IMWB

Electronic Rail In motion Weighing systems at
NTPC-Simhadri
Simhadri
Control and Instrumentation Department
Simhadri Super Thermal Power Station
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Content Click to edit Master title style
Installation and Commissioning of new

5
1 Basics of IMWB IMWB Click to edit Master text styles
2 Rail Weighing Concepts 6 Review of the concepts
3 Types of Weighing Systems 7 References
Pit less In Motion Weighing Systems

4
in detail
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© 2016 Your NTPCAll
Company Limited – Simhadri Super Thermal Power Station. All Rights reserved
Rights Reserved. 2
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Basics Master
In Motion title style
Weigh Bridge
 Measures the weight of the rolling stock while in motion and works on the principle
of Wheatstone bridge.
G
 Four resistances are arranged to form a square, with an electromotive force across
one diagonal and a galvanometer across the other.
 When all four resistance are of equal value, galvanometer shows no deflection. By
adjusting the resistance of one pair the unknown resistance of other pair can be
calculated.
 At weigh bridge two strain gauges are used as resistance with equal value to form half Wheatstone bridge.At no load
condition the bridge is balanced for zero output. In the dynamic condition when the wheel is on the strain gauge the
resistance values of the strain gauges change due to exertion of tensile or compressive forces.
 Due to this the balance condition of Wheatstone is disturbed and on output in mV proportional to the force applied by the
wheel is generated.
3
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Copyright © 2016 NTPC Limited – Simhadri Super Thermal Power Station. All Rights reserved
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Weigh Bridges title style
 STATIC  IN MOTION
– Installed below loading chute – Away from loading chute
– For loading pre - determined quantity – For check weighing loaded rake
as per Carrying Capacity of wagons
TIPPLER WEIGH BRIDGES

SPECIAL DESIGN
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Concepts title style
 STATIC WEIGHING  IN MOTION

– SINGLE DRAFT - DOUBLE DRAFT
• SINGLE PLATFORM – MULTI DRAFT
• DUAL PLATFORM
Pit Type weighbridge Pit less Type weighbridge
Pit Type weighbridge disadvantages Weighrail to overcome pit type WB disadvantages
• Extensive civil works-Reinforced concrete • New concept in In Motion Weighing
foundations, drainage etc • Based on rail mounted transducers
• Heavy mechanical works-weighbridge structure, • Strain gauges mounted on the neutral axis of
Checkrods, Anchor bolts etc the rail
• The speed of measurement restricted by the
weighbridge.
• Total cost and track downtime high
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Weighing System title style
 Each wagon has to be uncoupled from wagons adjacent to it
 Wagon has to be carefully positioned and stabled on to the weighbridge
 Then the weight is recorded
 Static Weigh Bridges – Installed at Loading Chutes areas Tipplers.
6
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TYPES Master
WEIGHING title style
SYSTEMS
Partial Weighing System Full Draft Weighing System
Each Axle weighed at a time All axles of wagon weighed at one time
Gross weight found by summing up and Gross Weight displayed
displayed For Liquids and Gaseous Commodities
For Solid Commodities
Mostly used in IR
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Weigh edit Master
– Modes title style
of Weighing
 MULTI DRAFT  SINGLE/UNI DRAFT

 Whole wagon at a time
 Axle by Axle
 For liquids
 Axle weights added to get wagon weight
 Predetermined type of wagons
 For solids and all types of wagons
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WEIGHING SYSTEM title style
 Unidirectional System
 Bi-directional System
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Single edit Master
Weighment title style
WST One pair of Rail Sensors RPM
One pair of Track Switch
1705 3100
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Click
Bi -to edit Master
direction Weighingtitle style
Approch Rail 5000 mm Weigh Rail Approch Rail
One pair of Rail Sensors
Weighing Zone
One pair of Track Switch
500 3100 1705 3100
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Weighing
Weigh Rail Load Cell

