1.

INTRODUCTION

Senlogics DS 505 & DL 405 In-motion Weighing System overcomes many of the limitation inherent of conventional static weighing systems by being able to weigh wagons on the move.

The state of art highly sophisticated yet simple in-motion weighing system has been designed and developed indigenously. With conventional systems, each wagon has to be uncoupled from those adjacent to it, and then carefully positioned and parked on the Weighbridge before its weight can be recorded.

To overcome time factor in the weighing, Senlogic DS 505 & DL 405 In-motion Weighing System can automatically identify the direction, type of wagon, engine and revoke the weight of wagon axle by axle or bogie by bogie by bogie without any manual operation, thus ensuring weighment accuracy.

DS 505 & DL 405 intelligent, innovative system is designed to detect the different type of wagons to initiate the axle or bogie weighing. Also it automatically detects the different type of engines and eliminates its weighment. The speed of wagon is directly related to the accuracy of weighment.

The high speed A/D Micro Controller are having a remarkable compatibility to achieve accurate weighment even upto a speed of 20KM/hr. The system is constructed to the highest international standards, embodies the latest techniques and utilize the best components to ensure the highest possible reliability and integrity, even when used in harsh environment.

The system can operate over wide temperature, power and hazard environmental condition without affecting the accuracy and reliability which are being achieved by stringent design and quality control.

The multiprocessor technology of the system allows independent processing of weight, Track logic and communication ensuring fast and accurate weighment essentially required for an Inmotion Weighing System.

1. SYSTEM OVERVIEW

The load cell based In-motion Weighing System consisting of 4 load cells, weigh bridge with prefabricated supporting structure and rail approaches. The load cells are strain gauge based sensors which convert weight in to electrical signal with very high accuracy and stability. Wagon movement on the weighbridge is identified by Track Switch, placed on either side of bridge, to detect the direction, type of wagon, start and stop weighment.

The signals from the load cells and track switches are fed into DS 505 & DL 405. The system automatically monitor the movement of wagon to initiate the weigh cycle & to record the weight of the wagon when rolls on the bridge.

The robust steel structure, supporting beams and approach beams are constructed with tight tolerance to with stand the abnormal impact.

The approach rails are rigidly tightened with approach beams to restrict the rail movement and smooth load transfer to the weighbridge. The misalignment of approach rails, and weighrail may induces error in accuracy.

1.1. TRACK SWITCHES

Track sensors / switches are placed along the approach and weighrails in a manner that 4 axle, 2 axle and engine movement can generate a fixed pattern to initiate the weighing cycle.

Since the foot print of rail wheel is 30 mm, a set of proximity sensors are placed with a set of stainless steel rod at a distance of 100mm (a distance between first and second arm of track switch), so that the train movement can operate and will generate a forward track logic pattern of: Track Pattern One arm hold Two arm hold Two one reach 0 1 1 0 0 Logic Pattern 0 0 1 1 0

In a similar way the wheel roll back is also identified.

Track switch pattern for two-axle wagon sw1/2 sw3/4

Track switch pattern for four axle wagon sw1/2 sw1/2 sw3/4 sw3/4

Track switch pattern for four axle wagon sw1/2 sw1/2 sw3/4

Track switch pattern for four axle coupled wagon sw1/2 sw1/2 sw1/2 sw3/4 sw3/4 sw3/4 sw3/4

Track switch pattern for engine sw1/2 sw1/2 sw1/2 sw1/2 sw3/4 sw3/4 sw1/2 sw1/2 sw3/4 sw3/4 sw3/4 sw3/4

1.2. TERMINATION BOX

JB boxes is provided to terminate all the loadcell, in a parallel connection. The parallel load cells are connected through 6 or 4 wire and shield with weighing console.

In a similar fashion track switches are terminated in an another JB to connect with console. These boxes are made by cast iron with tight rubber sealing to avoid entry of dust.

3. TECHNICAL SPECIFICATION

ANALOG

1. Dynamic Weighing Capacity 2. Static Weighing Capacity For 4 M W/B For 1.75 M W/B 3. Resolution Programmable for By Default 4. Maximum Weighing Speed 5. System Accuracy

: : : : : : : :

1,00,000 Kg. (100 MT) 50 / Ds 50,000 Kg (50 T) 25,000 Kg (25 T) 5,10,20,50,100 Kg 20 Kg 20 KM / Hr. 0.5% for Individual Wagon 0.2% for Unit Train

A/D SECTION

A to D Micro Computer EPROM E2PROM RAM

: : : : :

16 bit 100 K/S 80c31 / 80c320 20 Mhz 27C512 (64K x 8) 24C16 (2K x 8) 32K x 8

TRACK LOGIC

Micro Computer

89C52 11.0592 MHz

CONTROL BOARD

Micro Computer EPROM Non Volatile & RTC Non Volatile RAM

: : : :

80c320 20MHz 27c512 DS 1644 / 1643 (Optional) DS1230

SERIAL COMMUNICATION

Standard

Two RS 232 Channel One is for communication with control board & PC. Another is for a special and future use.

