1.

INTRODUCTION
INTRODUCTION:

The project is divided into two parts : 1.Axle temperature monitoring system

2.Railway wagon weighing scale

The number of accidents that take place due to the derailing of the wheels can be
reduced if a system is developed which would give an indication about the increase in
temperature of the wheel beyond the threshold level. The axle temperature monitoring
system will give an automatic indication when the temperature of the wheel increases
beyond a certain limit.

The railway wagon weighing scale is a system which would effectively measure
the weight of the railway wagons so that excessive loading of the wagons is avoided.

These two systems are cost effective, flexible and fully automatic. These systems
can replace the traditional methods which are carried out manually.
1.1 The methods currently used & their drawbacks :

A. For temperature monitoring:

1. The measurement of the temperature is carried out manually in many regions
wherein the worksmen manually touch the axle wheel to gauge the temperature of
the wheel and to predict whether it is under the danger limit.Being a manual process
it is not a reliable method.
2. The measurement of the temperature is also carried out with the help of the laser
gun system.This laser gun gives the temperature of the axle wheel from a distance
when the train is not moving.The laser gun is taken to every wheel of the wagon
when it is stationary and then an indication is obtained.This method is not applicable
when the train is in motion.

B. For weight measurement :

1. For keeping the weight of the wagon under the prescribed limits the distance of the
springs inside the wagon is measured. The spring inside the wagon expands or
contracts according to the weight of the goods loaded in the wagon. This method of
noting the distance of the spring is not accurate as a clear indication of the weight is
not obtained.
1.2 Benefits of the new systems:

A. Axle wheel monitoring system :

1. The axle wheel monitoring system will be fitted on the axle wheel and the
temperature sensor will always be in contact with the axle wheel. So whenever the
temperature crosses the prescribed limit then an indication is given and accordingly
the necessary measures can be taken on time.
2. As electronic components are used the result will be accurate.
3. A lot of effort and time is saved when this system is used.
4. Being an electronic system, it is reliable, flexible, cost effective and fully automatic.

B. Railway wagon weighing scale:

1. The railway wagon weighing scale will give the accurate weight of the wagon as
with the springs are connected two arms to which a potentiometer and digital voltmeter
circuit is connected which will give the accurate measure of the tension on the spring.

2. It is a very cost effective and reliable method.

These two systems overcome all the drawbacks of the current methods used and
have wide scope for up gradation.

PICTORIAL VIEW OF PROBLEMS OCCURING DUE TO HIGH

TEMPERATURE
PICTORIAL VIEW OF PROBLEMS OCCURING DUE TO HIGH TEMPERATURE
 2.LITERATURE REVIEW

2.1 RESISTANCE :

The electrical resistance of an object is a measure of its opposition to the passage of a

steady electric current. An object of uniform cross section will have a resistance
proportional to its length and inversely pro For a wide variety of materials and
conditions, the electrical resistance does not depend on the amount of current through
or the potential difference (voltage) across the object, meaning that the resistance R is
constant for the given temperature and material. Therefore, the resistance of an object
can be defined as the ratio of voltage to current, in accordance with ohms law.

In the case of a nonlinear conductor (not obeying Ohm's law), this ratio can change as
current or voltage changes; the inverse slope of a chord to an IV curve is sometimes
referred to as a "chordal resistance" or "static resistance".

portional to its cross-sectional area, and proportional to the resistivity of the material.

2.2 CAPACITOR:

A capacitor or condenser is a passive electronic component consisting of a pair of

conductors separated by a dielectric (insulator). When a potential difference (voltage)
exists across the conductors, an electric field is present in the dielectric. This field stores
energy and produces a mechanical force between the conductors. The effect is greatest
when there is a narrow separation between large areas of conductor, hence capacitor
conductors are often called plates.

An ideal capacitor is characterized by a single constant value, capacitance, which is

measured in farads. This is the ratio of the electric charge on each conductor to the
potential difference between them. In practice, the dielectric between the plates passes
a small amount of leakage current. The conductors and leads introduce an equivalent
series resistance and the dielectric has an electric field strength limit resulting in a
breakdown voltage.