Track Switch
Load cell cable
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Weigh Rail title style
 Strain gauge measuring device bonded to the web of the rail acts as Loadcell
 Distance between the sleepers (Typically 840 mm) is the active weigh zone
 Speed of weighing high
 Detect imbalance loads,not possible in weighbridges
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Pit less edit Master
Overview title style
 Rail Mounted Transducers

 Track switches (Track Switches)
 Advance Overspeed Indicators
 Weigh Processor Unit (DA100)
 PC and Printer
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Weighing Master
In Motion title style
- Concepts
 Weigh wagons on the move

 No need to stop,decouple or position wagons
 Eliminate locomotive automatically
 Automatic controlled weighing process
 Minimizes the system misuse or abuse
 Faster, Easier and Elegant
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Weigh In Motion
Click to edit Master title style
Rack wagon passing over the track mounted with Electronic weigh bridge system
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Weigh In Motion
WEIGHMENT PROCEDURE
 Load cells (strain gauge) mounted on weigh rail convert load into electrical signal.
 The Indicator transmits weight over RS232 serial Interface to PC.
 Operator feeds the other required information (Wagon no., Product, Supplier, Customer etc.) into
PC.
 Weighment of Rake completed.
 Lastly, the printer prints the ticket/transactions.
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Weigh In Motion
WEIGHMENT PROCEDURE
 Switch on the weighing system 15 min before the arrival of the rake for
warming up / thermal stability of the machine.
 Ensure ready to weigh caption appears on system
as well as on weighing machine.
 Now, system is ready for weighment.
 During passage of Rake Ensure printer gives out
Hard Copy.
 After weighment is finished, switch off the weigh machine.
 Feed the individual wagon number according to VG & indentify the over
loaded wagon and inform the control if over loading exists.

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Draft Master
DA100 – Pit lesstitle style
 Based on weighing axles and summing after averaging

 Based on strain gauge bonded rail
 Calibrated rails fitted directly on sleepers
 Weighing Accuracy : (OIML R106 CLASS 1)
• +/- 0.5% for wagon (Initial – First commissioning) +/- 1.0% (In service)
• +/- 0.25% for rake (Initial – First commissioning) +/- 0.5% (In service)
Rail Mounted Transducers:
 Produce Low Level Analog Signal (0.45 mv/v) Proportional to Wheel Load
 Signal is Carried In Screened Cables to the Transducer Junction Box/Interface Unit
 Distance between the Transducers and Junction Box Restricted to 50/150 Metres
प्रचालन एवं अनुरक्षण(सी एंड आई )विभाग O&M-C&I DEPARTMENT

Basic Building Blocks
WEIGH STRUCTURE
LOADCELL
JUNCTION BOX
WEIGHT INDICATOR
PERIPHERALS
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Components of Weigh Bridge
 Track switch  PC
 Weigh rail  CPU
 Load cell  Printer
 Junction box  UPS
 Cables  AC
 Weighing console (cubicle)  Fan
 Light

Click Weigh
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– In –Master
Motion title style
 MAIN PART’S
1. CUBICLE
This is a house in which the following components are housed
inside it -
a. Mother Board
b. input / output Board
c. Analog Board
d. Control Board

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Master title style

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Motion title style
MAIN PART’S
2. Other Parts of PC
a. VDU / Monitor
b. Key Board
c. Printer
3. Track Switches
4. Load cells
5. Junction Box
6. U.P.S
7. Lamp post
8. Earth pit
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Click to Track
editSwitches
Master title style
 FUNCTION OF TRACK SWITCHES
 Track switches identify:-
* Start of Train
* End of Train
* Direction of weighing / Identify the direction
* Forward direction
* Reverse direction
 Determination - Weighing Speed / Rake Speed
 Ensure Anti Rollback feature / Detect Roll Back
 Monitoring - Approach Speed (Track switches placed at 100 metres from the weighbridge)
 Identification - Wagons & Locomotives
 Activation - Wagon Weight
Copyright © 2016 Your Company All Rights Reserved. प्रचालन एवं अनुरक्षण(सी एंड आई )विभाग O&M-C&I DEPARTMENT 26
Click toTrack
editSwitch
MasterLayouttitle style

