CHAPTER - 1

INTRODUCTION

1.1 INDIAN RAILWAY SYSTEM

The railway system is the most commonly used transportation mode in India. It is also one of

those modes of transport that faces a lot of challenges due to human errors such as level cross

accidents, collisions, etc. A level cross, an intersection of a road and a railway line, requires human

coordination, the lack of which leads to accidents. Level crosses are controlled by manually

operated gates. In order to avoid the human errors that could occur during the operation of gates, we

introduce the concept of railway level crossing gate automation by means of bi-folding type gate.

Level crossings are managed by the gatekeeper and the gatekeeper is instructed by means of

telephone at most of the level cross from the control room. But the rate of manual error that could

occur at these level crosses is high because they are unsafe to perform without actual knowledge

about the train time table. Delay in the opening and closing of the gate could lead to railway

accidents. The present work attempts to develop a system which automates gate operations

(opening and closing) at the level cross using pulley mechanism and motor.

Thus the railway gate automation system aims to deal with two things. It reduces the total time

taken for the gate operation at the level cross and also ensures the safety of the passengers at the

1
level cross during when the train passes. The reduction in the direct human intervention during the

gate operation in turn helps to reduce the collision and accidents at the level cross. Since the gate

operations are automated based on the buttons, the time for which the gate closed is less. The paper

thus intends to develop an automatic railway gate control system which is reliable and secured than

the existing manual systems.

1.2 AUTOMATIC CONTROL SYSTEM

An automatic control system is an arrangement of physical components connected in such a

manner so as to direct or regular itself or some another system i.e. some controlled condition

forming part of the system is maintained in a prescribed manner. Automatic control system has

influenced the current way of life. In recent year automatic control systems have been rapidly

increasing importance in all fields of engineering. Its application covers a very wide range from

design of precision control devices to design of massive equipment used for manufacture of

steel and other industries.

1.3 WORKING OF AUTOMATIC CONTROL SYSTEM

In this project to lift the railway crossing gate D.C. series motor. Gear arrangement is used.

The Switches at two points on the either side of railway crossing gate is used. Hence the motor

will operate and with help of hinges, and the gate will open. In this way the automatic operation

of gate takes place. The gate which is unguarded, at such place the percentage of accidents is

more. Therefore to overcome this problem this system is capable. As it is fully automatic there

is no chance of failure due to human mistake.

CHAPTER-2

2
 LITERATURE REVIEW

 Nisha S Punekar, Archana, A Raut, August 2013, ‘Improving Railway Safety

with Obstacle Detection and Tracking System Using GPS-GSM Model’,

International Journal of Scientific and Engineering Research, volume 4, issue 8.

 Kiruthika M, Divya. M, Dhivya P, Yugapriya R, February 2014, ‘Wireless

Communication System for Railway Signal Automation at Unmanned Level’,

International Journal of Innovative Research in Science, Engineering and

Technology, vol3, special issue 1.

 Shweta Singh, Pratyush Jha, Vikrant Chandra, August 2014”Artificial Railway

Safety and Security System”, International Journal of Advanced Research in

Engineering, vol2,

issue 8.

 Amit Kumar, February 2012,”Human Behavioral Aspects of Level Crossing

Safety System with Special Reference to Indian Railways”, Jordan Journal of

Mechanical and Industrial Engineering, Volume 6, Number

CHAPTER-3
OVERVIEW OF PROJECT

3
3.1 INTRODUCTION OF OLDEST TECHNIQUE

In this technique first arrival of train information, station master take to gate

keeper which stand at near to railway crossing though telephone and then gate keeper

take a signal to road users for closing of gate and then he close the gate and he again call

to station master for closing information of gate and then station master take signal to

train for passing. When train completely pass from railway crossing then gatekeeper call

to again station master and take information of passing of train and station master say to

him for opening of gate. Then after gate keeper open the gate. In this techniques more

time is require there for at railway crossing more traffic will take place and different

type of pollution will be occur for more type like noise pollution, air pollution etc. and

more energy will be wastage. For above reason this technique is not safe and it totally

depend upon man which work at railway gate crossing. Single line diagram of oldest

railway crossing system is shown in fig 2.1. There for new techniques is invented it base

on microcontroller and sensors for make automatic railway crossing system. In this new

techniques no gate keeper is require.

(Fig 3.1:- Single line diagram oldest railway crossing technique)

3.2 INTRODUCTION OF AUTOMATIC RAILWAY LEVEL

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 In this project we are concerned of providing an automatic railway gate control at

unmanned

level crossings replacing the gates operated by gate keepers and also the automatically

operated gates. It is good then older system with two things.

