I DIGITAL AXLE COUNTER

G.D.CHANDOLIA

WHAT IS AXLE COUNTER ?

IT IS MEANS FOR DETECTION OF TRAIN ON A TRACK. IT IS HAVING TWO SETS OF TRANSDUCERS & A PROCESSSOR. ONE SET IS INSTALLED AT THE ENTRANCE OF LENGTH OF TRACK WHICH COUNTS IN. ANOTHER SET IS INSTALLED AT THE EXIT OF LENGTH OF TRACK WHICH COUNTS OUT. THE PROCESSOR PROCESS THE COUNTS IN & COUNTS OUT AND CLEAR THE LINE IF THEY ARE EQUAL & SHOWS OCCUPIED IF THEY ARE NOT EQUAL.

ADVANTAGES OF AXLE COUNTERS

MONITORS VERY LONG TRACK SECTIONS IMMUNE TO BALLAST RESISTANCE INSENSITIVE TO TEMPERATURE VARIATION INDEPENDENT OF TYPE & QUALITY OF RAILS, SAND FORMATION & WATER LOGGED TRACKS IMMUNE TO TRACTION RETURN CURRENTS

APPLICATION OF AXLE COUNTERS

TRACK CIRCUITING OF BERTHING TRACKS TRACK CIRCUITING OF POINT ZONE TRACKS VERIFICATION OF COMPLETE ARRIVAL OF TRAIN INTERMEDIATE BLOCK SIGNALLING AUTOMATIC SIGNALLING TRAIN ACTUATED WARNING DEVICE

TYPES OF AXLE COUNTERS

S.N TYPES OF AXLE O COUNTERS 1 2 3 NAME OF MANUFAC YEAR OF NO. OF INTROD. INSTAL 1977 1985 1988 2500 300 250 APPLICATIONS SINGLE ENTRY/EXIT BYC,POD CEL,DCM MULTY ENTRY/EXIT CEL,DCM SINGLE ENTRY/EXIT DCM (MICROPR. BASED) UNIVERSAL TYPE BYC,POD CEL,CGL FOR BERTHING TRACK,IBH,BLOCK FOR POINT ZONE FOR S.N0. 1 & 2

4 5

1994 2002

7000 100

FOR S.N0. 1 & 2 FOR S.N0. 1 & 2

DIGITAL AXLE CON. CEL,ALCA

NEED OF DIGITAL AXLE COUNTERS

DEFICIENCIES IN ANALOG AXLE COUNTERS
TROLLEY SUPPRESION TRACK CIRCUIT RELAY CONTACTS. NO DIAGNOSTIC FEATURES. REQUIRES INTERPHASE EQUIPMENT WITH OTHER TRANSMISSION MEDIA. ACCESSORIES SUCH AS RELAYS, CABLECONDUCTORS, SPACE & EQUIPMENTS AS WELL AS MAINTENANCE IS MORE NO. OF HARDWARES FOR FIXING TRACK DEVICES INTERFERENCE OF 5 KHz. SIGNAL WITH HARMONICS.

SINGLE SECTION DIGITAL AXLE COUNTERS(SSDAC)-BLOCK DIAGRAM

TX1 PULSE 1

Rx1
RX1 AXLE DETECTOR

SCC1

MLB 1

MODEM

TO NEXT SSDAC

TX2

SCC2
RX2

PULSE 2

MLB 2

RELAY DRIVE (24V)

VITAL SIGNAL RELAY 'Q' TYPE

AXLE DETECTOR

LEGEND SCC 1 & 2 : SIGNAL CONDITIONER CARD MLB 1 & 2 : MICROCONTROLLER LOGIC BLOCK

SSDAC SYSTEM COMPONENTS

AXLE DETECTOR 2 NOS. 2 NOS. SSDAC COUNTING UNITS RESET BOX

1 NO. (COMMON RESETTING) 2 NOS. (INDEPENDENT RESETTING) VITAL RELAY - QS3 ( 24V) 2 NO. POWER SUPPLY ARRANGEMENT 24 V DC(2 Nos.) AS PER

COMMUNICATION & SIGNALLING CABLES LOCATION

AXLE DETECTORS

FREQUENCY OF 21KHz & 23KHz TX/RX COILS ARE USED. WEB TYPE AXLE DETECTORS DEFLECTOR BRACKET ASSEMBLY COMPATIBLE WITH 90R,52 KG & 60 KG RAIL PROFILES DETECTION OF ALL WHEELS WITH WHEEL DIA > 400 MM

