SUMMER TRAINING REPORT

UNIVERSAL AXLE COUNTER

FOR RAILWAYS

CENTRAL ELECTRONICS LIMITED

SAHIBABAD (U.P.) INDIA

SUBMITED BY:

KIRAN NAUTIYAL
III-Year (ELECTRONICS AND COMMUNICATION
ENGINEERING) HINDUSTAN INSTIUTE OF TECHNOLOGY
1
GREATER NOIDA.

CONTENTS

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
Brief description
Specifications

Description of various modules of Axle Counter System

Other products of CEL

SPV products
Cathodic protection system
Ferrite Products

New Products

Self Evaluation

2
3
PROFILE

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)

4
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.

5
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:

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.

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.

Microwave Electronics:

This department manufactures microwave components such as

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

6
PRODUCTS OF CEL

The organization manufactures different products that can be

classified according to the divisions of CEL as follows:

Solar Photovoltaic Group :

Solar Cells/Modules

Solar Lantern

Street Light System

Home Light System

Water Pumping System

Electronic Systems Group :

Single / Multiple Entry / Exit Axle counters

Universal Axle counters

Block proving system

Railway Level Crossing Warning system

Solid State Interlocking System for Railways

Cathodic Protection system

Very Small Aperture Terminal (VSAT)

Electronic Switching Equipments

Components Group :

Different types of ferrite cores like Pot, RM, E, U, I, etc

Piezoelectric transducer elements

Special Bearings used in Heavy Water Plants

Microwave Ferrite Phase shifters

Direction Finding Systems

Frequency / Phase Correlators

7
NATION’S PIONEER & WORLD
LEADER IN SOLAR
PHOTOVOLTAIC

In an era of growing energy needs and rising concern for

environment, solar energy, the abundant and pollution free non-
conventional energy source, offers the best alternative solution.

CEL, with its commitment to harness the solar energy, has opened
up new vistas in the field of solar 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.

8
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.

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.

9
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.”

1
0
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”.

NEED FOR AXLE COUNTERS :

The track circuits are considered as the vital components of signaling

system to achieve safety of train operations. Various Accident Enquiry
Committees have recommended to bring more and more tracks under
track circuiting to safeguard against reception of trains on occupied
lines. The track circuiting could not achieve desired progress due to
virtual scarcity of wooden sleepers, prohibitive cost and environmental
consciousness in the country and the world at large. Availability of
concrete sleepers have solved the problem to some extent but track
circuiting on loop lines, 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:

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.

1
2
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.
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.
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:

Monitoring of berthing tracks in station areas and yards.

Monitoring of point zones in station areas and yards.
Automatic signaling systems.
Block section monitoring (between stations) through axle counters
using multiplexers with cable or radio communication (18 GHz).
Level crossing warning system.

1
3
FLOW CHART FOR
MANUFACTURING OF AXLE
COUNTER

Fabrication

Electronic

Components

Raw Materials

PCB
COMPONENT MOUNTING
CABINET FABRICATION
INSPECTION
INSPECTION
Accepted

Rejected

Accepted
Rejected

WAVE SOLDERING
Mechanical
CLEANING

Components

REWORK

MECHANICAL FITTING
STATION

INSPECTION
NG
CABINET WIRING CA
RD
Rejected Accepted TE LACQUE
STI RING
M INSPECTION
S TES
SYSTEM INTEGRATION Y TING
S
T SHIPMENT
E 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

Signal
R1

R2

Railway Track
R3
R4
T1

T2

T3

T4
Entry Point
Track Section
Exit Point
Signal Control

Cable

Relay Output
EVALUATOR

Cable

BLOCK DIAGRAM OF AXLE COUNTER INSTALLATION

15
BRIEF DESCRIPTION
The Axle Counter is an electronic device and the complete system
consists of :

Track mounting and trackside equipment.

Transmission media between trackside equipment and central

evaluator.

Central evaluator with EV relays and SUP relays as its output.

Reset box.

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.

1
6
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.