ClickInto editWeigh
Motion Master
Bridge title style
2 AXLE WAGON 4 AXLE WAGON
5MTR 2MTR 5MTR 2MTR
1.7Mtr 2.0Mtr 1.7Mtr 2.0Mtr
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Click to edit
Track Master
Switch title style
Dimensions
2960mm 1940mm 2960mm
IN
S1 S2
1A 1B 2A 2B 3A 3B 4A 4B
840mm
S1,S2 = WeighRail Sensors

1A to 4B = Track Switches
ClickAxle
to edit Master title style
Sequence
2 AXLE SEQUENCE
1 2 <WT> 3
1 2 <WT> 3
4 AXLE SEQUENCE
1 1 2 <WT> 3 , 2 <WT> 3
1 1 2 <WT> 3 , 2 <WT> 3
6 AXLE LOCO SEQUENCE
1 1 2 1 3, 2 1 3
1 1 2 1 3, 2 1 3
3 AXLE LOCO SEQUENCE

1 1 2 1 3, 2 1 3
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Click to Track
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Master
Layouttitle style
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Click
C
to edit
R/2
Master title style
H
P
M
Dimensions in mm. BCN-HL BOXN BOXN-HL BLC – A / B BLC – B / B BCN – A BCN BLC – A / A VPH
Length over headstock ‘H’ 10034 9784 10034 13625 12212 13520 14500 13625 21337
Length over center pivot ‘C’ 7153 6524 6690 9675 8812 9500 10000 9675 14783
Dimension ‘R’ 2881 3260 3344 3400 3400 4020 4500 4500 6554
Coupler length ‘S’ 930 930 930 940 950 930 930 940 960
Dimension ‘M’ 3811 4190 4274 4340 4350 4950 5430 5440 7514
Wheel base 2000 2000 2000 2000 2000 2000 2000 2000 2896
Dimension ‘P’ 1811 2190 2274 2340 2350 2950 3430 3440 4618
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Function of Load Cells
FUNCTION OF LOAD CELLS
It is the package in which strain gauges lies.
The strain gauges are combinations of resistance to form a half or a full bridge. (wheat
stone bridge)
It works on the principle of wheat stone bridge.
It converts load into electrical signals and then sending into digitizer. (weighing console)
It measures the Weight of stock. (Wagons, Brake vans as well as Loco)
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Load Cells
 A load cell is an electronic device and is classified as a force transducer. This device
converts force or weight into an electrical signal
 There are certain inherent advantages of using a load cell
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Click toInterface
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Unit DA100 title style
This Unit Contains Circuit Boards Based on Multiple Processors (8 Bit Z80) that communicate with
each other through dual ported shared memory :
Analog Board
 Providing Power For Exciting The Transducers
 Amplify and Filter the Weight Signals Produced by the transducers
 Acquire Data (60 Micro second per sample) based on signal threshold and store data in dual
ported memory
I/O Board
 Power (15 V DC) for Exciting the Track switches
 Filter the Signals (Debouncing) Produced By The Track switches
 Implements Track Logic
• Identify wagons for Associating weights
• Initiation and Termination of Train weighing
• Detect rollback and prevents multiple weighing
• Compute Train speeds
• Eliminates predetermined vehicles like Loco
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Click Interface
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DA100 title style
This Unit Contains Circuit Boards Based on Multiple Processors (8 Bit Z80) that :-
I/O Board
 Power (15 V DC) for Exciting the Track switches
 Filter the Signals (Debouncing) Produced By The Track switches
 Implements Track Logic
 Identify wagons for Associating weights
 Initiation and Termination of Train weighing
 Detect rollback and prevents multiple weighing
 Compute Train speeds
 Eliminates predetermined vehicles like Loco
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Interface Unit DA100
This Unit Contains Circuit Boards Based on Multiple Processors (8 Bit Z80) that :-
Control Board
Provides Interface to the users, Display and communicates with Analog and I/O Board
through dual ported Memory
Process the Raw counts provided by Analog board to weight units based on calibration
and no of transducers
Computes wagon weight based on I/O Board sequence
Applies correction to the wagon weights based on several parameters
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Functions of PC Software
 Manual Tare Entry
 Wagon Recall facility
 Display the individual wagons and Total rake weight on the monitor
 Provide Edit function to enable an operator to enter wagon number, batch code, product
code and other relevant information
 Store the data in a Data Base for Archive and report generation
 Generate Text File for data access in LAN
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Click toFunction
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of UPS title style
FUNCTION OF U.P.S
This guards against Voltage