Optional

RS 485 Installed in Channel

COMMUNICATION PROTOCAL

Band Rate Data Start bit Parity Stop bit

: : : : :

4800 8 bit per character 1 No 1

SYSTEM POWER SUPPLY 230 V 10% 50 Hz 2 Hz

Power Supply Voltage Power Supply Frequency

: :

ENVIRONMENTAL & MECHANICAL 00 C to + 550 C 00 C to + 700 C 20% to 95% RH 4 Meter 19 Inches Rack 75 Kg. 5 Kg.

Operating Temperature Storage Temperature Humidity Weighbridge or Rail sensor Console System Weight Track Switch Weight

: : : : : : :

4. BLOCK DIAGRAMS

The block diagram of DS 505 & DL 405 is subdivided into three parts 1. Main Section (Central Processing Board) 2. Track Logic Section 3. Analog and Digital Section

MAIN SECTION

TRACK LOGIC SECTION ACK

ANALOG & DIGITAL SECTION

START / STOP / END WEIGH

MAIN SECTION

PERSONAL COMPUTER

HIGH SPEED MAIN CONTROLLER

PRINTER

KEY BOARD

NON VOLATILE MEMORY FOR DATA STORAGE

LCD & 7 SEGMENT DISPLAY

ANALOG AND DIGITAL SECTION

LOAD CELL

INSTRUMENTATION AMPLIFIER

ANALOG TO DIGITAL CONVERTER

ANALOG TO DIGITAL CONTROLLER

TRACK LOGIC SECTION

WHEEL SENSOR

OPTO ISOLATOR & BOUNCE FREE ELLIMINATOR

TRACK LOGIC CONTROLLER

4.1. DESCRIPTION OF BLOCK DIAGRAMS

Basically, the Central Processor interfaced with the control board does the combined function of track logic controller and the atod processor. The track logic controller and the main controller are interfaced through serial communication with ACK signals. The track logic controller sends the speed, wagon forward, wagon reverse, unknown vehicle and other track side status to the main controller.

The main controller, keyboard and all other are combined with the central processor. Once a valid track pattern is detected by the track controller, it issues a START WEIGH and STOP WEIGH. For this command the A/D initialize its weigh cycle, consisting of WAIT cycle and WEIGH cycle. End of the wagon is detected by the track logic, which sends the control signals to A/D, so that it can send the add weight of a current wagon under weighment.

The main CPU receives the speed and weight for display through serial communication and sends to printer for printing.

4.1.1. ANALOG TO DIGITAL CONTROL

The load cell produces the mV/ V output to the weight applied with specified accuracy and with zero, span stability, to be converted into digital form for processing and printing & display.

The weigh transducer (load cell) produces low level signal for its applied load, which are to be amplified and converted into a digital form for the processing. The A/D board is having the high speed A/D and very fast instrumentation amplifier with built in reference to achieve good gain and stability.

4.1.2. DISPLAY AND DIAGNOSTIC BOARD

Diagnostic Board:

This board contains six sections with gold coated switches for simulating the wagon pattern to diagnose the system operation, when required. Also remote and reset switches are produced for the wieghbridge operation.

A high efficient RED six digit seven segment LED display is provided with 2 x 16 character backlite LCD display for the weight and message.

10

5. MENU OPERATION FLOW DIAGRAM The following shows the menu flow diagram
MENU

SETUP

STATIC MODE

CLOCK

CALIBRATION

DIAGNOSTICS

UNIT

DATE

CAPACITY

RAW COUNT

RESOLUTION BRIDGE LENTH TIME

RAM 1 TEST

CALIB WEIGHT BRIDGE TYPE

RAM 2 TEST

FULL SCALE CAL

PC COMM. TEST

ENTER AUTO ZERO

ZERO SCALE CAL

PRINTER TEST

ENTER CAL COUNT HEADER 1

DISPLAY TEST

ENTER TAR COUNT HEADER 2 SHUNT VAL Y/N HEADER 3

AD RAM TEST

AD EEPROM TEST

AD COMM. TEST DRIFT COUNT TRAC COMM. TEST KEY BOARD TEST LOAD DEFAULT VALUE TRAC SWI TEST

LAMP POST TEST

11

5.1. SETUP FLOWCHART

MENU

SETUP

UNIT

STATIC MODE

BRIDGE LENTH

BRIDGE TYPE CLOCK EXIT AUTO ZERO CALIBRATION

HEADER 1

DIAGNOSTICS

HEADER 2

HEADER 3

DRIFT COUNT

LOAD DEFAULT VAL

12

5.2. CLOCK FLOWCHART

MENU

SETUP

STATIC MODE DATE

CLOCK TIME CALIBRATION

DIAGNOSTICS

13

5.3. CALIBRATIION FLOWCHART

MENU

SETUP

STATIC MODE

CLOCK

CALIBRATION

CAPACITY

RESOLUTION DIAGNOSTICS CALIB WEIGHT

ZERO SCALE CAL

FULL SCALE CAL

ENTER CAL COUNT

ENTER TAR COUNT

SHUNT VAL Y/N

14

5.4. DIAGNOSTICS FLOWCHART

MENU

RAW COUNT

RAM 1 TEST SETUP RAM 2 TEST STATIC MODE PC COMM TEST CLOCK

PRINTER TEST

CALIBRATION

DISPLAY TEST

AD RAM TEST DIAGNOSTICS AD EEPROM TEST

AD COMM TEST

KEY BOARD TEST

TRAC COMM TEST

TRAC SWI TEST

LAMP POST TEST

15

6. MENU OPERATION DETAILS

The software menu provides options like SETUP, STATIC MODE, CLOCK, CALIBRATION and DIAGNOSTICS.

