AUTOMATIC AXLE BOX TEMPERATURE RECORDING SYSTEM

Axle box temperatures in coaches/wagons are being recorded manually with

non-contact thermo hunters by two staff on either side of the rake after the train
halts in a station. The staff on offside is experiencing difficulty in the absence of
clear path way for movement and obstructions like water hydrants. Staff on the PF
side also experience similar hindrance as it is difficult for him to reach out to the
axle box from the PF as the gap between coach and PF is too narrow to allow the
focused rays.

To overcome these shortcomings, Chennai Division has developed a

computerised temperature recorder and installed at the following locations,

Working
S.No Location Photos
from

DN Main line of
1 AJJ-KPD section 19-06-2018
near LC53/KPD

UP Main Line at
2 18-01-2019
TPT End/JTJ

UP Main Line of
GDR-MAS
3 09-02-2019
section near LC
76/NYP
 WORKING PRINCIPLE:

This System Consists of 2 recording devices one (proximity sensor) for counting
the Axles and the other (infra red thermo sensor) for recording the Axle Box
temperature.

Proximity Sensor fitted inside the track Infra Red Thermo Sensor fitted on either side

The recorded temperatures are saved in a PC provided at the site in MySQL

Database.

The saved data are transferred to centralized web server and that data can be
viewed through URL : www.sraxleboxtemp.com.
 The application page gives colour indication and buzzer sound when the
temperature of Axle Box is more than 600C or the difference in temperature
between two axles in a rolling stock exceeds 200C.

Method of working:

In this system Analog output of LH & RH - IR Temperature sensors and digital

output of proximity sensors are connected to a Micro Controller Board(Arduino
Uno) and the microcontroller acts as brain of the system. The USB port of Micro
controller is connected to a mini computer available in the field unit.

Internet
Cloud

Digital
Input
Power supply TS2
RAYMI3 Analog Micro Controller cum proximity
IR Thermo Sensor sensor
Input (Arduino Uno interface
board
Board TS1

ifm
ID5058
RAYMI3 COMM Proximity Sensors
Communication Box
 ALGORITHM OF WORK FLOW

The Micro controller continuously monitors the status of proximity sensors TS1
& TS2. In normal condition, Proximity Sensor TS 1 and TS 2 remain high (5 V).
When the first axle of the vehicle touches TS1, it becomes low (0 V) and starts
counting the Axle numbers when the wheel moved over TS2. The Micro controller
starts capturing LH & RH temperature of the Axle Box with the axles passing over
TS2 and transfer the data to mini compute through Serial port. The Visual Basic
program running on the computer captures the readings and stores them on the
MySQL database with timestamp (Date and Time of Recording) and Axle Box
number. After the passes of all axles the system will wait for 45seconds, if there is
no more axle to count, the microcontroller will put “End train”. This will be sensed
by VB program running on mini PC and assign a dummy train number to the saved
data and transfer the data to centralised web server.

The application page gives colour indication and buzzer sound when the
temperature of Axle Box is more than 600C or the difference in temperature
between two axles in a rolling stock exceeds 200C.
 Materials Specification:

S.No DESCRIPTION QTY TECHNICAL SPECIFICATION

1
 Temperature range: -50 to 975 °C
 Optical resolution: 25:1
 Spectral range: 8 - 14 μm
AXLE BOX  System accuracy (at ambient temperature 23 ±5
TEMPERATURE °C) : ±1 % or ±2 °C
MEASUARING  Response time:
SENSOR Analog output(90%) : 6 ms or better sensitive
2 Nos. sensor less than 6ms
(Non-contact IR
Digital output(50%) : 3ms or better sensitive
sensor for high sensor less than 3ms
speed  Environmental rating
measurements) Sensing head : IP65 (NEMA-4)
Electronic box : IP65 (NEMA-4)
 Cable length : 15m
 Power Supply : 8–36 VDC
2 Electronic rectangular inductive proximity sensor with 50
mm sensing range (flush mountable) with normally
PROXIMITY open/closed output function, evcoie connector and cable of
2 No
SENSOR 15 meter length, operating voltage: 10 to 30 v DC, make:
IFM NO. 5058 or equivalent