Capacitors are widely used in electronic circuits to block the flow of direct current while
allowing alternating current to pass, to filter out interference, to smooth the output of
power supplies, and for many other purposes. They are used in resonant circuits in
radio frequency equipment to select particular frequencies from a signal with many
frequencies.

2.3 SEVEN SEGMENT LED DISPLAY:

A seven-segment display , less commonly known as a seven-segment indicator, is a
form of electronic display device for displaying decimal numerals that is an alternative to
the more complex dot-matrix displays. Seven-segment displays are widely used in
digital clocks, electronic meters, and other electronic devices for displaying numerical
information.

A seven segment display, as its name indicates, is composed of seven elements.

Individually on or off, they can be combined to produce simplified representations of the
arabic numerals. Often the seven segments are arranged in an oblique (slanted)
arrangement, which aids readability.

Each of the numbers 0, 6, 7 and 9 may be represented by two or more different glyphs
on seven-segment displays.

2.4 USING IC 741 (In temperature sensor) :

The LM741 series are general purpose operational amplifiers
which feature improved performance over industry standards
like the LM709. They are direct, plug-in replacements
for the 709C, LM201, MC1439 and 748 in most applications.
The amplifiers offer many features which make their application
nearly foolproof: overload protection on the input and output, no latch-up when the
common mode range is exceeded,
as well as freedom from oscillations.
The LM741C is identical to the LM741/LM741A except that
the LM741C has their performance guaranteed over a 0C to
+70C temperature range, instead of 55C to +125C

Pin Diagram of IC 741

2.5 Data Collecting and Transmission unit:

The Data Collecting and Transmission unit has the main functions to collect the data
coming from all the
TVS units and to transmit the information to the locomotive driver cellular phone and/or
to the Central
Station.
The DCT unit is also capable to store the data received form the sensors (temperature
and vibrations)
so to retrieve such data (with relevant time tags) in a later stage for due analysis.
Furthermore the DCT unit is connectable to a Palm Top Computer to allow the following
operations on
the system by means:
1. System set up (initialization).
2. System diagnostic functions.
3. Download of stored data.
4. Physically the DCT unit is a metallic box containing the following sub-parts:
5. Receiving circuitry.
6. Control logics.
7. GPRS/GSM modem.
8. Power supply and shut-down circuitry.
2.6 TWS Unit :
It is a small metallic box including the sensors and the electronics. The box has also the
function to
protect internal components against atmospheric agents and mechanical stresses
(vibration and shock)
granting the operating functions the unit has to carry out.
The following elements are enclosed in the box:

1. Low consumption microprocessor based card.

2. Temperature sensors.
3. Accelerometers.
4. Receive and Transmitting (RX/TX) unit.
5. Power supply and shut-down circuitry.
3.METHODOLOGY
3.1 SCHEMATIC DESIGN WITH CAPTURE:
1. Click on FILE Menu , choose new then choose project New project, Dialog box
appears.
2. Type name for new project in the name textbox.
3. Use the browse button to select a new directory.
4. Select analog or mixed A/D
5. Click on OK
6. The create P-spice project dialog box appears. In this select the option creates
the blank project then click OK.
7. A schematic window ORCAD Capture appears in the ORCAD Environment.
8. Select place menu and choose part.
9. A window will open select P-spice option and select all libraries available in the
P-SPICE folder .Click on open.
10. Again window will open; write the name of component which you want, You will
get different families of component ,you select the desired one and click on ok.
11. On page click and drag the components where you want and press ESC.
12. In this way different components are selected and connected through wire.
13. If you want to select source place-part ->select the source option available in the
library list and write name e.g. A.C or D.C.source

3.2 SIMULATION WITH CAPTURE :

 1. Click on P-spice Menu, choose new simulation profile and then click Write Name
-> create. Also simulation settings are done as per Users ned.
2. Type name for new project in the name textbox.
3. Click on symbol Run.
4. After this in main circuit file level marker place on Input result & output side of
circuit diagram and then again click on Run.