Select SETUP option to configure the system. The system features like auto zero, bridge length, bridge type, units, header etc., are configured by selecting this option.

Select STATIC MODE option to display the weight. Select CLOCK to set DATE and TIME. Select CALIBRATION option to calibrate the system. Select DIAGNOSTICS to check for correct functioning of the system.

The options detailed above are sequential in order of their occurrence in the MENU. The MENU is invoked by the KEY F1. When the indicator is switched ON a Display Test is performed where in all the digits of weight display will glow from 9 to 0 and now the system is ready to take weighment with auto calibration.

Press key F1 to invoke MENU. The following message is displayed in message display

MENU <SETUP>
Use left to right arrow to move to STATIC MODE, CLOCK, CALIBRATION & DIAGNOSTICS options.

To select setup option move to SETUP and press the key Enter. The following are the options of the SETUP menu.

16

6.1. SETUP MENU OPTIONS 6.1.1. Units

In this option we can select either kilogram or tons by using left arrow key or right arrow key and then by pressing enter key.

6.1.2. Bridge Length (CM)

Using this option enter the weight bridge length between second arm of track switch One and Second arm of track switch Two for accurate speed calculation.

6.1.3. Bridge Type

Using this option select bridge type either 1.75 meter or 4 meter by using left arrow key or right arrow key and then press enter key.

6.1.4. Auto Zero

This option requires 0/1/2/3 of resolution, which enables automatic zeroing of weight below the selected resolution. This is useful to arrest any change in tare weight of scale over a period of time, due to accumulation of debris etc. select the required value and press Enter. Selecting the value 0 will disable this operation. The default value is 0.

6.1.5. Auto Latch

Using this option select auto latch either YES or NO by using left arrow key or right arrow key and then press enter key. When you select `YES` the weight in the weight display will change only when the next change of weight is less or more than 2-resolution. The default is NO than is disable condition.

17

6.1.6. Header

Using this option we can change the printer header string. The Maximum string size is 30 charters. The default string is SENLOGIC AUTOMATION (P) LTD.,

6.1.7. Default Values

Using this option we can change all setup and calibration parameters. The default parameters are: UNITS BRIDGE LENGTH Kilograms 120 cm 1.75 meter 0 (Disable) SENLOGIC AUTOMATION (P) LTD., 30,000 Kg 20 Kg 1,100 Kg 1633 4558 No (Disable)

BRIDGE TYPE OR SENSOR AUTO ZERO HEADER CAPACITY RESOLUTION CALIBERATION WEIGHT CALIBRATION COUNT TARE COUNT SHUNT VALUE -

6.2.

STATIC MODE MENU OPTIONS

This option involves loading the weigh bridge, with calibrated block weights and checking that the indicated weight is within the prescribed error allowances. To invoke this option use right or left arrow key and enter key. The test procedure is as follows:-

18

1. Enter the static mode menu & ensure zero display 2. Load the weigh bridge, with calibrated weights note down the indicated reading as each weight is placed on the weigh bridge. Check that any deviation between the actual and indicated weights are within the prescribed error allowance. 3. Remove the weights note down the indicate reading as each one is removed. Check that the indicate weight is within the prescribed error allowance if the indicate weights are outside the prescribed limits, recalibrate the system (Ref.6.4 Calibration Menu of this manual )

6.2. CLOCK MENU OPTIONS

Real Time Clock is provided for storing the date and time of the weighment taken on the system. This is 24 hours mode clock with programmable DATE and TIME Battery backup is provided for the RTC.

To view DATE & TIME use arrow keys & move to CLOCK and press Enter. The message display will show

DATE 15/09/2002
Use right or left arrow keys to show TIME & DATE display.

To set DATE view the DATE in message display and press Enter, the message display will show

DATE _

19

Enter the correct date and press Enter. For example : 8 MAY 98 will be entered as 08/05/98.

To Set TIME view the display and press enter, the message display will show

TIME _
Enter the correct time and press Enter. The time should be enter in 24 hours mode only. (Eg. 18:45:00 for 6.45 PM)

6.3. CALIBRATION MENU OPTIONS

This is to be done by authorized persons only. Using arrow Keys move to CALIBRATION and press Enter. The message display will show

ENTER PASSWORD _

Enter the correct password and press enter. Then the message display will show

<CALIBRATION> <ENTER CAPACITY>

6.4.1. Capacity

Using this option enter the scale CAPACITY in Kgs as required and press Enter. The defaults value of capacity is 30000 Kgs.

