KAWACH
(Train Collision Avoidance System)
Kernex Microsystems (India) Limited
2021 KERNEX - KAVACH 1
System Functions Overview
▪ Prevention of SPAD(signal passing at danger)
▪ Train Trip when a train passes a stop signal at ON or End of Authority
▪ Control of Speed at PSR (Permanent Speed Restriction) / TSR (Temporary
Speed Restriction)
▪ Display of Distance of Signal and Movement Authority
▪ Speed Control in Loop Lines
▪ Protection of Roll back
▪ Prevention of Head-On Collision
▪ Prevention of Rear-End Collision
▪ Prevention of Collision due to Unusual Stoppage in Block Section
▪ Manual SOS Generation/cancellation Feature in Station TCAS
▪ Manual SOS Generation/cancellation Feature in Loco TCAS
▪ Auto whistling on approach of Level Crossing Gate
2021 KERNEX - KAVACH 2
Kawach – Principle of Operation
(GPS)
Station TCAS Station TCAS
Loco 1
RFID Loco 2 Loco 3
2021 KERNEX - KAVACH 3
KERNEX – KAWACH
RIU (Remote Interface
Unit)
STATION Loco Controller Unit
2021 KERNEX - KAVACH LOCO 4
Kawach Installation - Locomotives
2021 KERNEX - KAVACH 5
KAWACH – LOCO - ARCHITECTURE
2021 KERNEX - KAVACH 6
LOCO SUB MODULES
❖ MIE1&MIE 2 – Micontroller based Intelligent Equipment Vital Computer(2 00
2 Architecture)
❖ MIE3&MIE 4 – Micontroller based Intelligent Equipment Communication
Computer(2 00 2 Architecture)
❖ FIM – Field Input Module
❖ FOM – Field Output Module
❖ PSM – Power Supply Module
❖ FTM – Filter Module
❖ GPS-SPM – Global Positioning System – Speedo
❖ ICL – Isolation and Current Loop
❖ Data Logger
❖ RADIO MODEM
❖ RFID
❖ DMI – OCIP (Operation cum Indication Panel)
❖ BIU
2021 KERNEX - KAVACH 7
KAWACH – LOCO - Power ON
❖ Before turning ON system MCB
make sure MR Cock , BP Cock
BIU switch es are in correct
position
2021 KERNEX - KAVACH 8
KAWACH – LOCO - Power ON Procedure
2021 KERNEX - KAVACH 9
LOCO - Power ON Procedure
2021 KERNEX - KAVACH 10
LOCO SELF TEST
❖The Loco Kavach equipment shall perform an
automatic self-test when the equipment is switched
ON.
❖This self-test shall perform Normal Brake, Full Service
Brake & Emergency Brake shall be tested on boot-up.
❖The result of self-tests shall be indicated on LP-OCIP
2021 KERNEX - KAVACH 11
LP OCIP
2021 KERNEX - KAVACH 12
LOCO SELF TEST
❖ Break testing MR. 7.5Kg
❖Break testing BP 5 Kg
❖Break testing NSB applied 5Kg
❖Break testing FSB applied 4.5 Kg
❖Break testing EB 3.5Kg
❖Break testing Success
❖Select Train Configuration
2021 KERNEX - KAVACH 13
CONFIGURATION
2021 KERNEX - KAVACH 14
KAWACH LOCO Modules View
2021 KERNEX - KAVACH 15
KAWACH LOCO – PROCESS BIN View
2021 KERNEX - KAVACH 16
MODULES INTERFACES Details
❖ FIM 1,3,5 are interfaced to MIE 1
❖ FIM 2,4,6 are interfaced to MIE 2
❖ Each FOM interfaced to MIE 1 and MIE 2
❖ DMI 1 / 2 or LP OCIP 1/2 are interfaced to MIE 1 and MIE 2
❖ Radio Modem 1 are interfaced to MIE 3
❖ Radio Modem 2 are interfaced to MIE 4
❖ GPS 1 interfaced to MIE 3
❖ GPS 2 interfaced to MIE 4
❖ RFID 1 interfaced to MIE 5
❖ RFID 2 interfaced to MIE 6
2021 KERNEX - KAVACH 17
LOCO – POWER BIN- DATA LOGGER
2021 KERNEX - KAVACH 18
LOCO KAWACH POWER MODULES
2021 KERNEX - KAVACH 19
POWER SUPPLY DISTRIBUTION
❖Electrical : 110V DC ( 60-150V DC)
❖Diesel : 72V DC ( 40-100V DC)
❖PSM 1 – 5V > MIE , FIM , MOM , ICL ….