fluctuations in the main Power Supply.
Its full form is Uninterrupted Power
Supply. when main supply goes off
U.P.S. take care of all the equipments
for some time.
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Earth Pit
Earth Pit
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Conditions for accurate Weighing
 The wagon coupler and Buffer forces must be small and constant
 Wagons must be free Rolling
 Track Stability
 Track Geometry
 Wagon Defects
Wagon couplers on accuracy of Weighing
 Load can be transferred through the couplings to the adjacent wagon being weighed
 Load transferred is a function of
• Total mass, length, speed of the train
• The condition of the rail track
• Misalignment in coupler height
Weighing Errors
 Systematic
• Due to permanent physical characteristics like Track Gradients, Bends, Crossings,
Stability etc
• Can be minimized by comprehensive range of correction biases in electronics
 Random
• Due to Transitory disturbances during weighing like acceleration, electrical noise,
wagon defects etc
• Can be minimized by weighing the same wheel several times at different places
Causes of Dynamic disturbances in Wagons
 Dynamic disturbances in wagon are caused by a number of factors including the following
– Track geometry
– Track stability and rigidity
– Truck discontinuities and irregularities
– Passing traffic
– Wagon defects
– Train accelerations
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Click todiscontinuities
Track edit Master title style
& Irregularities
Track discontinuities and track irregularities can be a major cause of

disturbances
– Typical discontinuities are:
– fish plated rail joints
– Switches
– Typical track irregularities are:
– Rail Corrugations
– Badly welded rail joints
– Badly worn rail head
– Ideally CIMW systems should be installed in continuously welded track- this is particularly
important if the system is going to be operated at speed above 10 Km/h
Wagon defects title style
Badly maintained wagon can not be weighed accurately
The main defects that cause weighing error are:

– Collapsed suspensions and brooked springs
– Sticking brakes
– Flat wheels
Collapsed suspensions causes impact loading to occur
Sticking Brakes impedes free movement of the wagon
Flat Wheels cause dynamic impacts the magnitude of which can be 4 – or more – times the static
load.
Check List
WEIGH-IN-MOTION
Accuracy class of weighbridges
Accuracy class % of mass of single wagon or total train, as appropriate
Initial verification In-service inspection

0.2 ± 0.1 % ± 0.2 %
0.5 ± 0.25 % ± 0.5 %
1 ± 0.5 % ±1%
2 ±1% ±2%
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Parameters affecting accuracy
Track parameters
Track to main line standards
Track gauge NOT TO BE TIGHT
Cross level to be maintained such that wagon CG will not shift
Packing below sleepers to be rigid to prevent pumping
No gradient in line(1 in 400) 100 mts on either side
Layout to be straight 100 mts on either side of weigh rail.
Rigid joints of the rails
Proper insulation of weigh-rail
No shifting of center point of weigh-rail with respect to support sleepers
Proper drainage on both side of the track.

Speed of the train
Excessive speed causes error in determining peak value
Driving skill of driver
Jerks cause load shift between wagons
Rake being weighed should be moved 50 – 100m from weigh-line to achieve uniform
speed
Proper voltage to electronics panel
Non-fluctuating power supply
Proper earthing to avoid damages from surges / line transients

Proper working of PC
Keep weigh-house clean and dust-free
Scrap below weigh-rail
Will restrict deflection of weigh-rail
GEN: Switch on machine 15-minutes before weighment

for thermal stability.