VIEW OF COUNTING UNIT

COUNTING UNIT FRONT VIEW

ADJ

ADJ Tx
CLOCK MLB 1 CLEAR CLOCK MLB 2 CLEAR RELAY DRIVE OCCUPIED CLEAR OCCUPIED CLEAR

5V 12V 24V GND

2.2V DC

2.2V DC

STATUS SIGNALS

STATUS SIGNALS

Rx MODE CD

0V DC

0V DC

PULSE OK LD OK OSC OK

PULSE OK LD OK

+15V ISO

OSC OK

SCC - 1

SCC - 2

MLB1

MLB2

MODEM CARD

RELAY CARD

DC- DC

COUNTING UNIT - FUNCTIONS

GENERATION OF CARRIER SIGNAL FOR TX COILS DEMODULATION OF SIGNAL FROM RX COILS GENERATION OF VALID PULSES COUNT THE PULSES TO COMPUTE THE NUMBER OF PASSING WHEELS EXCHANGE & COMPARISON OF COUNTS BETWEEN TWO SSDAC UNITS GIVING A VITAL RELAY OUTPUT ERROR CHECKING AND DISPLAY

COUNTING UNIT- OTHER FEATURES

DESIGNED AS PER CENELEC STANDARDS OF HIGHEST SAFETY INTEGRITY LEVEL 4 (SIL-4). BASED ON FAIL SAFE PRINCIPLE BASED ON 2 OUT OF 2 LOGIC ALL THE CARDS ARE OF EXTENDED SINGLE EURO SIZE(220mmX100mm) MOTHERBOARD FOR INTER CARD CONNECTIONS PHYSICAL DIMENSIONS 300X133X300mm FIRST TIME DEVELOPED INDIGENOUSLY BY CEL & RDSO.

* CENELEC-Committee European de Normalisation Electro technique IMPORT SUBSTITUTE.

COUNTING UNIT - CONSTIUENTS

CARD 1 CARD 2 CARD 3 CARD CARD 4 CARD CARD 5 CARD 6 CARD 7 CARD 8

SIGNAL CONDITIONING CARD FOR 21 KHz SIGNAL CONDITIONING CARD FOR 23 KHz MICRO CONTROLLER LOGIC & ERROR DISPLAY MICRO CONTROLLER LOGIC & ERROR DISPLAY EVENT LOGGER CARD(OPTIONAL) MODEM CARD RELAY DRIVER CARD DC-DC CONVERTOR CARD

SIGNAL CONDITIONING CARD FUNCTIONS

GENERATION OF CARRIER SIGNALS OF 21 KHz OR OF 23 KHz FOR TX COILS DEMODULATION OF RECEIVER COIL SIGNAL OF 21 KHz OR OF 23 KHz FROM RX COILS ADJUSTMENT OF RECEIVER SIGNAL WITH POTENTIOMETER GENERATION OF WHEEL PULSE PULSE SHAPING TROLLEY SUPPRESSION TRACK CIRCUIT GENERATION OF SUPERVISORY SIGNAL

SIGNAL CONDITIONING CARD SALIENT FEATURES

THE CARRIER SIGNALS OF 21 KHz OR OF 23 KHz FOR TX COILS ARE GENERATED WITH OUTPUT VOLTAGE AS 30V TO 40V rms & FREQUENCY VARIATION OF 20 KHz. THERE IS A LEVEL DETECTOR CIRCUIT WHICH CHECKS THE LEVEL OF RECEIVER COIL OUTPUT TO ADJUST THE LEVEL OF DEMODULATED SIGNAL FROM RX COIL, POTENTIOMETER HAS BEEN PROVIDED. TO INHIBITE COUNTING DUE TO TROLLEYS , TRACK CIRCUIT CONTACTS ARE CONNECTED PULSE SHAPER CIRCUIT HAS BEEN PROVIDED BY USING HYBRIDS .

SIGNAL CONDITIONING CARD INDICATIONS

LED INDICATIONS ARE PROVIDED FOR
OSC OK PROPERLY LD OK PULSE OK PROPERLY TP CONNECTED/ TPR PICKED UP ON ON ON ON OSCILLATOR WORKING LD WORKING PROPERLY PULSE SHAPER WORKING TRACK CIRCUIT CONNECTED

UNDER NORMAL CONDITION ,THE LED WILL BE GLOWING.