20

6.4.2. Resolution

Using this option enter the scale RESOLUTION in Kgs as required and press Enter. The default value of resolution is 20 Kgs.

6.4.3. Calibration Weight

Using this option enter the scale CALIBRATION WEIGHT in Kgs as required and press Enter. The default value is 1100 Kgs.

6.4.4. Zero Scale Calibration

Using this option makes the zero scale calibration. When you select this option and press Enter, the message display will show

KEEP SCALE CALER

Clear the scale and ensure platform is empty, press Enter. The system makes the current A/D value as zero and shows the value 0 in weight display.

6.4.5. Full Scale Calibration

Using this option makes the full scale calibration. When you select this option and press Enter, the message display will show

MINIMUM min_val

MAXIMUM max_val

21

Place the entered calibration weight on scale. The reading displayed on weight display will be within the proportional range of full scale raw count corresponding to the scale capacity. The calculation for minimum expected raw count reading and maximum expected raw count reading for the given calibration weight is as follows:-

30,000 Minimum Expected Value = -------------------------------- X

CALIBRATION WEIGHT ON

SCALE CAPACITY SCALE

50,000 Maximum Expected Value = -------------------------------- X

CALIBRATION WEIGHT ON

SCALE CAPACITY SCALE

Adjust the GAIN potentio meter in AD board such that the reading on weight display is brought to within or close to the calibration range and press Enter. Now the system is calibrated and the calibration weight is displayed on the weight display.

6.4.6. Shunt Value Y/N

Using this option we can do the initial calibration. The procedure is as follows:Make zero scale calibration Switch on the shunt value Measure load cell output in mV. Calculate the weight according to the weight Enter the calculated weight Make full scale calibration Switch off the shunt value

22

6.5. DIAGNOSTICS MENU OPTIONS

This option provides for self diagnosis of DS 505 & DL 405 IMS. Move to this option and press Enter. The menu chart for this option is as follows:

6.5.1. Raw Count

Invoking this option you can view the internal raw A/D count corresponding to the current weight displayed in the weight display. This is mainly useful during calibration

6.5.2. RAM Test

This is to check whether the memory chips are okay or not. Move to this option and press Enter. The system will show the message either RAM OK, if the memory is accessible or RAM NOT OK if the memory not accessible.

6.5.3. PC Communication Test

This option is used to check the serial communications are okay or nor. Using arrow keys move to this option and press Enter. The system sends the string SENLOGIC AUTOMATION to personal computer.

6.5.4. Printer Test

This options is used to check whether the printer connected to the system is okay or not. Using arrow keys move to this option and press Enter. The system checks the printer communication and if any error, displays the message PRINTER OFF or PRINTER ERROR. If the printer is okay the system will print the titles 1 to 3 entered in the HEADER option.

23

6.5.5. Display Test

This option is used to check all the segments in the weight display are okay or not. Using arrow keys move to this option and press Enter .the system will glow 9to 0 in the weight display.

6.5.6. AD RAM Test

This is to check whether the memory chips are okay or not Move to this option and press Enter. The system will show the message either AD RAM OK if the memory is accessible or AD RAM NOT OK if the memory is not accessible.

6.5.7. AD EE- PROM Test

This is to check whether the non-volatile memory chips which is used to store calibration constants are okay or not. Move to option and Enter. The display will show the message PLEASE WAIT and display either EE-PROM OK if the memory is accessible or AD RAM NOT OK if the memory not accessible.

6.5.8. AD Communication Test

This is to check, Analog to Digital converter board is either working or not working. Move to this option and press Enter. The system will show the message AD COM OK if AD board is working else AD COM NOK if AD board is not working.

24

6.5.9. Track Communication Test

This is to check track logic board is either working or not working. Move to this option and press enter. The system will show the message TRACK COM OK if Track logic board is working else TRACK COM NOK if Track logic board is not working.

6.6. F4 REPORTS OPTIONS

This option is used to take current reports and rakewise reports. The following options are used in reports.

6.6.1

Current Report

REPORTS CURRENT REPORT

Use arrow keys to select this option and press Enter. The system prints current rake information.

6.6.2

Rake wise Report

REPORTS RAKE WISE REPORT

Use arrow keys to select this option and press Enter. information.

The system prints entered Rake

25

7. WIRING DIAGRAMS
Yellow

Fuse 250 mA

1 Yellow

8 V/2V

Line Line Filter

Line Blue

230 V A/C Neutral

2 Blue Neutral Brown 3 Brown

8 V/0.2V

14V/0.5V

J10 TRFORM 1

Gray 1 14/0/14V 0.5A

White Gray Violet 2 Violet

14V/0.5A

26

27

7.