1
7
Line Verification Box :

This box is required to be kept near monitored track portion

outside Station Master’s (SM) office for achieving co-operative
feature. This is a box consisting of a lock with a key fixed inside.
The lock gets actuated only when the key is inserted, turned and
pressed. Whenever there is a failure of axle counter, SM will
depute his ASM/Switchman to verify whether the track section
controlled by axle counter is clear or not. ASM/Switchman after
verification of the track, if found clear, will report to SM who in turn
will handover the key of line verification box for operation.

TYPE OF SYSTEMS :

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

One Device (1-D) System.

Two Device (2-D) System.

Three Device (3-D) System.

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

1
8
“Track clear” indication, otherwise it gives the “Track occupied”
indication.

2-D System :

The principle of working of this system is similar to 1-D System

except that in this system there are two detection points, one at
each end of the monitored section. This system is useful for
providing track circuiting on berthing track.

3-D System :

In this system, there are three detection points. The principle of

working of this system is similar to 2-D system. This system is
useful for providing track circuitry on points, crossings and sidings.

4-D System :

In this system, there are four detection points. The principle of

working of this system is similar to 2-D system. The system is
useful for providing track circuiting on branch lines, sidings and
points and diamond crossings.

The design of 4-D system is such that it can be converted into a 2-

D system or a 3-D system and vice–versa.

1
9
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.
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 – 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.

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

6. Relay Drive Voltage for 1000 ohm

Max. 1500 mv.rms
Shelf type 4F / 4B relay or Q Style
> 10 V

Plug in Relay 1000 ohm, 4F / 4B

2
0
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 :

Relative Humidity
95 % - 98%

Temperature range :
Non Condensing

Universal Evaluator
0 to + 60 ˚C

Junction Box & Track Devices

0 to + 70 ˚C

2
1
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)
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
515
330
170
15

ASSEMBLY

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 :
22
Rack :

The identification label of the rack is put at the left hand top on the
front side of the rack with inscription.
For a 2D system Universal axle Counter, ACS – 55 with EV – 542
Evaluator.
For a 3D Universal Axle Counter System, ACS – 56 with EV – 543
Evaluator.
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.

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 :
2
3
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”.

2
4
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.

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 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.

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).

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).

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.

2
6
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.

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;

2
7
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.

General Supervision Card (Card no. 8) :

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

the following evaluator circuits :

Comparator Supervision.
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.
Pulse Shaper (Card no. 3 and 4) supervision for all the eight
channels.
Failure Supervision.

Relay Driver (Card no. 9) :

This is a double sided PCB (Size: 225mm X 275mm) and it houses

the following circuits :

Level detector circuits for all the 8 channel inputs to ensure the
presence of proper channel input levels.

The ‘VOLTAGE MONITOR’, which serves as, a ‘WATCH DOG’ for

the +5V power supply to the Evaluator.

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
2
8
the display. This card is mounted on front panel of evaluator and
counts are recorded in decimal system.

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.

Mother Board :

This is a double sided PCB (Size: 420 mm X 260 mm) mounted at

the back of the Evaluator. The PCB is mounted at right angles to
the other 10 PC Cards and serves the purpose of providing
various interconnections between them. The female parts of the
Euro Connectors are mounted on this PCB and corresponding
male parts which are mounted on the PCBs (Cards 1 to 10) mate
with them when the card modules are inserted in the unit. The
mother board also provides access, through MS Couplers, to feed
various inputs like channel inputs from the tracks, power supply
and trolley protection and to feed outputs to the EV and the
Supervisory Relays kept in the rack.

(n)Reset Relay :

This is mounted at the back of the Evaluator on the motherboard. A

67DP-24-4C3 OEN Relay is mounted on this PCB with a mounting
socket. This Relay resets the System whenever required to do so.

2
9
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)

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).
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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 :

Regulator / Oscillator Card.

Receiver Amplifier Card-1.
Receiver Amplifier Card-2.
4W / 2W Converter Card.

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.

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

31
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.

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.

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.

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.

32
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.

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3
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.

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4
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.

3
5
36
OTHER PRODUCTS OF CEL

SOLAR WATER PUMPING SYSTEMS :

A Solar Photovoltaic Water Pumping System essentially consists of an
SPV panel or array directly powering a water pump. Water pumped during
the day can be stored in the storage tanks for use during the night.