The reduction of time for which the gate is being kept closed. And

To provide safety to the road users by reducing the accidents that usually occurs due

to carelessness of road users and at times errors made by the gatekeeper.

By employing the automatic railway gate control at the level crossing the arrival of train

comes in contact with switch placed on either side of the gate at about 5km from the level

crossing. Once the switch gets pressed the motor is activated and the gates are closed. The

departure of the train is detected by switch placed at about 1km from the gate, which in turn

operate the motor and opens the gate. Thus, the time for which the gate is closed is less

compared to the manually operated gates, since the gate is closed depending upon the

telephone call from the previous station.It is high as it is not subjected to manual errors.

BIFOLDING GATE

PUSH SWITCH PUSH SWITCH

Push type Switches for controlling
the railway gate opening and
DC MOTOR closing.

(Fig. 3.2:- Basic block diagram of automatic railway crossing system)

3.3 WORKING OF BLOCK DIAGRAM

5
 Train arrival detections:-

The Detection of a train total two switches required. S1 arrival and S2 departure of train

by the switches.

 Warning for road users:-

At the moment the train arrival is sensed on either side of the gate, road users are warned

about the train approach by RED signals placed to caution the road users passing through

the gate. RED signal appears for the road user once the train cuts the sensor placed 5Km

before the gate.

 Gate closing operation:-

Once the switch is pressed, then it automatically generates to operate the motor through

battery and hence close the gate for the passage of train. Actually rotary motion occurs in

a motor. This rotary motion is converted to linear motion of the gate using pulleys.

 Train Departure Detection:-

Detection of train departure is also done using switch technique as explained under the

head of train arrival detection. Train departure sensing is done by switch R2.

 Gate operating:-

When the train departure is sensed by the switch, which operates the motor in reverse

direction and the gates are opened. Once the gate is opened signal for road users are made

GREEN so that the vehicles can pass through the gate.

CHAPTER-4

MECHANISM

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4.1 BI-FOLDING GATE MECHANISM
A folding door is a type of door which opens by folding back in sections or so-called

panels. Folding doors are also known as ‘bi-fold doors', in spite of them most often having

more than two panels. Another term is ‘concertina’ doors, inspired by the musical instrument

of the same name.

Folding doors can be used as internal or external room dividers and are made from a variety

of materials. Most folding doors are glazed and the panels have frames of either

wood, aluminium or PVC. They can open up and fold either internally or externally and are

widely used in modern extensions.Opposed to a conventional door with a

standard aperture of 700-900 mm, most modern folding door (sets) can be up to several

meters in width, and thereby considerably increase both physical and visual accessibility

between either two internal rooms or an internal room and an outside space.Historically

folding doors were already known by the Romans as excavations in Pompeii have

revealed. Peter Connolly writes in his book ‘Pompeii’ that the Romans ‘disliked single-leaf

doors and wherever possible, both inside and out, they used double or even folding doors’.

(Fig 4.1a):- ancient

folding gate

Types of mechanism

The main types of

door mechanisms used here are:

 Hinged doors

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 Most doors are hinged along one side to allow the door to pivot away from the

doorway in one direction, but not the other. The axis of rotation is usually vertical. In

some cases, such as hinged garage doors, the axis may be horizontal, above the door

opening.

Doors can be hinged so that the axis of rotation is not in the plane of the door to

reduce the space required on the side to which the door opens. This requires a

mechanism so that the axis of rotation is on the side other than that in which the door

opens. This is sometimes the case in trains or airplanes, such as for the door to the

toilet, which opens inward.

 Sliding doors

It is often useful to have doors which slide along tracks, often for space or aesthetic

considerations.

 Automatic doors

Automatically opening doors are powered open and closed either by electricity,

spring, or both. There are several methods by which an automatically opening door is

activated:

1. A sensor detects traffic is approaching. Sensors for automatic doors are generally:

8
 A pressure sensor – e.g., a floor mat which reacts to the pressure of someone standing

on it.

 An infrared curtain or beam which shines invisible light onto sensors; if someone or

something blocks the beam the door is triggered open.

 A motion sensor which uses low-power microwave radar for the same effect.

 A remote sensor (e.g. based on infrared or radio waves) can be triggered by a

portable remote control, or is installed inside a vehicle. These are popular for garage

doors.

2. A switch is operated manually or automatically, perhaps after security checks. This

can be a push button switch or a swipe card.

3. The act of pushing or pulling the door triggers the open and close cycle. These are

also known as power-assisted doors.