❖PSM 2 – 12V > RFID
- 24V > RADIO MODEM
❖ PSM 3 – 24V > FIM , FOM ,
2021 KERNEX - KAVACH 20
FIM Interface
❖Each FIM has 24
channels
❖Each input 24V
excitation
❖Optical isolation
❖Inputs are read by MIE
❖All channels health
check
❖Failure of module
detection
2021 KERNEX - KAVACH 21
LOCO INPUTS
❖ COMMON
❖ SOS
❖ CANCEL
❖ LEADING
❖ NON LEADING
❖ CAB1
❖ CAB2
❖ RUN FORWARD
❖ RUN REVERSE
❖ BP COCK
❖ MR COCK
❖ BIU NORMAL - ISOLATION
2021 KERNEX - KAVACH 22
MIE
2021 KERNEX - KAVACH 23
FOM Interface
❖ 24 Channels or outputs
❖ all out puts are AND
logic
❖Outputs are 24V driven
❖Two MIE need to drive
output
2021 KERNEX - KAVACH 24
LOCO OUT PUTS
❖TCAS OK
❖SOS COUNTER
❖TCAS NOT OK
❖TRIP COUNTER
❖SOS ❖ISOLATION COUNTER
❖BUZZER
❖HORN
❖NORMAL BRAKE
❖FULL SERVICE BRAKE
❖EMERGENCY BRAKE
2021 KERNEX - KAVACH 25
GPS Interface
❖ Date and Time updation
❖Generate PPS / pulses
❖PPS configurable
❖Radio communication
synchronization
❖Frequency : 1,575.42 ± 1.023MHz
2021 KERNEX - KAVACH 26
GPS Interface
❖Time Pulse : 2 SEC /
PPS
❖Used for time
synchronization of
TCAS Radio
communication
❖Time stamp events
logging
2021 KERNEX - KAVACH 27
GPS Logical Functioning
2021 KERNEX - KAVACH 28
SPEEDO / PULSE GENERATOR Interface
2021 KERNEX - KAVACH 29
SPEEDO
❖ read the pulses
❖Calculate speed
❖Calculate distance
❖Per rotation – wheel dia .
1.09 m. Approx.
❖1.09 m x pulses / sec
2021 KERNEX - KAVACH 30
ICL Interface
❖ All comports are isolated
❖Radio modems isolated
❖GPS isolated
❖RFID isolated
2021 KERNEX - KAVACH 31
RADIO MODEM Interface
❖SUPPLY : 24V
❖WATT : 10 W max / adjustable
❖INTERFACE : RS 232
❖UHF - 406 – 470 MHz
2021 KERNEX - KAVACH 32
RADIO MODEM Interface ….
❖ Working frequency : 406 - 470 MHz UHF
❖ Channel Bandwidth : 25KHz
❖ SET UP port – Diagnosis
❖ DATA port - communication
❖ Mode of operation : Full-Duplex
❖ Data rate : 19200bps over-the-air; Output Power : 10W
❖ Power Supply: 24V
❖ Two radio modems are used for redundancy
2021 KERNEX - KAVACH 33
RADIO MODEM Interface
2021 KERNEX - KAVACH 34
RADIO MODEM Freq.
