1 No.
2. Evaluator
-- 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)
box , JB-533
-- for 3D system (ACS-56-3D)
-- for 4D system (ACS-57-4D)
5. Reset box
-- RB 257B
6. Track Device
Assembly
TR 556
1 No.
PARAMETER
2 Nos.
3 Nos.
4 Nos.
2 Nos.
3 Nos.
4 Nos.
1 No.
SPECIFICATIONS
2/3/4
200 kmph
3. Counting Capacity
1023
Power Requirement :
Powers required by various units are as follows :
DC DC Converter
24 V (-10% to +20%)
Evaluator 24 V
(21.6 28.8 V DC)
1.5 Amps
Junction Box 24 V
(21.6 28.8 V DC)
< 250 mA
Reset Box 24 V
(21.6 28.8 V DC)
500 mA
(only when reset key is
pressed)
Environmental Conditions :
Relative Humidity
95 % - 98%
Non Condensing
Temperature range :
Universal Evaluator
0 to + 60 C
0 to + 70 C
21
PHYSICAL CHARACTERISTICS :
The approximate dimensions and weights of various units of Universal
Axle Counter are given as follows :
Name of UNIT
SINGLE
570
650
1065
70
DOUBLE
600
650
1460
100
EVALUATOR
482
439
310
21
JUNCTION BOX
208
280
170
RESET BOX
255
175
115
2.3
TRACK DEVICE
ASSEMBLY
LINE
VERIFICATION
BOX
515
330
170
15
150
135
80
1.20
RACK
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 :
22
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, (JB533) 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 the front
side and the Sr. No. label is on the right side cover.
Track Devices :
23
Labels indicating the Tx and Rx coil of the Track Devices are given on
each track transducer.
DC DC Converter :
It is the 10th Card Module inside the Evaluator and it is marked as
POWER SUPPLY.
24
DESCRIPTION OF VARIOUS
MODULES OF AXLE COUNTER
SYSTEM :
1. EVALUATOR :
The Evaluator consists of 10 PCB modules. The interconnections
between the various PCB cards are made with the help of a
motherboard. The polarization arrangement (to avoid wrong insertion
of modules) is provided on the aluminum modular sheets in each.
Hence it is important to ensure correct fitting of modular shield in
each card. In the Universal Axle Counter System manufactured by
Central Electronics Limited , relevant card number has been number
punched for easy identification to ensure correct fitting of modular
shields. A brief description of each P.C. assembly is given below.
25
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).
26
27
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.
29
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)
(ii)
(iii)
(iv)
2. 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.
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.
4. POWER SUPPLY :
The Power Supply, to the Evaluator is fed by a DCDC Convertor.
The various output voltage of the DCDC 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.
32
WAVE SOLDERING :
All the PCBs 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.
33
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.
34
CARD POLARISATION :
Polarizing holes on the card modules and guiding pins from the Mother
Board side are used to provide card polarization to ensure correct card
slotting.
MODULE TIGHTENING SCREWS AND CARD HANDLES :
Module tightening screws are provided to fix the cards along with the
module in the unit smoothly. By loosening, the cards can be removed
from the unit. Two card handles are provided on each module. The
modules can be taken out with the help of these handles.
COUNTS DISPLAY :
The Counts display is given on a PCB and mounted on the front panel
inside and is viewed through display viewing plate at the front panel of
the Evaluator.
EVALUATOR MARKINGS :
In each unit input /output labels, the supply, channel markings and trolley
protection A / B, C / D are marked.
35
36
37
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.
ENVIRONMENTAL FRIENDLY
PORTABLE
RUGGED AND DEPENDABLE
SILENT OPERATION
APPLICATIONS :
38
39
40
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.
PROJECT INFORMATION :
41
:
:
:
:
:
Coating Details :
The pipelines shall have yard coated coal for tar coating with fiberglass
reinforcement. The coating resistance in normal soil shall be 7000 /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
Mn
C
Cr
Fe
:
:
:
:
:
42
4 % to 15.5 %
0.8 %
1.4 %
4.5 %
remaining
PROFESSIONAL FERRITES
INTRODUCTION TO FERRITES :Ferrites are dense homogeneous ceramic structures having a general
molecular formula MFe2O4 where M is an oxide of a divalent metal.
When M has more than one metal than it is called Mixed Ferrite.
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.
43
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.
44
CALCINATION
(PREFIRING)
Batch
Mixing
Manganese
Oxide
LUBRICANT
PRESSING
BINDER
GRANULATION
MILLING
(SPRAY DRYING)
SINTERING
AIR GAP
ADJUSTMENT
PRINTING
QUALITY
ASSURANCE
PRODUCTION
TESTING
LAPPING
STORES
AND
DESPATCH
45
46
NEW PRODUCTS
SINGLE SECTION DIGITAL AXLE
COUNTER
A state-of-the-art Digital Axle Counter has been developed by CEL for
track monitoring of single section in railways.
The system is designed with :
High frequency track coils.
Track side electronic counting unit including vital relay drive.
The system has two detection points for monitoring either end of the
section. When the train is entering the section the wheel counts are
registered and stored in the 1st SSDAC unit. When the train is entering
the section the wheel counts are registered and stored in the 2nd SSDAC
unit. After exchange of counts stored in both SSDAC1 and SSDAC2
units, the section is declared as CLEAR in case the counts are equal.
Otherwise the section is shown as OCCUPIED.
The health of SSDAC1 and SSDAC2 units are continuously monitored
and proved in vital relay drive circuits.
The vital relay drive is available independently at either end of the
section from SSDAC1 and SSDAC2 units.
47
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.
48
SYSTEM OPERATION :
A track device actuated solar powered VHF transmitter located 3-4 Kms,
from the level crossing (i.e. Far End) sends a coded radio signal towards
the level crossing when an approaching train crosses the Far End. The
radio signal is received by solar powered receiver located at the level
crossing (Gate End) which after decoding the signal actuates an AudioVisual Alarm for forewarning the traffic. The system is ideal for remote
railway level crossings. The ruggedized system is under extensive field
trials.
49
SELF EVALUATION
These 45 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.
KIRAN NAUTIYAL
III-Year
(ELECTRONICS AND COMMUNICATION
ENGINEERING)
HINDUSTAN INSTIUTE OF TECHNOLOGY
GREATER NOIDA.
50