MOTHER BOARD CONNECTION DETAILS

U5 7805 (To 3 Pakage) 1 2 3 I/P GND O/P GND I/P O/P

7805

U5 7805 (To 3 Pakage) 1 2 3 I/P GND O/P Collector Base Emitter

2N3055

J6 1 2 3 4 5 6 7 Excitation (+) Excitation (-) Signal (+) Signal (-) Shield Sense (+) Sense (-)

28

JP8

26 - Pin flat cable to diagnostic board

J7

34 - Pin flat cable to display board

JP1 to JP4

32 x 2 Female Euro Connector.

JP9 & JP10

32 x 2 Female Euro Connector

J14 RS232 Secondary Port for communication with PC for weighment. 1- N.C 2- RXD 3- TXD 4- N.C 5- GND

J5 RS232 Primary Port for communication with PC for diagnostic purpose. 1- N.C 2- RXD 3- TXD 4- N.C 5- GND

29

J1- The key board connection details are: 1- SCLK 2- SDATA 3- N.C 4- GND 5- Vcc (+5V)

Load Cell Wiring

7 Pin DIN Connector male for loadcell connection from J6 in Mother Board.

Shield

Excitation ( + )

1 2

6 5

Sense ( - )

Excitation ( - ) 3 4

Sense ( + )

Signal ( + )

Signal ( - )

30

Connector

Signal

J6 in Mother Board

1 2 3 4 5 6 7

Excitation ( + ) Excitation ( - ) Signal ( + ) Signal ( - ) Sense ( + ) Sense ( - ) Shield

1 2 3 4 6 7 5

Keyboard Wiring

5 pin male connector from keyboard to connector in J1 in mother board.

SCLK

1 4

3 5

N.C

GND

Vcc ( +5V ) 2

DATA

31

RS 232 Wiring

2 - TXD 3 - RXD 5 - GND

RS 232- WRITING TO PC

2 3 5

TXD RXD GND

RXD TXD GND DTR

2 3 5 4 6 7 8

9 pin D type male connector in DN 505 & DN 405

DSR RTS CTS

RS 232 9 pin D type male connector in PC

32

2 3 5

RXD TXD GND

TXD RXD GND RTS

2 3 7 4 5 6 20

RS 232 9 pin D type male Connector in DS 505 & DN 405

CTS DSR DTR

RS 232 25-pin D type male connector in PC

Printer connection

25 pin D type female connector JP5 in mother board for centronics parallel interface to printer.

1 2 3 4 5 6 7 8 9 10

STROBE DATA DATA 1 DATA 2 DATA 3 DATA 4 DATA 5 DATA 6 DATA7 PRNACK

11 12 13 14 15 16 17

BUSY PE N.C AUTO ERROR INIT N.C GND

18 to 25 -

33

Track switch connection

25 pin D type male connector in back panel to track switch. The connection details are:-

1 2 3 4 5 6 7 8 9 10

TXI RED LAMP TX2 YELLOW LAMP TX3 GREEN LAMP TX4 SIREN TX5 GND

11 12 13 14 15 16 17 19 20 21

TX6 VCC TX7 N.C TX8 N.C TXA TXB T-GND TXC

22 - T- GND 24 - 12 V

34

8.

TRUBLE SHOOTING

In the trouble shooting is aimed at isolating the fault to be either with the weighing console or with connected accessories. The following are the testing procedures.

Step

Action

Result

1.

Supply power to the system & Y - Goto setup 2 switch ON the system. The N - May be fault fuse. power ON switch should glow. Replace fuse.

2.

A display test will be performed Y - The system is ready for where in all digits of weight normal operation

display will glow from 9 to 0, N - Possible problem in the message display will okay. power supply main / Display Board.

35

9.1. WEIGHT NOT DISPLAYED OR DISPLAYED IS INCORRECTLY

Step 1.

Action

Result

Select RAW COUNT in diagnostics option Y - Recalibrate the system place known Weight on scale and remove the N - Go to step 2 same. The raw Count reading should increase and decrease linearly.

2.

a. If the raw count reading is not changing

Y Go to step 3 N Go to step 2b

b. If the raw count is changing linearly

Y Problem with loadcell or A/D Section

3.

Are all load cell are okay

Y Go to step 4 N Replace load cells

4.

All load cell connection & platform okay

Y Go to step 5 N Rectify connection

5.

Check excitation voltage, if it is okay

Y Problem in A/D borad N- Problem in power supply

36

9.2. PROBLEM IN PARALLEL PRINTER COMMUNICATION

Step

Action

Result

1.

Switch ON power to system. Switch ON Y-printer communication okay. printer, make sure Paper is loaded N- Go to step2 Select printer in Diagnostics and press enter key. The heading will be printed on printer.

2.

If the printer switch ON and the ONLINE Indication in printer will show

Y - Check interface cable N - Switch On printer and press ONLINE.

37

10. SOFTWARE OPERATION ( DOS VERSION )

This is the completely automated software with few user interactions Data acquisition, data storing and all other operations are through the computer running on DOS based Menu Driven Software . Through the software you can communicate with the In- motion Weighing System. There are few things user should know before going to operate the system,

When you switch on the computer it normally shows the Main Menu as follows:

26.10.2002

SENLOGIC AUTOMATION (P) LTD. In motion weighing system

12:11:36

SNO

WT

SPEED

KM

COMMENTS

SW

COUNT

DS505&DL405

VER1.0

KEEP SYS ON & PRESS A KEY WHEN SYS IS READY

HELP

F1

EXIT

F10

38

When you press any key the system will show the following Popup Menu WEIGH, PRINT, SETUP and EXIT.