FREQUENCIES
STATION TCAS LOCO TCAS
Rx (MHz) Tx(MHz) Rx(MHz) Tx(MHz)
Default-F0 441.8 441.8 441.8 441.8
Link 2 416.8 456.8 456.8 416.8
Link 3 426.8 466.8 466.8 426.8
2021 KERNEX - KAVACH 35
TIME SLOT ALLOTMENT RDSO SECTION
36
Radio Packets
• Access Request Packet (Loco)- F0
• To request time slot
• To Request Frequency Pair
• To exchange Random number with Station for secure
communication
• Access Authority Packet (Station)- F0
• Allocates time slot and Frequency pair
• To exchange Random number with Loco for secure communication
• Loco verifies secure communication status(CBC – MAC)
Radio Packets
• Loco Regular Packet (Loco)- (Fmn –Fsn)
• Transmitted in allotted time slot
• To request MA and Track Data
• Verify CBC MAC Code with assigned Station Random Number
• Signal Information Packet (Station) -(Fsn –Fmn)
• Transmitted only when secure radio communication is successful
• Transmits MA, Signal Aspect and Track Data to loco
• Emergency Status Packet (Station)-F0
• Manual SOS/ Loco Specific SOS
• Static Speed Profile Packet (Station) -(Fsn –Fmn)
• Track Data (Gradient Info, LC gate info and Speed profile)
RADIO ANTENNA
❖Gain 3 dB, Frequency band : 406 - 512 MHz
❖Input Impedance : 50 Ohm
❖Polarization : Vertical
❖Radiation pattern : Omni directional
❖Wind rating : 200 km/hr
❖4 Antennae (1-TX and 1-RX antenna for each radio
modem)
2021 KERNEX - KAVACH 39
LP OCIP
2021 KERNEX - KAVACH 40
LP OCIP Display Details
2021 KERNEX - KAVACH 41
LOCO OPERATING MODES
❖Stand By Mode:
❖The Stand-By mode shall be default mode and shall not be possible to be selected by the loco pilot.
The Loco TCAS unit shall perform the Standstill Supervision in Stand-By mode.
❖Staff Responsible Mode
❖The Staff Responsible mode allows the loco pilot to move the train under his own responsibility in TCAS territory.
If MA or SSP is received from Stationary TCAS unit, Loco TCAS unit shall exit from this mode.
❖Limited Supervision Mode
❖The Limited Supervision mode enables the train to be operated in areas where partial trackside information
(Movement Authority/Section speed) is available for supervision of the train.
❖Full Supervision Mode
❖The Loco Kavach unit shall be in the Full Supervision mode when all train and track data including Movement Authority
and Static Speed Profile up to Movement Authority or up to 3000m or movement authority, whichever is less,
❖In case of new train formation, train has crossed at least one stop signal in OFF condition. In case of new train
formation, Loco TCAS shall continue in SR mode and shall not display any Signal Aspect or and Movement Authority or
SSP shall not be sent by the station till it crosses at least one stop signal in OFF condition.
❖Full Supervision mode cannot be selected by the loco pilot, but shall be entered automatically when all the necessary
conditions are fulfilled.
❖The Loco TCAS unit shall display the train speed, the permitted speed, the target distance and the target speed to the
loco pilot.
2021 KERNEX - KAVACH 42
Loco Operating Modes (cont.)
❖Override Mode
❖ The Override mode enables the train to pass the signal at danger.
❖ Entry to override shall be selected by the loco pilot.
❖ The Loco TCAS unit shall supervise the train movement against a ceiling over- ride speed (default : 15 kmph).
❖On Sight Mode
❖ The On Sight mode enables the train to enter into a track section that could be al- ready occupied by another
train.
❖ On Sight mode shall be entered automatically.
❖ The Loco TCAS unit shall supervise train movements against a ceiling speed of On Sight Mode (default : 15
kmph).
❖Trip Mode
❖ When a Train in Full Supervision or Limited Supervision Mode passes a stop- signal at ON or End of Authority
+ 30m, the loco TCAS unit shall enter into Trip Mode.
❖ The Loco TCAS unit shall perform the Standstill Supervision in Trip mode.
❖Post Trip Mode
❖ The Post Trip mode shall be entered immediately after the loco pilot acknowledges the trip mode.
❖ Loco TCAS unit shall supervise the train against a ceiling speed of Post Trip Mode (Default: 15 kmph) and shall
exit the Post Trip Mode after crossing the next approaching signal at OFF.
2021 KERNEX - KAVACH 43
Loco Operating Modes (cont.)
❖Non Leading Mode
❖The Loco TCAS unit shall not perform any train movement supervision in Non-Leading mode.
❖Loco TCAS Unit shall attempt to transmit an Onboard-to- Stationary Radio Packet at a periodicity of not less
than 02 minute selected access- timeslots merely to indicate the Loco TCAS mode to NMS through Stationary
TCAS Unit.