3.3 OrCAD LAYOUT DESIGN :

1. Select the File Name.dsn file from program Manager.

2. Select Tool-create Net list from the Create Net list Window.
3. Click on the layout select Run ECO to Layout.
4. Use properties in inches or millimeters.
5. Specify the path and name of .mnl file or keep the default name. Click OK. You
see .mnl file created in output folder in Program Manager.
6. Open the Or-CAD Layout :

a. Open Or-CAD layout by double clicking on layout icon.

b. Click on File select New-Load Template File window appears.

c. Select default.tch file and click open.

d. Load Net list source Window appears Specify the path for .mnl file created in
Capture.

e. Specify the name and click save.

3.4 PCB FABRICATION PROCESS

3.4.1. Schematic Preparation :
Schematic is a circuit that is drawn either with the help of software or
manually on paper with standard symbols. If the circuit is big and complicated then
multilayer schematic is made otherwise single layer schematic is made. The schematic
is drawn with colored pens indicate different layers, power lines and ground lines.

3.4.2 Artwork Preaparation :

After making the schematic on paper same is suplicated on
transparent acrylic plastic sheet the circuit is called artwork. The artwork is made either
bigger or smaller or same or same size of the desired PCB.The artwork is drawn with
different colour tapes to idetify the signal lines,power lines and ground lines.The artwork
should be proper without leaving any connections or making any excess connections or
shorts.

3.4.3 Etching of Copper Clad Board :

After the artwork is completed the final copper pattern is formed by
removal of unwanted copper,which is not protected by etching .For etching the copper
clad is dipped in ferric chloride solution .This process takes quite a long time.After
etching processwe can see the copper tracks.

The solution in which the PCB is dipped is Fecl3 .The following chemical
reaction takes place .

2Fecl3 + Cu > Cucl2 + 2 Fecl2

3.4.4 Drilling of Holes :

 The PCB is now ready for drilling operation.The holes are now drilled at
places wherever the components are to be placed.the size of the drills should be either
more or less than required.

3.4.5 PCB Testing :

PCB is checked for all interconnections through multimeter ,whether
the tracks are broken or short at any place , thereby connections are done through
soldering.

3.4.6. Assembling of the unit :

Components are assembled in proper directions to avoid the touching
of the components to one another.Heat sink is to be put wherever required with sink
compound.
4. TOOLS
4.1 Metal ring (for temperature sensor) :
To keep the temperature sensor in contact with the axle to monitor the
temperature of the axle wheel we have used a metal ring. The metal ring has a radius of
11 cm. The metal ring will cover the axle wheel completely. A hole is drilled inside the
metal ring to place the temperature sensor ; viz lm35.

4.2 Springs ( for weight measuring device) :

We have employed a spring to connect the metal plates so that when the
weight is kept on the metal plate & the spring will contract. We have used the shock up
of a moped to create this prototype of the wagon weighing scale . This shock up is fitted
to the lower metal plate using a screw arrangement.

For the actual weight measuring device 9 springs will be used wherein each
spring has the capacity to withstand weight of about 20 tonnes.

4.3 Metal plates ( for weight measuring device ) :

The object whose weight is to be measured is kept on the metal plate. For
the prototype two metal plates are employed. The lower metal plate has a dimension
22cm x 22 cm. and the upper metal plate has the dimension 20 cm x 20 cm . The two
plates are connected by the spring and the two metal plates are surrounded with the
help of rods.
4.4 Pictorial view of the mechanical arrangement for weight
measurement :

Pictorial view of the mechanical arrangement for weight measurement

4.5 Pictorial view of the spring :

Pictorial view of the spring

 5. DESIGN & IMPLEMENTATION

5.1.1 CIRCUIT DIAGRAM OF TEMPERATURE SENSOR

5.1.2 CIRUIT DESCRIPTION OF TEMPERATURE SENSOR :
 The temperature sensor circuit uses lm 35 as a temperature sensor. In this
circuit ,external heat is provided to lm35 and this external heat is sensed by lm35 and
corresponding output voltage increases with the rise in the temperature. The output
voltage is directly proportional to the temperature. The circuit is very simple and
requires very less power.