In addition to activation sensors automatically opening doors are generally fitted with

safety sensors. These are usually an infrared curtain or beam, but can be a pressure

mat fitted on the swing side of the door. The purpose of the safety sensor is to prevent

the door from colliding with an object in its path by stopping or slowing its motion. A

mechanism is set in modern automatic doors to ensure that door will be in open state

in case of power failure.

 Inward opening doors are doors that can only be opened (or forced open) from

outside a building. Such doors pose a substantial fire risk to occupants of occupied

buildings when they are locked. As such doors can only be forced open from the

outside, building occupants would be prevented from escaping. In commercial and

9
 retail situations manufacturers have included in the design a mechanism that allows

an inward opening door to be pushed open outwards in the event of an emergency

(which is often a regulatory requirement). This is known as a 'breakaway' feature.

Pushing the door outward at its closed position, through a switch mechanism,

disconnects power to the latch and allows the door to swing outward. Upon returning

the door to the closed position, power is restored.

(Fig 4.1b:- current folding gate)

4.1.1 SPECIFICATION OF BIFOLDING GATE

The bi-folding gate mechanism used in this project has the following design specification:

10
S.NO MATERIAL DIMENSIONS

1. Number of hinges 6

2. Overall Length of the gate 100 cm

3. Number of grills 3

4. Height of the gate 40 cm

5. Weight of gate 20 kg

6. Type of flame used AWS A.51: E6013

IS 814 : ER 4211X

7. Welding type Gas welding

8. Flame size 3.15 x 350 mm

9. Length of each grill 30 cm

10. Thickness of gate 2.5cm

(Table 4.1.1:- specification of folding gate)

4.1.2 MANUFACTURING PROCESS

Welding is a fabrication or sculptural process that joins materials

usually metals or thermoplastics, by using high heat to melt the parts together and allowing

them to cool causing fusion. Welding is distinct from lower temperature metal-joining

11
techniques such as brazing and soldering, which do not melt the base metal. The most

common gas welding process is oxy-fuel welding also known as oxyacetylene welding. It is

one of the oldest and most versatile welding processes, but in recent years it has become less

popular in industrial applications. It is still widely used for welding pipes and tubes, as well

as repair work. The equipment is relatively inexpensive and simple, generally employing the

combustion of acetylene in oxygen to produce a welding flame temperature of about

3100 °C. The flame, since it is less concentrated than an electric arc, causes slower weld

cooling, which can lead to greater residual stresses and weld distortion, though it eases the

welding of high alloy steels. A similar process, generally called oxy-fuel cutting, is used to

cut metals.

Welds can be geometrically prepared in many different ways. The five basic types of

weld joints are the butt joint, lap joint, corner joint, edge joint, and T-joint (a variant of this

last is the cruciform joint). Other variations exist as well—for example, double-V

preparation joints are characterized by the two pieces of material each tapering to a single

center point at one-half their height. Single-U and double-U preparation joints are also fairly

common—instead of having straight edges like the single-V and double-V preparation

joints, they are curved, forming the shape of a U. Lap joints are also commonly more than

two pieces thick—depending on the process used and the thickness of the material, many

pieces can be welded together in a lap joint geometry.

After welding, a number of distinct regions can be identified in the weld area. The weld itself

is called the fusion zone—more specifically, it is where the filler metal was laid during the

welding process. The properties of the fusion zone depend primarily on the filler metal used,

and its compatibility with the base materials. It is surrounded by the heat-affected zone, the

12
area that had its microstructure and properties altered by the weld. These properties depend

on the base material's behavior when subjected to heat. The metal in this area is often weaker

than both the base material and the fusion zone, and is also where residual stresses are found.

(Fig 4.1.2:- Bifolding gate model)

COMMON TYPE OF JOINTS USED IN WELDING PROCESS:

(1) Square butt joint

(2) Edge joint,

(Fig 4.1.2:- types of weld joints)
(3) Lap joint,

(4) Corner joint

(5) Tee-joint.

CHAPTER-5
COMPONENTS AND DESCRIPTION

13
5.1 COMPONENTS USED

S.NO COMPONENTS

1 DC MOTOR

2 WIRE ROPE DRIVE

3 ROTATABLE WHEEL

4 PULLEY

5 BATTERY

6 PUSH TYPE SWITCH

7 TRIGGER TYPE SWITCH

8. BIFOLDING GATE

9 CENTRE HINGE

COMPONE
(Table 5.1:- components)

5.1.1 DC MOTOR

A DC motor is any of a class of rotary electrical machines that converts direct current

electrical energy into mechanical energy. The most common types rely on the forces

produced by magnetic fields. Nearly all types of DC motors have some internal mechanism,

14
 either electrode chemical or electronic, to change the direction of current flow in part of the

motor.