26.10.2002

SENLOGIC AUTOMATION (P) LTD. In motion weighing system

12:11:36

SNO

WT

SPEED

KM

COMMENTS

SW

COUNT

DS 505 & DN 405

VER1.0

WEIGH PRINT SETUP EXIT

HELP

F1

EXIT

F10

39

Use the bottom arrow

key to select WEIGH, PRINT, SETUP and EXIT options.

WEIGH OPTION

To select weigh option move to WEIGH and press Enter key, it will show

SYSTEM READY TO WEIGH

After pressing any key the system will wait for the wagon weights. If the Train enters the weigh bridge each and every wagon will be displayed serially in the Main menu. After the train passed the user should given the command Ctrl T to totaling the wagon information.

CTRL

- To totaling the wagon information

PRINT OPTION

Using the aroww key to move PRINT option and press Enter. The system will produce printout of the current weighment information.

SETUP OPTION

Using the arrow key to move SETUP option and press Enter key, it will show the following popup menu.

40

TEST STATIC

TEST TRACK SW

PRODUCT INFO

EXIT

The TEST STATIC option will show the Current Weight of the In-motion weighing System.

The TEST TRACK SWITCH option is used to testing the track switches are working properly or not.

The PRODUCT INFO option shows the product details of the system.

The EXIT option return to the main popup menu

EXIT OPTION Using the arrow key to move EXIT option and press Enter key. The EXIT option come out from the main screen and enter into the Data Entry Screen.

41

DATA ENTRY SCREEN

Before going to the Data Entry Screen the gross weight will be restored automatically and it will show the current rake number and the previous rake number.

26/062002

SENLOGIC AUTOMATION (P) LTD.

12:22:02

DATA ENTRY REPORTS INITIALIZATION MODIFICATION

VIEW M.I.S. REPORT QUIT

42

DATA ENTRY OPTION

Using the arrow key to move into DATA ENTRY option and press Enter key. In the Data Entry Option will show the following screen.

RAKE NUMBER ENTER DATA IN

: :

PROD . NAME TIME IN TIME OUT TO

: : : :

ENTER DATA OUT : FROM :

Every time it will show the current rake information of Date In, Date Out, Time In, Time Out and Gross Weight. At the time of data entry the user want to edit the previous rake information through entering the rake number.

After entering the rake information Press <Esc> to save the current rake information.

REPORTS OPTION

Using the arrow key to move into REPORTS opption and press Enter key. In the Reports Option will show the following screen.

PRINTING REPORTS ENTER RAKE NO Esc to Quit :

43

When user select the REPORTS option it will ask the rake number. After entering the rake number it will produce the printout of the given rake number.

INITIALIZATION OPTION

Using the arrow key to move into INTIALIZATION OPPTION AND PRESS Enter key. In this option will show the following screen.

Enter password: Erase data(Y/N) From Rake No : : To Rake No: Are you sure (Y/N):

This option is used to erasing the rake information. When user select the INITIALIZATION option it will ask the password. After entering the password it will ask from which rack number to which rake number the user want to delete.

44

MODIFICATION OPTION

Using the arrow key to move into MODIFICATION option and press Enter key. It will show the following screen.

RAKENUMBER ENTER DATE IN

: :

PROD. NAME TIME IN TIME OUT TO

: : :

ENTER DATE OUT: FROM :

This option is used to modifying the existing rake information except the gross weight. This screen format will be same as the Data Entry Screen.

VIEW OPPTION

Using the arrow key to move into View Option and press enter key. In the View Option the system will ask the following command.

DO YOU WANT TO VIEW ( Y / N ) : _

The user will press Y it will show all the existing rake number information. The user select the particular rake number and view the same.

45

M.I.S. OPTION

Using the arrow key to move not M.I.S option and press enter key. When the user select the M.I.S option it will show the popup menu as follows:

PRODUCT WISE REPORT

RAKEWISE REPORT

SOURCEWISE REPORT

QUIT

PRODUCTWISE REPORT

This is the periodical Product wise report. When user select this option, (using arrow key )it will ask the FROM DATE and TO DATE. It will generate all the product wise information, which are loaded with in that period.

RAKEWISSE REPORT

The Rakewise Report is not related with any periodical information. After completion of weighment the system will automatically generate the rake number comparing with the previous

46

one. The user want to generate the report of rakewise information they should give the FROM RAKE NO and TO RAKE NO.

SOURCEWISE REPORT

This is the periodical Source wise report. When user select this option, it will ask the FROM DATE and TO DATE. It will generate all the source wise information, which are loaded with in that period.

QUIT

This will exit the current popup menu and focus into Date Entry Screen.