Site Conditions
Gradient: Max. 1 in 100

Straight Track of 1 rake length on either side of weigh zone free from points and crossings
-- Recommended Line,Level and Gauge has to be regularly maintained over this length.
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Accuracy of +/- 0.5% for wagon and +/- 0.25% for rake is totally dependent on:
1. Uniform steady speed during weighment - No
stopping, braking, or change in acceleration.
2. Condition of the subbase - For long term accuracy,
regular maintenance of subbase will be required.
3. Buffering of wagons to be avoided.
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TRACK CONDITIONS:
Well settled and compacted track.
Free from water logging.
Approach and exit tracks should have pre-stressed Concrete sleepers
preferably of the flat type.
For track having overhead traction, weigh rails have to be isolated with
respect to Approach & Exit rails.
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Click
Calibration Table of to edit Master title style
IMWB
INITIAL CALIBRATION RESULTS
In Time Trial Test Recorded Accur Test Recorded Accur Test Recorded Accur Test Recorded Accur Test Recorded Accurac Std. Rec. Rake Speed
No. Wagon 1 Weight acy Wagon 2 Weight for acy Wagon 3 Weight foracy Wagon 4 Weight for acy Wagon 5 Weight for y Rake Rake Accuracy
Weight for Test Weight Test Weight Test Weight Test Weight Test Weight Weight
Wagon 1 Wagon 2 Wagon 3 Wagon 4 Wagon 5
16:00 1 69.91 50.24 - 85.72 40.69 25.26 25.2 271.8 271.1
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POWER REQUIREMENTS:
230V 50Hz free from surges and spikes.

Earthing : - Earth - Neutral < 2V max.
Separate Earthing for Weighrail and Instrumentation
Lightning Protection
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Click to edit
Types Master
of failures title style
Analog failure
Due to problem in analog board
Programme error
Due to problem in mother board & control board
Zerro error
Unknown vehicle
due to defect in track switch, improper operation.
Track switch not working
defect in track switch and its cable.

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Types title style
of failures
Weighed only ‘X’ wagons out of 59 wagons
due to cable between junction box to weighing console and

between stain gauge junction box.
Less weight
defect in load cell
Shows 2 axle instead of 4 axle (wrong counting of axle)
Monitor not displaying
communication port problem. Software corrupted.
Printer not working
Power backup problem (defective battery)
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Role of C&I Maintenance
 Yearly verification-: Using test wagon conducting repeatability test jointly along with FM Department,
Inspector of Weights and Measures Department and representative of OEM.
 Reporting problem more than 48 hours in the performance of weigh bridge to site vigilance
 BMC for IMWB
 Arrange for stamping certificate through OEM from the state government official.
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Time schedule for installation of new In Motion Weigh
Bridge
Time Schedule for installation of new weighbridge
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Documents and Other details to be maintained
Pertaining to Individual Weigh Bridge
 Failure since installation

 Equipment and parts renewed
 Complaints about weighment if any
 Cost of the Machine and year of installation.
 Expenditure incurred so far
 Mandatory items to be displayed in the weigh bridge.
 Inspections to be carried out periodically and inspection missed.
 Any replacement proposal
 Analysis of rakes weighment data
 Updating of wagon library
 Other inspection data as required by the specification.
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ClickWeighing
to edit Master
Systems title style
at NTPC-Simhadri
Load Line Empty Line
Two Nos . Installed and working 02 Nos. installed
One Rice Lake Weighing Systems India Limited 02 Nos. Rice Lake Weighing Systems India Limited
Another by M/s Senlogic Automation Pvt.Ltd.
DO’s DON’T”s:
TEST PERFORMANCE OF TRACK SWITCHES AT ×AVOID WELDING IN THE VICINITY OR ON THE
REGULAR INTERVALS WEIGHRAIL.
REGULARLY CHECK EARTH RESISTANCE × AVOID USING RAILS AS GROUND TO WELDING EQPT.
IN CASE OF SITES HAVING OVERHEAD TRACTION, ×AVOID WEIGHRAIL FROM SUBMERSION IN WATER.
TRACK
ISOLATION IS TO BE CHECKED REGULARLY.
LINE, LEVEL AND GAUGE OF TRACK TO BE CHECKED × AVOID USING THE POWERLINE DEDICATED TO THE
SYSTEM FOR ANY OTHER USE.
Periodical calibration is followed before time.