COMPONENTS

(Fig 5.1.1:- dc motor)

5.1.2 ROPE DRIVE

The Rope drive is a form of belt drive, used for mechanical power transmission.

Rope drives were most widely used as power transmission in mills and factories, where a

single mill engine would have a large rope drive to each floor, and then line shafts across

each floor distribute power to the individual machines. These multiple rope drives replaced

the earlier technique of a vertical wrought iron shaft with bevel gears at each floor.

15
 (Fig 6.1.2a:- rope drive)

Rope drive is classified into following two types:

1. Fiber ropes

2. Wire ropes

Here we are using wire ropes for operating the bi-folding gates.

(Fig 5.1.2b:- wire rope drive)

5.1.3 WHEEL

A wheel is a circular block of a hard and durable material at whose center has been

bored a circular hole through which is placed an axle bearing about which the wheel rotates

when a moment is applied by gravity or torque to the wheel about its axis, thereby making

together one of the six simple machines. When connected to a crank, the wheel produces or

transmits energy (e.g. the flywheel).

16
(Fig 5.1.3:- wheel)

5.1.4 PULLEY

A pulley is a wheel on an axle or shaft that is designed to support movement and

change of direction of a taut cable or belt, or transfer of power between the shaft and cable

or belt. A pulley may have a groove or grooves between flanges around its circumference to

17
 locate the cable or belt. The drive element of a pulley system can be a rope, cable, belt,

or chain.

(Fig 5.1.4:- pulley)

5.1.5 BATTERY

Batteries are a collection of one or more cells whose chemical reactions create a flow

of electrons in a circuit. All batteries are made up of three basic components: an anode (the '-'

side), a cathode (the '+' side), and some kind of electrolyte (a substance that chemically

reacts with the anode and cathode). Batteries are made up of three basic components:

an anode, a cathode, and an electrolyte

18
 (Fig 5.1.5:- battery)

5.1.6 PUSH BUTTON

A push-button (also spelled pushbutton) or simply button is simple switch mechanism

for controlling some aspect of a machine or a process. Buttons are typically made out of hard

material, usually plastic or metal. The surface is usually flat or shaped to accommodate the

human finger or hand, so as to be easily depressed or pushed. Buttons are most often biased

switches, although many un-biased buttons (due to their physical nature) still require

19
a spring to return to their unpushed state. Terms for the "pushing" of a button

include pressing, depressing, mashing, slapping, hitting, and punching.

(Fig 5.1.6:- push button)

5.1.7 TOUCH SWITCH

A touch switch is a type of switch that only has to be touched by an object to operate. It

is used in many lamps and wall switches that have a metal exterior as well as on public

computer terminals. A touchscreen includes an array of touch switches on a display. A touch

switch is the simplest kind of tactile sensor.

20
 (Fig 5.1.7:- tough switch)

5.1.8 BI FOLDING GATE

21
 (Fig 5.1.8:- bi-folding gate)

 Very secure with opening and closing in approx. 7-12 seconds.

 Controls housed inside a IP65 secure steel enclosure and Heavy duty 24v

hydraulic ram with built in slowdown in both opening and closing

movement producing smooth quiet operation.

 Galvanized and Powder Coated.

 Hinges comprising 40mm shaft with heavy duty sealed for life roller

bearings.

 Unique drive mechanism.

5.1.9 HINGES

A hinges is a mechanical bearing that connects two solid objects, typically

allowing only a limited angle of rotation between them. Two objects connected by an

ideal hinge rotate relative to each other about a fixed axis of rotation: all

22
 other translations or rotations being prevented, and thus a hinge have one degree of

freedom. Hinges may be made of flexible material or of moving components.

In biology, many joints function as hinges like the elbow joint.

(Fig 5.1.9:- Hinges)

CHAPTER-6
PART DIAGRAM

6.1 DC MOTOR

23
 (Fig 6.1:- dc motor)

6.2 WIRE ROPE DRIVE

(Fig 6.2:- wire rope drive)

6.3 WHEEL

24
 (Fig 6.3:- wheel)

6.4 PULLEY

(Fig 6.4:- pulley)

6.5 BATTERY

25
 (Fig 6.5:- battery)

6.6 PUSH BUTTON

(Fig 6.6:- push button)

6.7 TOUGH SWITCH

26
 (Fig 6.7:- tough switch

6.8 BIFOLDING GATE

(Fig 6.8:- bi-folding gate)

6.9 HINGES

27
(Fig 6.9:- hinges)

CHAPTER- 7

28
7.1 COMPONENTS SPECIFICATION

S.NO PART MATERIAL NO.OF

1 DC MOTOR - 1

2 ROPE BELT RUBBER 1

3 WHEEL CAST IRON 1

4 PULLEY STAINLESS 4
STEEL
5 BATTERY ELECTRONIC 1

6 PUSH TYPE SWITCH ELECTRONIC 2

7 TRIGGER TYPE SWITCH ELECTRONIC 2

8 BIFOLDING GATE ALLUMINIUM 1

9 CENTRE HINGE MILD 6

STEEL

(Table 7.1:- component specification)

CHAPTER-8
ADVANTAGES AND APPLICATIONS

29
8.1 ADVANTAGES

 It results in economy of operation.