QUIT OPTION

This will exit the Date Entry Screen and focus into the Main Screen.

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Rail In Motion Software: (Window Based)

This is completely automated software with few user interactions. Data acquisition, Data storing and all other operations are through the computer running on window based software. Through the software, you can communicate with the In-Motion Weighing System. When you switch on the computer it normally shows the main menu as follows:

The Main Menu contains:

In Motion Tare Entry Report Edit

Setup Wagon Entry Merge Tare

Exit

Weigh Option 48

When you press WEIGHING Command it show following weighing mode menu.

Now, Communication status it shows Communication Error!!!. These messages appear RS 232 (Serial Communication) not communicate properly to computer. Then you check the communication cable, again go to main menu then press WEIGHING command button. Now, Communication status it shows

Communication OK.
When this message appears you have select GROSS or TARE ratio button. Then you have select type of wagon that is

BOXN or BOBR

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After selecting type of wagon, now, system is READY TO WEIGH. When the rake is enters the weighbridge, the system automatically detect the type engine and eliminate the engine weight. The system detects each wagon, and weight will be displayed serially in the weighing menu. After the train passed the weighbridge operator press or click the END OF WEIGHMENT then press PRINT Command button. Now, the system will produce printout of the current rake information. The rake serial no is automatically incremented.

Gross printout like,

Then the rake serial no automatically incremented, after taking printout you press Back Button on the weighing menu screen. System shows main menu screen. Now, You press

Tare Entry

Command button in the main screen.

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Rake Information Screen;

Now, select the Gross rake in rake information mode. Then give the input of Rake No R.R.No Invoice No Indent No From Product To (Destination) PCC + -

The above field is enterable; PCC limit is 1 to 9. Enter your PCC limit (0 to 9), then the wagon no, tare entry screen open automatically, The tare entry screen as bellow.

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Tare Entry Screen.

Tare Entry: Here first you select wagon type, then enter wagon no, wagon field limit is 20 characters. Then enter wagon tare weight, automatically calculated C.C.weight. The input field is: Wagon No C.C.Weight : : 20 Characters (Alpha Numeric Value) 05 Characters (Numeric Values, 00.00) 05 Characters (Numeric Values, 00.00) Tare Weight :

The caring capacity is correct then enters next tare weight otherwise, you correct caring capacity. Once again you check all tare weight, Wagon no & C.C. Then press or click SAVE command button. All data storing in your database, here automatically calculate Net weight, Permissible C.C, Under Load, Over Load, Penal Load, Chargeable Weight. Then you want print out of complete rake information, you press PRINT command button, the print out automatically generated.

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The net print out format likes;

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REPORT
Our system generated the following MIS report,

Rake wise Report Daily Report Monthly Report Customer Report Gross Report

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Rake Wise Report The rake wise report is not related with any periodical information. After completion of weighment, the system will automatically generate the rake number comparing with previous one. The user wants to generate the report of rake wise information they should select the RAKE NO only. Daily Report
These reports create on particular date rake summary information.

Monthly Report
When user select this option, it will ask the FROM DATE and TO DATE. It Will generate all the rake summary information which are loaded with in that period.

Customer Report
When user select this option, it will ask the FROM DATE, TO DATE and CUSTOMER NAME. It will generate all particular customer rake summary information which is loaded with in that period. The rake report it shows Slno, Wagonno, CC, PCC, Gross, Tare, Net, Under Load, Over Load, Speed. The under load & over load calculation generated automatically. The date wise Report Like:

Edit: When user select this option, it will ask the RAKE NO. You edit the wagon no, tare weight, caring capacity 55

Database Security The proposed software will have multilevel of password and to prevent the data being handled by unauthorized person. The password is to be designed with hirarchive pattern, So that at every level we can control the usage of the system data. The multilevel not only provided the security it gives very high encrypted data production in case of any wrong access of the data.

Exit
This will exit the main menu screen it will focus to computer normal screen.

SHUT DOWN
This will shut down your computer.
In-Motion Software Installation

Step 1: First insert in CD in your CD drive. Step 2: Go to Setup Folder in your CD drive Step 3: Double Click SETUP icon.

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Software Setup first Window Step 4: Click Next Button.

Fig.1.0.1

Software Setup Second Window.

Fig.1.0.2

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Here you must change the software path like; D:/Inmotion Once again you conform your path is correct, then click Next Button.

Software Setup Third Window Now, Click Next Button

Fig.1.0.3

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Software Setup Third Window Here Click Create a desktop icon

Fig.1.0.4

The software icon automatically created in your computer desktop.

Software Setup Third Window

Fig.1.0.5

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The software is Ready to Install in your computer system Now, you click Install Command.

The Software is automatically installed in your computer system, & Click Finish Button. You go & see your program group of your system.

Note:

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The important file is D:/Inmotion Senlogic.Exe Main.Mdb

Computer Specification
Intel Pentium 4 Processor @ 2.0 GHZ 256 KB CACHE Intel 845 GE Chipset 400 Mhz Front Side Bus 1 Parallel Port 2 Serial Port 2 USB Port TVS Key Board & Scroll Mouse 15 Colour Moniter Windows XP OS 132 Column Printer Reputed Make.