❖Reverse Mode
❖The Reverse mode allows the loco pilot to change the direction of movement of the train and drive from the
same cab, i.e. the train orientation remains unchanged.
❖The Loco TCAS unit shall supervise train movements against a ceiling speed (Reverse mode speed limit
configurable, Default: 15 kmph), con- figurable distance (Default: 500m) and configurable time out (Default:
300s)
❖Shunt Mode
❖A TCAS equipped traction unit shall be capable of being moved in shunt mode.
Shunt mode shall be selected by the loco pilot. It shall only be accepted when the train is at standstill.
❖TCAS shall supervise Shunt Mode to a permitted speed (Default: 15 kmph) and shunting limits.
❖it shall be possible to manually select Shunting from Stand By, Staff Responsible, Limited Supervision and Full
Supervision mode.
❖System Failure Mode
❖The Loco TCAS unit shall switch to the System Failure mode in case of a fault, which affects the functioning of
Loco TCAS. The Loco TCAS unit shall permanently command the Emergency Brakes. The Loco Pilot shall isolate
TCAS.
2021 KERNEX - KAVACH 44
RFID Interface
2021 KERNEX - KAVACH 45
RF ID TAG Reader Antenna Arrangement
❖ Under CAB 1 and CAB 2 fixed
2021 KERNEX - KAVACH 46
RFID ANTENNA
❖Freq - 865 – 867 MHz
❖Supply 12V
❖IP 65
❖Able to work submerged
water
2021 KERNEX - KAVACH 47
KaWach Installations - RFID Tags
RF Tag mounted on Tag Frame, fitted RF Tag mounted on Tag Frame, fitted
to sleeper to sleeper, with protective lid/dome
RFID Tags are
programmed with
location and other data,
prior to mounting on
the sleepers
2021 KERNEX - KAVACH 48
TAGS TYPES
Type of tag Basic Functions
❖Normal Tag (NT) • Distance / Odometer error correction
• every 1km
❖Signal Foot Tag (SFT) • Signal Post Foot to the approaching train
• loco crosses this without MA, loco enters into Trip mode
❖Signal Approach Tag • Placed 150-200 ahead of the Signal foot tag to correct the
(SAT) distance / odometer error
❖Adjustment Tag (AT) • To correct or reset the route km
❖TIN discrimination tag • Placed normally on switches to distinguish the TINs of different
(TIN) routes.
❖Banner/Caution • Temporary Speed Restrictions of track section
Indicator tag
❖TCAS exit tag (TET) • TCAS territory exit
2021 KERNEX - KAVACH 49
TAG – Placement
❖Able to work even when submerged in water
❖Frequency of operation – 865-867 MHz
❖Suitable for reliable working at RFID reader
❖ Speed upto 200 KMPH
❖ IP 68 protection
❖Redundant TAGs
2021 KERNEX - KAVACH 50
DATA LOGGER
❖ GSM – redundant
❖USB – Log data download
❖LCD for status observation
❖KMS – key management
❖Event transfer to servers
2021 KERNEX - KAVACH 51
DATA LOGGER –GSM Interface
❖Two GSM modems
are used for
redundancy
❖ Faults logging
❖To get Security Keys
from KMS
❖To send critical info
to server
2021 KERNEX - KAVACH 52
KMS( Key Management System)
• GPRS (General Pocket Radio Service)
• UDP (UNIDATA GRAM PROTOCOL)
• KEY Management Services – 30 key – 120 days
• 1 key – 4 days
• Date and Time
• Key updation – 15 keys completion
• LOCO Faults info transfer to server
2021 KERNEX - KAVACH 53
Data Logger Display View
❖ LOCO ID
❖Date and
TIME
❖Key Valid
Duration
❖GSM status
2021 KERNEX - KAVACH 54
LOCO MODULE HEALTH – GPRS LIST