 Elimination of human error.

 If frees human beings from mental tasks.

 Saving in energy requirements.

 Increase in efficiency.

8.2 APPLICATIONS

 Real time automation in transport systems.

 Human intervention at level crossing can be removed

 Many level crossing accidents can be prevented.

 Unmanned level crossing can be decreased.

CHAPTER-9
FUTURE PLANS OF INDIAN RAILWAYS

9.1 UPCOMING DEVELOPMENT PLANS BY INDIAN RAILWAYS

30
 Indian Railways have high density of level crossing and is a major contributory factor

for loss of human life on account of railway accidents. To monitor the condition of level

crossing a unique ID is provided to every level crossing and being managed through a

module of Level Crossing in “Safety Information Management System”.

Road map has been made to eliminate the unmanned level crossings and same has been

envisioned in “VISION-2020”. Accordingly concrete steps are being taken for improving the

safety at level crossings in Indian Railways and the progress is satisfactory.

(Fig 9.1:- unmanned railway crossing)

9.2 NEWS ON RAILWAY LEVEL CROSSING

A ministry official said 109 rail accidents have occurred at unmanned

crossings across the country since 2014-15. Railway board chairman Ashwani

Lohani announced that all such crossings will be eliminated by the year

31
2020.Railway sources said the accidents at unmanned crossings were more frequent

in rural areas while such crossings in cities have either been eliminated or manned.

An official said 49 unmanned railway crossings exist in the Delhi division of Indian

Railways that comprises neighboring areas in Uttar Pradesh and Haryana. However,

Lohani said no step the railway ministry takes could be completely foolproof against

negligence of people and urged them to be careful while crossing tracks. “While

crossing unmanned level crossings, the primary responsibility lies with the road user,

and not with the railways. In this case, the driver of the school van did not stop. But

because the accidents happen in our territory, it remains our concern," he said.

Officials said 1,565 unmanned crossings were eliminated in 2017-18 and the target is

to remove 1,600 in 2018-19.Railway minister Piyush Goyal held a high-level

meeting on Thursday to assess the safety of the network and also the status of

unmanned crossings. The railway ministry claimed that accidents at unmanned level

crossings have reduced by 79 per cent in the last four years while the average rate of

elimination of such crossings has also increased by nearly two thirds during this

period. Earlier in the day, Goyal had ordered an inquiry into the accident.

CHAPTER- 10

CONCLUSION

32
Using this project automatic railway crossing system we improve the rail road

transportation facility and this technique has fast operation thane oldest system and

we reduce the accident. This technique is most suitable in rural and suburban area.

These techniques do not require any gatekeeper at the railway crossing. The accidents

are avoided at places where there is no person managing the railway crossing gates.

Here we use the dc motor to open and close the gates automatically when it is rotated

clockwise or anticlockwise direction. When the train touches the switch in a

particular direction, generates appropriate power to motor through battery and

generates an interrupt. When the interrupt is generated the dc motor rotates in

clockwise direction. When the interrupt from other direction of departure, the dc

motor rotates in anti-clock wise direction.

REFERENCE

33
 Part of stepping motors by Douglas W.Jones, the university of IOWA Department

of computer science.

 Report of the Railway Safety Review Committee 1998.

 ‘Report of High Level Safety Review Committee (Kakodkar Committee)”,

Feb. 2012, Ministry of Railways, Govt. of India.

 “Indian Railways Vision 2020 (Dec. 2009)”, Ministry of Railways, Govt. of India.

 ‘Railroad-Highway Grade Crossing Handbook’, Department of Transportation,

Federal

Railroad Administration, USA.

Following are some internet sites, books, magazines taken as reference for this

project:

1. http://www.scribd.com/doc/6852743/AUTOMATIC-RAILWAY-GATE-

CONTROL

2. http://sdl-forum.org/SAM_contest/Li_Probert_Williams/Railway_doc.pdf

3. http://indianengineer.wordpress.com/2009/08/03/automatic-railway-gate-

control-trackswitching.com

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35