MICRO CONTROLLER LOGIC CARD- FUNCTIONS

TWO IDENTICAL CARDS TO HAVE 2 OUT OF 2 LOGIC MONITOR & RECEIVE PULSE SIGNAL OUTPUT PULSE SIGNAL TO OTHER MICRO CONTROLLER LOGIC CARD DETECT THE DIRECTION OF MOVEMENT COUNTING THE WHEELS PASSSING OVER DETECTOR SUPERVISION OF AXLE DETECTORS, PRESENCE OF CARDS CODE MESSAGE PACKETS FOR TRANSMISSION TO REMOTE COUNTING UNIT

MICRO CONTROLLER LOGIC CARD- FUNCTIONS( CONT.)

DECODE MESSAGE PACKETS RECEIVED FROM REMOTE COUNTING UNIT DETERMINE THE NUMBER OF AXLES IN THE SECTION CONTROL & SUPERVISE THE STATUS OF VITAL RELAY. GENERATION OF SYSTEM ERROR CODES GENERATION OF CLOCK RECEIVING THE RESET COMMAND FROM MODEM CARD

MICRO CONTROLLER LOGIC CARDSALIENT FEATURES

MICRO CONTROLLER IS BASED ON STANDARD 89C51 RS232 COMPATIBLE SERIAL PORT FOR MODEM CONNECTIVITY

1OK BYTE ON CHIP FLASH ROM FOR PROGRAM STORAGE 256 BYTE ON CHIP RAM PARALLEL PORTS FOR ADDRESS /MODE INPUT, PULSE INPUTS & VITAL RELAY OUTPUT

LED DISPLAY FOR COUNT PROGRESS/ ERROR DISPLAY LED INDICATORS FOR SECTION STATUS

MICROCONTROLLER LOGIC BOARD INDICATIONS

LED INDICATIONS ARE PROVIDED FOR

CLEAR OCCUPIED ERRORS BLOCK

1 3 5 7 2 4 6 8

ON ON

CLEAR CONDITION OCCUPIED CONDITION

1 4 10 40

2 8 20 80

LIST OF ERRORS
S.NO 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. CARD_TEST RELAY_TEST CARD_TEST_INLINE LINK_ERROR SEQUENCE_ERROR SELF_COUNT_MISMATCH INPUT_ERROR OUT_B4_IN_ERROR NEGATIVE_COUNT_ERROR SHUNT_ERROR SUP_ERROR COMM_ERROR ERROR ERROR NUMBER (HEX NUMBER) 14 15 24 30 31 32 33 34 35 36 37 40

LIST OF ERRORS (CONTD)

S.NO ERROR ERROR NUMBER (HEX NUMBER) 50 51 52 53 61 62 70 73 80 7F 3F 13. RELAY_DIAG_OPEN 14. RELAY_DIAG_OCC 15. RELAY_UNOCCUPIED 16. RELAY_OCCUPIED 17. SECONDARY_CUP_ERROR 18. SECONDARY_CUP_FAIL 19. CONFIG_ERROR 20. CONFIG_ERROR_INLINE 21. REMOTE_ERROR 22. REMOTE_RESET_ERROR 23. SELF_RESET_ERROR

MODEM CARD- FUNCTIONS

IT PROVIDES SIGNAL CONVERSION FROM DIGITAL TO ANALOG AND VICE-VERSA AS PER CCITT V.21 STANDARD.

IT IS USED FOR COMMUNICATION BETWEEN TWO COUNTING UNITS WHICH IS IN THE FORM OF DATA PACKETS

DATA PACKETS CONSISTS OF COUNT CHANGE INFORMATION, COUNT UPDATE INFORMATION, POWER ON/RESET INFORMATION & ERROR INFORMATION IF ANY.

IT INTERFACES WITH SERIAL RS232C PORT OF BOTH MICRO CONTROLLER LOGIC CARDS.

MULTIPLEX RS232C INPUTS & SELECTS ONE CHANNELS.

MODEM CARD- SALIENT FEATURES

MULTIPLEXES THE TWO SERIAL PORTS AMD 7911 FSK MODEM CHIP V.21 MODE OF OPERATION (2 WIRE) 300 BAUD RATE TRANSMISSION SETTING IN ORIGINATOR(ENTRY UNIT) & ANSWERER(EXIT UNIT) MODE.