The external heat that will be provided in the application part will be the heat
on the axle of the wagon. Thus an indication of the rise in temperature is obtained with
the help of this circuit.
5.1.3 Graph of Temperature v/s Output voltage (for the temperature
sensor) :

VOLTAGE
5.1.4 Pictorial view of the axle wherein the device will be installed :

Pictorial view of the axle wherein the device will be installed

PCB Layout of Temperature Sensor Circuit
5.2.1 Circuit diagram for digital voltmeter with LED display ( for
weighing scale ) :

Circuit diagram for digital voltmeter with LED display ( for weighing scale )
5.2.2. Circuit description for the digital voltmeter with LED display
( for weighing scale ) :
This is an easy to build, but nevertheless very accurate and useful digital
voltmeter. It has been designed as a panel meter and can be used in DC power
supplies or anywhere else it is necessary to have an accurate indication of the voltage
present. The circuit employs the ADC (Analogue to Digital Converter) I.C. CL7107 made
by INTERSIL. This IC incorporates in a 40 pin case all the circuitry necessary to convert
an analogue signal to digital and can drive a series of four seven segment LED displays
directly. The circuits built into the IC are an analogue to digital converter, a comparator,
a clock, a decoder and a seven segment LED display driver. The circuit as it is
described here can display any DC voltage in the range of 0-1999 Volts.

5.2.3. Technical Specifications - Characteristics

Supply Voltage: ............. +/- 5 V (Symmetrical)

Power requirements: ..... 200 mA (maximum)
Measuring range: .......... +/- 0-1,999 VDC in four ranges
Accuracy: ....................... 0.1 %
FEATURES:
- Small size
- Easy construction
- Low cost.
- Simple adjustment.
- Easy to read from a distance.
- Few external components.
5.2.4 PCB Layout of the circuit :

PCB Layout of the circuit

5.2.5 Pictorial view of the developed circuit :

Front view of the circuit

Back view of the circuit

5.2.6 Power supply circuit:

Power supply circuit

6.LIST OF COMPONENTS
6.1.1 For temperature sensor:

SR NO TYPE NAME VALUE

Resistance R1 9k

2 Resistance R2 1k

3 IC 741 - -

4 Lm35 - -

5 Power supply 5 volts

6.1.2 For digital voltmeter circuit ( for weighing scale ) :

SR NO TYPE NAME VALUE

Resistance R1 180 k

2 Resistance R2 22k

3 Resistance R3 12k

4 Resistance R4 1M

5 Resistance R5 470k

6 Resistance R6 560 ohms

7 Capacitor C1 100pf

8 Capacitor C2,C6,C7 100nf

9 Capacitor C3 47nf

10 Capacitor

C4 10nf

11 Capacitor C5 220nf

12 MAN 6960 - -
common anode
led displays

13 Trimmer multi turn P1 20k

6.2 Datasheets of components used :
LM35:
TEMPERATURE ACCURACY:
Lm 135-Lm235 LM335A Lm335
Parameter Unit
Min. Typ. Max. Min. Typ. Max.
Operating output
voltage Tcase=+250 2.95 2.98 3.01 2.92 2.98 3.04 V
C ,IR=1mA