CEL offers SPV Water Pumping Systems for both shallow as well
as deep well conditions. Such systems have been deployed all
over the country. The system has also been exported to many
developing countries.

The generated electricity from the SPV array is fed to the pump
through a switch. Normally low storage batteries are provided, as
the water can be stored in the storage tanks if required.

SOLAR PHOTOVOLTAIC LIGHTING SYSTEMS :

CEL’s Solar Photovoltaic Lighting Systems are ideal sources for
providing indoor/outdoor illumination in remote and unelectrified
settlements/ villages. The SPV Lighting System essentially
consists of an SPV panel battery, a charge controller and lights.
The SPV panel converts the sunlight incident on it directly to DC
electricity that can be stored in the battery and used to energize
the lights when required. The charge controller prevents the
overcharging and deep discharge of the battery.

SPV INDOOR LIGHTING SYSTEMS :

Two types of indoor lighting systems are available (DLS- 02 and DLS -04)
depending on the lighting requirements. DLS-02 has two numbers of 9W

3
7
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.

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
3
8
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

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
3
9
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.
4
0
CATHODIC PROTECTION
SYSTEM

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

Owner intends to provide permanent cathodic protection system

consisting of 13 nos. of impressed current cathodic protection
station to cathodically protect the underground coated pipeline for
a design life of 35 years.

BASIS IN BRIEF :
Permanent CP System has been designed for CTE coating having
coating resistance of 7000 ohm / m factor of safety as 1.3. Designed
life of anode bed is 35 years and that of the CP system is 20 years.

SUMMARY OF PERMANENT CP SYSTEMS :

Designed current density considered for design
:
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 :
4
1
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

4
2
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 :

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.

4
3
Toroids :

They are used in Pulse Transformers, Delay lines, Chokes,

Converter / Inverter Transformers, Wide Band Transformers,
Impedance matching Transformers, etc.

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.

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.

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.

4
4
FERRITE PROCESS FLOW CHART

Batch
Man
Iron Oxide gane
Zinc Oxide se

Oxid
e

Mixing
 CALCI
NATIO
N
(PREF
IRING)

LUBRICANT

BINDER (SP
RA
Y
DR
YIN
G)
PRODUCTION
SINTERING
LAPPING
PRESSING TESTING

GRANULATI
ON

MILLING AIR GAP

PRINTING
 AN
D

AS
SU
RA
ADJUSTMENT NC
E

STORES

QUALITY

DE
SP
AT
CH

4
5
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.

4
7
SOLID STATE INTERLOCKING

Solid State Interlocking (SSI) is Signaling System to select and

operate the routes in station for guiding the movement of the trains.
The system replaces the conventional Route Relay Interlocking. The
system is designed with “2 out of 2” Microprocessor with hot standby.
The system has software redundancy.

The operator panel is used to control and command and display

the status of SSI.

FEATURES :

System capacity: 450 Input, 72 Output.

Dual Microprocessor Based (2 out of 2) Fail-safe design.

Hot standby for High System Availability.

On Line self-diagnostic facility.

Data Logging with Time Stamping of all SSI Inputs and Outputs for
Off-line analysis.

Opto Isolated Inputs and Outputs.

Modular design for easy maintenance and expansion.

4
8
SOLAR POWERED RAILWAY
LEVEL CROSSING RADIO
WARNING SYSTEM

(SOLARGUARD ™)

CEL has developed this system, in association with Research,

Designs and Standards Organization (RDSO) for providing early
warning of a train / locomotive approaching unmanned level
crossing, to the people and road traffic crossing the Railway line.

SYSTEM OPERATION :
A track device actuated solar powered VHF transmitter located 3-4
Kms, from the level crossing (i.e. Far End) sends a coded radio
signal towards the level crossing when an approaching train
crosses the Far End. The radio signal is received by solar powered
receiver located at the level crossing (Gate End) which after
decoding the signal actuates an Audio-Visual Alarm for
forewarning the traffic. The system is ideal for remote railway level
crossings. The ruggedized system is under extensive field trials.

4
9
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.

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