SWITCH SELECTABLE GAINS IN RECEIVE & TRANSMIT PATH LED INDICATORS FOR SECTION STATUS

MODEM CARD INDICATIONS

LED INDICATIONS ARE PROVIDED FOR

TX RX

FLASHING FLASHING

TRANSMITTING THE SIGNAL RECEIVING THE SIGNAL NOT IN NETWORKING CARRIER IS DETECTED

MODE OFF CD ON

RELAY DRIVER CARD- FUNCTIONS

IT CHECKS & GENERATES THE VITAL RELAY DRIVE OUTPUT. THIS OUTPUT IS USED TO DRIVE FAIL SAFE VITAL RELAY THE OUTPUT IS GENERATED ONLY WHEN THE SELF COUNT & REMOTE COUNTS ARE MATCHED AND EQUAL

ALSO THE SUPERVISORY SIGNALS ARE NORMAL AT BOTH LOCATION.

RELAY DRIVER CARD- SALIENT FEATURES

DUAL CLOCK CHECKING CIRCUIT OPTO ISOLATOR CIRCUIT VITAL RELAY DRIVE OUTPUT CIRCUIT LED INDICATORS FOR CLOCK. CLEAR PULSE RELAY DRIVER OUTPUT

RELAY DRIVER CARD INDICATIONS

LED INDICATIONS ARE PROVIDED FOR

MLB1 BALANCED MLB1 CLOCK MLB2 BALANCED MLB2 CLOCK RELAY DRIVE

CLEAR FLASHING CLEAR FLASHING ON

COUNTS ARE SECTION IS CLEAR COUNTS ARE SECTION IS CLEAR 24V DC AVAILABLE

DC-DC CONVERTOR CARDFUNCTIONS

IT RECEIVES 24V BATTERY/IPS INPUT. IT GENERATES 5V,12V,24V OUTPUT WITH COMMON GROUND

A SEPERATE 15V WITH ISO GROUND IS ALSO GENERATED

IT GENERATES LED INDICATION FOR BOTH INPUT & OUTPUT SUPPLY.

DC-DC CONVERTOR CARD- SALIENT FEATURES

INPUT RANGE IS 18V TO 30V OUTPUT RATING 5V 2A, 12V 200mA, 24V 300mA & 15V100mA

LOAD REGULATION 0.1% & 0.5% INPUT & OUTPUT PROTECTED AGAINST SHORT CIRCUIT INPUT REVERSE POLARITY PROTECTION LOW RIPPLE, EFFICIENCY BETTER THAN 50%, NO OVERSHOOT/UNDERSHOOT.

DC-DC CONVERTOR CARD INDICATIONS

LED INDICATIONS ARE PROVIDED FOR

5V 12V 24V 15V

ON ON ON ON

PRESENCE OF 5V PRESENCE OF 12V PRESENCE OF 24V PRESENCE OF 15V

OFF INDICATES FAILURE

RESETTING SYSTEM- FUNCTIONS

IT IS REQUIRED TO MAKE THE SYSTEM NORMAL IN CASE AXLE COUNTER HAS FAILED/SWITCHING ON POWER SUPPLY.

IT IS DONE WITH THE HELP OF SMs RESET BOX. (PREPARATORY RESET)

AS PER SAFETY REQUIREMENT, TO NORMALISE THE AXLE COUNTER, THE FIRST TRAIN SHALL BE PILOTED IN THE SECTION AFTER RESETTING TO REGISTER BALANCE OF COUNTS IN THE SYSTEM

RESET BOX- SALIENT FEATURES

IT IS HAVING LED INDICATION FOR SECTION STATUS IT IS HAVING SMS KEY ACTUATOR & RESET BUTTON COUNTER FOR RECORDING NO. OF RESET PREPARATORY RESET RELAY (PPR1) MINITURE RELAY INPUT VOLTAGE 24V DC 24V TO 48V DC- DC CONVERTOR 48V IS USED FOR RESETTING

RESET BOX INDICATIONS

LED INDICATIONS ARE PROVIDED FOR

CLEAR OCCUPIED PREPARATORY RESET STATE POWER ON ON

ON ON

SECTION IS CLEARED SECTION IS OCCUPIED PREPARATORY RESET

ON

PRESENCE OF 24V

OFF INDICATES FAILURE

INDIAN RAILWAYS INSTITUTE OF SIGNAL & TELECOM. ENGINEERS

STATION TO STATION BLOCK

STATION A BLOCK SECTION STATION B

TYPICAL 10 - 20 KM AS 4
VITAL RELAY POWER

4 2

4 SSDAC-2

4
VITAL RELAY POWER
BLOCK/ INTERLOCKING EQUIPMENT

BLOCK/ INTERLOCKING EQUIPMENT

SSDAC-1

THANKS