3 METAL BOX 1 No 4*3 feet box. Drawing enclosed

4 Control unit 1 unit ATMEL Based microcontroller board
5 Integrated GPRS/GSM modem including SIM with
Modem 1 No. 2 years internet & SMS package.
6 DUAL CORE CORE 2 DUO CELERON PROCESSOR OR
HIGHER HAVING HDMI/VGA/LVDS WITH
 8GB OF DDR3L 1333 RAM,
Embedded PC  MINIMUM 1 COM PORT 3.5 OR 25:
(Industrial)
2 Nos.  64 GB SATA HDD
 ONE MINIPCI WHICH SUPPORTS WIFI,
 MINIMUM 2 USB.
 OS WINDOWS 7 OR HIGHER
MODEL 101 1900 OR EQUIVALENT
7. Up to 30mtrs electrical connection including earth
ELECTRICAL and
work if needed. Earth pit to be provided by the firm
Earth pit
near field unit.
8. Commercial LED
1 no. 32” COMMERCIAL 24*7 LED DISPLAY
TV 24*7
9. Fixing Brackets for
Each
proximity & IR As per requirement.
2 Nos.
Temperature sensor
10. Base for fixing IR
1’ X 1’ concrete base to a height of rail level on either
temp. sensor 2 Nos.
side of the track with Anchor bolt
bracket.
 Cost of the System:

Qty
S.No Item Rate Value
(For 1 ABTR)
Non Contact Infrared Thermometer Along
With Communication Box And Power
Supply Unit
MODEL NO. PSC- SSS OF process
1 38350.00 2 nos. 76700.00
sensors corporation (or)
MODEL NO. RAY MI 310 LTF CB8 of
Raytek (or)
MODEL NO. CT FAST OF OPTRIS.
Electronic rectangular inductive proximity
sensor with 50 mm sensing range (flush
mountable) with normally open/closed
2 output function, evcoie connector and 5485.82 2 Nos. 10971.64
cable of 4 meter length, operating
voltage: 10 to 30 v DC, make: IFM NO.
5058 or equivalent
Fanless Embedded Pc Systemwith Dual
Core Core2 Duo Celeron Processor
Having Hdmi Vga And Lvds Nterface 8gb
Of Dor3l 1333 Ram, Minimum 2 Com
3 Port 3.5 Or 25: Sata Hdo One Minipci 33040.00 2 Nos. 66080.00
Which Supports Wifi, With 3g Module
And Sim Card For 3g 4g Connectivity,
Minimum 2 Usb. MODEL 101 1900 OR
EQUIVALENT
Metal box (2ft X 3ft) for automatic
computerized axle box temperature
recorder with: (1) A T mega 328P based
micro controller arduino Uno bo 1 No. (2)
SD card shield- 1 No. (3) Proximity
4 18880.00 1 No. 18880.00
sensor interface board with power supply
1 No. (4) 12 V DC (1A) adopter for
arduino Uno board- 1 (5) MCB- 1 NO.
The metal box is siemens grey colour
powder coated.
5QHz 300 Mbps 13 dbl outdoor point to
point access point. Model CPE510 TP
5 14455.00 1 Set 14455.00
link or equivalent. Consisting one
transmitter and one receiver.

LED TV 80 CM (32) LG32 LU 522 OR

6 BETTER MODEL MAKE LG OR SONY 21102.08 1 No. 21102.08
OR SAMSUNG OR MICROMAX.

Total Cost 208188.70

Cost of Improved version:
RAILWAY COST in PRIVATE COST in
TYPE OF SYSTEM
Rs /unit Rs/unit

30 KMPH (20ms Response time) 2,08,188 -

60 KMPH (06ms Response time) 3,42,488 4,19,960
 DETAILS OF HOT BOX DETECTOR AT MAS DIVISION

Location No. of Hot Date of Make No. Of No. of No. of Other Other cases found
Box installation Axles Cases Cases of cases
Recorded > 650 C detected
detectors detected Hot Axel detected
installed

LC53/KPD DN 3( 3 WARM
01 19-06-2018 INDIGENEOUS 5,50,556 4 1 152
Main Line BOX)

UP MAINLINE
18-01-2019
AT TPT 01 1,67,958 - - - 46
END/JTJ INDIGENEOUS

LC76/NYP/UP
01 09-02-2019 37,850 - - - 2
MAINLINE INDIGENEOUS
NUMBER OF CASES DETECTED: 3

AXLE BOX
DATE TRAIN / WAGON NO DETACHED AT
TEMP

FCOP/PLMD/BCN-SE BCNAM1
13-02-2019 30079373613 (LD)KGPW:09.05.18 R4-980C JTJ
RD:06/19

14-02-2019 WFD/CONT/CN BLCB 62250425279 (LD) R4-920C JTJ

RYPS:28.10.15 MNGT:22.12.18 RD:06/20

18-02-2019 WFD/CONT/CN BLCB 62250004634 (LD) L4-700C JTJ

KTTW:04.08.15 MNGT:23.10.18 RD:03/20.