Review of conceptsClick to edit Master title style
IMWB refers to
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Non contact type Track Switches are used for
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Which of the following weighment systems are generally accurate?
Static
In Motion
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Any maintenance required to be done on IMWB should have approval of
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Which of the following will have high accuracy and stability?
1)IMWB on Precast Concrete Slab
2)IMWB on Ballast base
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Which of the following is most important in an In Motion Weighment System
1)Ambient Conditions
2)Surge arrestors & Earthing for weighment processing system
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References Click to edit Master title style
1. PMI Course Material

2. NTPC - Simhadri Stage-I & II Control & Instrumentation Drawings
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Electronic Rail In motion Weighing systems at

Installation and Commissioning of new

2 Rail Weighing Concepts 6 Review of the concepts

3 Types of Weighing Systems 7 References

Pit less In Motion Weighing Systems

TIPPLER WEIGH BRIDGES

 STATIC WEIGHING  IN MOTION

 Each wagon has to be uncoupled from wagons adjacent to it

 Wagon has to be carefully positioned and stabled on to the weighbridge

 Then the weight is recorded

 Static Weigh Bridges – Installed at Loading Chutes areas Tipplers.

Partial Weighing System Full Draft Weighing System

 MULTI DRAFT  SINGLE/UNI DRAFT

WST One pair of Rail Sensors RPM

One pair of Track Switch

Approch Rail 5000 mm Weigh Rail Approch Rail

One pair of Rail Sensors

One pair of Track Switch

500 3100 1705 3100

Weigh Rail Load Cell

Load cell cable

 Rail Mounted Transducers

 Weigh wagons on the move

 The Indicator transmits weight over RS232 serial Interface to PC.

 Weighment of Rake completed.

 Lastly, the printer prints the ticket/transactions.

Copyright © 2016 Your Company All Rights Reserved. 18

 Based on weighing axles and summing after averaging

प्रचालन एवं अनुरक्षण(सी एंड आई )विभाग O&M-C&I DEPARTMENT

Copyright © 2016 Your Company All Rights Reserved. 22

Copyright © 2016 Your Company All Rights Reserved. 23

Copyright © 2016 Your Company All Rights Reserved. 24

Copyright © 2016 Your Company All Rights Reserved. 27

2 AXLE WAGON 4 AXLE WAGON

5MTR 2MTR 5MTR 2MTR

1.7Mtr 2.0Mtr 1.7Mtr 2.0Mtr

2960mm 1940mm 2960mm

S1,S2 = WeighRail Sensors

6 AXLE LOCO SEQUENCE

3 AXLE LOCO SEQUENCE

It is the package in which strain gauges lies.

It works on the principle of wheat stone bridge.

 There are certain inherent advantages of using a load cell

This guards against Voltage

Track discontinuities and track irregularities can be a major cause of

Badly maintained wagon can not be weighed accurately

The main defects that cause weighing error are:

Sticking Brakes impedes free movement of the wagon

Accuracy class % of mass of single wagon or total train, as appropriate

Initial verification In-service inspection

Copyright © 2016 Your Company All Rights Reserved. 50

Copyright © 2016 Your Company All Rights Reserved. 51

GEN: Switch on machine 15-minutes before weighment

Copyright © 2016 Your Company All Rights Reserved. 52

Gradient: Max. 1 in 100

INITIAL CALIBRATION RESULTS

16:00 1 69.91 50.24 - 85.72 40.69 25.26 25.2 271.8 271.1

230V 50Hz free from surges and spikes.

Due to problem in analog board

due to defect in track switch, improper operation.

Track switch not working

defect in track switch and its cable.

Weighed only ‘X’ wagons out of 59 wagons

due to cable between junction box to weighing console and