RFID1_FAIL
SPEEDO1_FAIL
MIE5_FAIL
MODEM1_FAIL
RFID2_FAIL
SPEEDO2_FAIL
MIE6_FAIL
MODEM2_FAIL
RFID1_ANTENA_FAIL
RFID2_ANTENA_FAIL
RFID1_OTHER_FAIL
RFID2_OTHER_FAIL
2021 KERNEX - KAVACH 55
Kawach Installation Loco
2021 KERNEX - KAVACH 56
STATION TCAS
2021 KERNEX - KAVACH 57
STATION
2021 KERNEX - KAVACH 58
STATION
2021 KERNEX - KAVACH 59
STATION TCAS
2021 KERNEX - KAVACH 60
STATION INPUTS
❖ DECPR – GREEN
❖ HECPR – YELLOW
❖ RECPR- RED
❖ HHECPR - DOUBLE YELLOW
❖ UP ..ASCPR – UP BLOCK CLEARANCE
❖ DN ..ASCPR – DOWN BLOCK CLEARANCE
❖ LTPR … TRAIN LENGTH
❖ NWKPR – NORMAL POINT
❖ RWKPR – REVERSE POINT
❖ COHECPR – CALL ON
❖ OMPTR – BERTH TRACK
2021 KERNEX - KAVACH 61
Station Master’s Operator Cum Indication Panel
2021 KERNEX - KAVACH 62
STATION OCIP- INPUTS - OUTPUTS
❖COMMON ❖SOS
❖CANCEL ❖SOS COUNTER
❖SOS ❖HEALTH OK
❖HELATH FAIL
❖BUZZER
2021 KERNEX - KAVACH 63
SM OCIP - LCD DISPLAY
DISPLAY MESSAGES
-----------------------------------
❖SOS PRESSED
❖SOS CANCELLED
❖RM1 LINK FAIL
❖RM2 LINK FAIL
❖SYSTEM FAIL
2021 KERNEX - KAVACH 64
SOS Generation
❖SOS PRESS by Station Master
❖SPAD JUMP
❖TIN CONFLICT
❖TAG CONFLICT
2021 KERNEX - KAVACH 65
STATION DATA LOGGER
2021 KERNEX - KAVACH 66
STATION – RIU LINK
2021 KERNEX - KAVACH 67
FIBER RING – STATION – RIU INTERFACE
2021 KERNEX - KAVACH 68
TOWER - ANTENNA
2021 KERNEX - KAVACH 69
RADIO MODEM- ANTENNA
❖Base station Stacked Dipole type omni directional
antenna with a gain of 9.0 dBi
❖Frequency band : 406 - 512 MHz
❖Input Impedance : 50 Ohm
❖Polarization : Vertical
❖Radiation pattern : Omni directional
❖Wind rating : 200 km/hr
❖4 Antennae (1-TX and 1-RX antenna for each radio
modem)
2021 KERNEX - KAVACH 70
2021 KERNEX - KAVACH 71
Components of Kavach – Loco Controller
Component, Quantity & Location Function
Loco Controller Unit comprising processor, Processes inputs from all peripherals,
I/O, GPS, GSM/GPRS, RFID Reader interfaces assesses situations and issues commands for
– One, in the Loco nose/short hood/engine execution; Communicates with other
room (depending on loco type) Kavach station and locos units
Interface for Loco Pilot to interact with the
Driver Machine Interface (DMI) - Two units
system. Displays signals ahead and other
installed in the loco cabin
status information / alerts
Brake Interface Unit – One, in the Loco
For application of normal/service/
nose/short hood/engine room (depending on
emergency brake as required
loco type)
Facilitate communication between various
Antennae for Radio (4), GPS (2), GSM/GPRS
Controller Units of Kavach; GPS facilitates
(2) – on loco roof top
time synchronisation
RFID Reader Antennae – Two, installed at To read the RFID tags on the sleepers and
either end of the undercarriage of the loco pass on data to Loco Controller
Pulse Generators – Two units, mounted on Provides loco speed input to the Loco
either2021
axle ends of power wheels of the loco Controller
KERNEX - KAVACH 72
Future Developments
❖Station to Station Communication
❖Temporary Speed Restriction(TSR)
❖Electronic Interlocking(EI) Interfacing
❖Balis Reader Integration
❖Long Term Evolution(LTE)
2021 KERNEX - KAVACH 73
Kawach WAY SIDE
40 meter Tower
RIU
Station TCAS and Relay
Racks
2021 KERNEX - KAVACH 74