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TRACK SWITCH SPECIFICATION:

In - Direction

4 Mtr Rail Sensor

SW1

1 2

3 4

SW2

SW4

4 3

2 1

SW3

Out - Direction Distance: Sensor Weigh Rail Sensor Bar SW1 (1) to SW2 (4) SW1 (2) to SW2 (3) SW3 (1) to SW4 (4) SW3 (2) to SW4 (4) : : : : : : 4 Mtr (Each)

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SENSOR TECHNICAL SPECIFICATION:

System Capacity of the Rail Sensor Rated Excitation Maximum Excitation Bridge Resistance Temperature Effects. Span / degree C (of load) Span / degree C (of load) Zero/degree C (FSO) Combined Error (FSO) Safe Overload (FSO) Ultimate Overload (FSO) Protection Class

: :

In motion Weighing system. Adequate Capacity to measure 100 Mt.

15V AC /DC 25V AC/DC 700 Ohms (Nominal >1000 Meg Ohm @50 VDC +/- 0.006% +/- 0.006% +/- 0.008% <+/- 0.085% 150% 300% IP 67

Bridge Configuration : Quad strain guage Encapulated .8

Surge Protection: a) Transient voltage suppressers. b) Semi Conductor fuse. Advantages: 1) Improved mv/v output 2) Better sealing. 3) Better isolation so no need of isolate the approach Rails 4) Best Quality strain gauges. Long term stability, span & Zero effect.
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LOAD CELL Load cells are utilized in nearly every electronic weighing system. In understanding load cells, youll be better able to comprehend the systems in which they are used. The following is a brief summary of the inner workings of a load cell. While this explanation does not answer every question, it can provide the basic framework for understanding load cells.

System Components:
In contemporary control applications, weighing systems are used in both static and dynamic applications. Some systems are technologically advanced, interfacing with computers for database integration and using micro-processor based techniques to proportion material inputs and feed rates. To send the weight information to computers, signal conditioners are utilized to permit direct communication from the load cell via conversion of the load cells analog signal to a digital signal. An entire system can be constructed, one piece at a time, from basic modules. Parts of a system can include:

Load cells Cable Junction Box (summing up the load cell signals up to one output), Instrumentation (indicators, signal conditioners, etc), Peripheral Equipment (printers, scoreboards

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Shear beam Single Ended Shear Beam

3 mV/V, .03% nonlinearity, 350 ohms, 20 ft cable, stainless steel with threaded hole. Environmentally protected. Bridge Resistance
Input Ohms Output Ohms 343-357 349-355

Applications include Hostile Environments, Tank weighing, Bin and Hopper scales

Capacity A1 A2 B
1,000 Lbs shear beam 2,500 Lbs shear beam 4,000 Lbs shear beam 5,000 Lbs shear beam 10,000 Lbs 1.2 2 1.2 2 1.2 2 1.5 0 1.5 1.22 1.22 1.22 1.50 1.50 5.1 2 5.1 2 5.1 2 6.7 5 6.7

C
.62 .62 .62 .75 .75

D
1.0 0 1.0 0 1.0 0 1.5 0 1.5

E
3.00 3.00 3.00 3.75 3.75

F
2.2 5 2.2 5 2.2 5 3.0 0 3.0

G
.53 .53 .53 .78 .78

H Thread
1/2 -20 UNF-2B, 0.53 x .61DP. C'Bore 1/2 -20 UNF-2B, 0.53 x .61DP. C'Bore 1/2 -20 UNF-2B, 0.53 x .61DP. C'Bore 3/4-16 UNF-2B, 0.78 x .75DP. C'Bore 3/4-16 UNF-2B, 0.78 x .75DP. C'Bore

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shear beam

TECHNICAL SUPPORT If this product fails to operate satisfactorily upon arrival, contact your Senlogic dealer of Senlogic to arrange for an exchange. Tel: 044- 2486 8937 FAX: 044-2486 5640 Upon contacting Order Entry, you will be given a Return Material Authorization (RMA) number. The RMA number is your authorization number. Please write this number on your purchase order and shipping label. Send all authorized returns to: Senlogic Automation (P) Ltd. New No.6, 4th Street, Suresh Nagar, Valasaravakkam, Chennai 600 087.

For technical assistance, contact Senlogics Measurement and Control Division (MCD) Applications Engineering: To arrange for service, contact the Customer Service Office: Tel: 044 2486 8397 You must provide the Customer Service Office with the following information: Model number Serial number Purchase order number Quantity being returned Detailed description of the malfunction Your Bill To and Ship To addresses Our Customer Service Coordinator will provide you with the following: Customer service order number (CSO) Warranty status of the units being returned Repair charge, if any Send all authorized return to: Senlogic Automation (P) Ltd. New No.6, 4th Street, Suresh Nagar, Valasaravakkam, Chennai 600 087.

Or mail at: dwsravi@md3.vsnl.net.in

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