0
Uncaliberated 1 3 2 6 C
Temperature error 2 5 4 9
(IR=1mA)
Tcase=+25oC
Tmin<=Tcase<=Tmax

0
Temperature error with 0.5 1.5 1 2 C
25oC calibration 0.5 1
Tmin<=Tcase<=Tmax
IR=1mA

0
Caliberated error at 2 2 C
Extended temperature
Tcase=Tmax

Non-linearity (IR=1mA) 0.3 1 0.3 1.5Lm

Lm135-Lm235 0.3 1.5
Lm 335
lm335A
 MAX1044 ICL7660
PARAMETER CONDITIONS UNITS
MIN TYP MAX MIN TYP MAX

RL = , TA = +25C 30 200 80 175

pins 1 and 7 TA = 0C to +70C 200 225
Supply Current no connection, TA = -40C to +85C 200 250 A
LV open
TA = -55C to +125C 200 250
RL = , pins 1 and 7 = V+ = 3V 10
Supply Voltage RL = 10k , LV open 3.0 10.0 V
Range (Note 1) RL = 10k , LV to GND 1.5 10 1.5 3.5
TA = +25C 65 100 55 100
IL = 20mA,
fOSC = 5kHz,
TA = 0C to +70C 130 120
LV open TA = -40C to +85C 130 140
TA = -55C to +125C 150 150
Output Resistance
fOSC = 2.7kHz (ICL7660), TA = +25C 325 250
fOSC = 1kHz (MAX1044), TA = 0C to +70C 325 300
V+ = 2V, IL = 3mA, TA = -40C to +85C 325 300
LV to GND
TA = -55C to +125C 400 400
COSC = 1pF, V+ = 5V 5 10
Oscillator Frequency kHz
LV to GND (Note 2) V+ = 2V 1
Power Efficiency RL = 5k , TA = +25C, fOSC 5kHz, LV open 95 98 95 98 %
Voltage Conversion Efficiency RL = , TA = +25C, LV open 97.0 99.9 99.0 99.9 %
Oscillator Sink or Pin 1 = 0V 3
VOSC = 0V or V+, LV open A
Source Current Pin 1 = V+ 20
V+ = 2V 1.0 1.0 M
Oscillator Impedance TA = +25C
V+ = 5V 100 100 k

Datasheet of ICL7660:
ELECTRICAL CHARACTERISTICS
7. Result
7. 1 Axle wheel monitoring system :

Thus we have developed a circuit which can effectively detect the crossing of
temperature beyond a threshold level. The circuit is a simple circuit and will occupy very
less space. The circuit will be fitted near the axle with the help of the metal ring
arrangement which will cover the axle completely. This circuit can replace the manual
operation . The number of accidents due to derailment can be considerably reduced by
employing this system.
7.2 Railway wagon weighing scale :

We have developed a prototype of the railway wagon weighing scale.It effectively

measures the weight of any object placed on it. The circuit is made of mechanical and
electronic equipments.The mechanical arrangement will deal with the placement of the
object and the electronic circuit ( digital voltmeter circuit ) will give the output on the LED
display by the movement of the potentiometer by the correspoding movement of the
arms connecting the two metal plates.

Thus, this method is much more advanced and accurate than the technique
used at present.
8.CONCLUSION & FUTURE SCOPE
8.1 CONCLUSION :

1. The axle wheel monitoring system is applicable to monitor the increase in the
temperature of the axle wheel beyond the certain threshold level. The device
developed is very cost effective and can be suitably upgraded with the increase
in the cost of the system.
2. The railway wagon weighing scale is a effective weight measuring device which
can measure weight of the wagon ( object) without the use of any expensive
material. The indication is given clearly on the led display and if any excess
loading on the wagons is done ,then it can be detected easily using this device.
8.2 FUTURE SCOPE :

8.2.1 For axle temperature monitoring system :

1. The axle temperature monitoring system can be used for other vehicles also to keep
a watch on the increase in the temperature of the wheel and to avoid accidents.

2. A large number of vehicular accidents can be avoided by using this device.

3. With the large investment the all connections can be wireless on ISM band with proper
wireless technology within restricted area of wagon.

4.All inter connectivity can be possible with the help of WSN (wireless sensor network).
8.2.2. For railway wagon weighing scale :
1. The railway wagon weighing scale is a very cost effective device.Many possible
innovations can be made with the increase of the cost of the device.

2. It can not only measure the weight of the wagon but other heavy objects can also be
measured with ease with the help of this device.
9.REFERENCES
9.1 References:
1] www.sitep.it

2] www.datasheet.com

3] A stationary system of non-contact temperature measurement and hotbox detecting.

Milic,S.D;Srekovic ,

M.Z Vehicular technology,

IEEE Transactions on volume 57,issue 5, sept 2008. Pages :2684-2694

9.2 Abstract of reference paper :
In this paper, we propose an intelligent stationary system of uninterrupted noncontact
temperature measurement and detection of overheated bearings in trains. The
proposed measurement system is a stand-alone class, based on remote infrared (IR)
measurement and recognition of the hot lid of axle bearing. The measurement system is
useful for continuous maintenance without traffic interruption. It consists of three parts:
1) the measurement device; 2) the alert device; and 3) a PC with a virtual instrument
and appropriate database. The measurement device is based on an IR detector
installed on both railway sides on the same axis as the wheel axle. The whole system is
installed at three locations, which are located 500 m apart. The communication among
system parts is done using RS-232/485 interfaces and radio modems. This system has
a vital role in safe railroad operations, preventive maintenance, and damage avoidance
of axle wheel bearings in railways.