DESCRIPTION OF VARIOUS MODULES OF AXLE

COUNTER SYSTEM

I. EVALUATOR
The Evaluator consists of 10 PCB modules. The interconnections between
the various PCB cards are made with the help of a motherboard. The polarization
arrangement (to avoid wrong insertion of modules) is provided on the aluminum
modular sheets in each. Hence it is important to ensure correct fitting of modular
shield in each card. In the Universal Axle Counter System manufactured by
Central Electronics Limited , relevant card number has been number punched for
easy identification to ensure correct fitting of modular shields. A brief description
of each P.C. assembly is given below.

(a) Attenuator/Amplifier & Rectifier Card (Card no. 1):

This is a double-sided PCB (Size: 225mm X 275mm). It contains four
identical channels, each comprising of a 5 kHz high pass filter, a line matching
transformer, attenuator pads, a two stage amplifier and a full wave rectifier. The
output of each channel can be set precisely by means of a lockable shaft
potentiometer mounted at the front end of the PCB module. Typical output is 300
mv (P-P) or 105-mv rms.

(b) Attenuator/Amplifier & Rectifier Card (Card no. 2):

This is a double-sided PCB (Size: 225mm X 275mm). It contains four
identical channels, each comprising of a 5 kHz high pass filter, a line matching
transformer, attenuator pads, a two stage amplifier and a full wave rectifier. The
output of each channel can be set precisely by means of a lockable shaft
potentiometer mounted at the front end of the PCB module. Typical output is 300
mv (P-P) or 105-mv rms.
 For 1D and 2D Systems, there will be one such card (Card no. 1) while for
3D and 4D Systems, the evaluator will have two nos. of such cards (Card nos. 1
& 2).

(c) Pulse Shaper Card (Card no. 3):

This is a double-sided PCB (Size: 225mm X 275mm). It contains four
identical channels, each consisting of a low pass filter, an Schmitt trigger, an
impulse time filter and a 10 V to 5 V level converters. The outputs of these
channels are TTL compatible. In addition to above, each channel comprises of a
Trolley Suppression Circuit.

(d) Pulse Shaper Card (Card no. 4):

This is a double-sided PCB (Size: 225mm X 275mm). It contains four
identical channels, each consisting of a low pass filter, an Schmitt trigger, an
impulse time filter and a 10 V to 5 V level converters. The outputs of these
channels are TTL compatible. In addition to above, each channel comprises of a
Trolley Suppression Circuit.
For 1D and 2D Systems, there will be one such card (Card no. 3) while for
3D and 4D Systems, the evaluator will have two nos. of such cards (Card nos. 3
& 4).

(e) Logic – I (Card no. 5):

This is a double-sided PCB (Size: 225mm X 275mm). This card generates
‘IN COUNTS’ and ‘OUT COUNTS’, depending upon the direction of the train
movement, due to the dips caused form the track transducers E, F, G, H. In
addition to main count pulses, duplicate incount and outcount pulses are also
generated here for supervision purpose. The ‘IN COUNT’, ‘OUT COUNT’,
‘Duplicate In count’ and ‘Duplicate Out count’ pulses are fed separately to
different combiner gates housed in card 6 (Logic II) and thereafter fed to the
counter card (Card 7) for further processing.
 As E, F, G, H channel inputs are used only in case of 3D or 4D Systems,
card 5 will be used only with the 3D and 4D Evaluators.

(f) Logic – II (Card no. 6):

This is also a double-sided PCB (Size: 225mm X 275mm). This card
houses the logic circuitry to generate ‘IN COUNTS’, ‘OUT COUNTS’,
‘DUPLICATE IN COUNTS’ and ‘DUPLICATE OUT COUNTS’ due to the dips
caused from channel inputs from the track detection points A, B, C and D. It also
has combiner gates, which combine the count pulses generated from all the
detection points AB, CD, EF and GH. The outputs of these gates are fed to the
counter card (Card no. 7) for counting and counts supervision.
Card 6 also has an ‘INTERROGATOR’ circuit. This generates four clock
pulse trains. All these four pulse trains are staggered in phase, with each of
these pulse trains having a phase difference of 25µ sec. As compared to the
subsequent one.
The interrogator ensures that even if more than one incount or more than
one outcount are fed simultaneously from different detection point, the final count
pulses fed to the counter card get staggered and thus counts are not missed.
In addition to above, this PCB also houses the IN/OUT supervision
circuits, both counter checking each other. In case of any malfunction the system
latches to failure condition. This card also houses the 1st outcount inhibit circuit
which ensures latching up of the system in the event of 1st count getting
registered being an ‘OUT COUNT’ instead of an ‘IN COUNT’.

(g) Counter Comparator (Card no.7):

This is a double-sided PCB (Size: 225mm X 275mm). This card houses
two 10 stage digital counters. One for counting the ‘IN COUNTS’ and the other
for ‘OUT COUNTS’. It also has count super- vision circuits, both for in counts as
well as the out counts, to check the integrity of the counters. In addition, there are
two comparators; one being a duplicate of the other, to compare the counts from
the two counters the ‘IN COUNTER’ and the ‘OUT COUNTER’.
 The outputs of the comparators are further compared with EX-OR chain to
ensure integrity of the comparators.

(h) General Supervision Card (Card no. 8):

This is a double-sided PCB (Size: 225mm X 275mm). It houses the following
evaluator circuits:
(i) Comparator Supervision.
(ii) A series of monoshots forming a chain for static supervision i.e. to
prove the effectiveness of a number of DC levels of the system and a
few ground points.
(iii) Pulse Shaper (Card no. 3 and 4) supervision for all the eight channels.
(iv) Failure Supervision.

(i) Relay Driver (Card no. 9):

This is a double-sided PCB (Size: 225mm X 275mm) and it houses the following
circuits:
(i) Level detector circuits for all the 8 channel inputs to ensure the presence
of proper channel input levels.
(ii) The ‘VOLTAGE MONITOR’, which serves as, a
‘WATCH DOG’ for the +5V power supply to the
Evaluator.
(iii) Relay driver outputs for driving the EV relay and the
supervisory relay.

(j) Counts Display Card:

This is a double sided PCB (Size: 225mm X 275mm) containing four
seven segment LED’s for ‘IN COUNTS’ and four seven segment LED’s for ‘OUT
COUNTS’ and it can count upto 1023 counts in both the display. This card is
mounted on front panel of evaluator and counts are recorded in decimal system.
 (k) EV & SUP Relay Indication LEDs:
The output of the Evaluator is used to drive two 12 Volts DC, 4F/4B shelf
type relays or 12 Volts DC, Q-style 4F/4B plug-in relays which are used to
indicate the track clear or track occupied indications to control signal aspects.
Two 10 mm dia. LEDs (Green and Red) have been provided in the front side of
the Axle Counter Rack in a metallic strip for locally displaying the position of the
above relays. These LEDs have to be suitably wired at the time of installation as
per requirements from the terminal strip connections provided at the rear side of
the Axle Counter Rack.

(l) Mother Board:

This is a double-sided PCB (Size: 420 mm X 260 mm) mounted at the
back of the Evaluator. The PCB is mounted at right angles to the other 10 PC
Cards and serves the purpose of providing various interconnections between
them. The female parts of the Euro Connectors are mounted on this PCB and
corresponding male parts which are mounted on the PCBs (Cards 1 to 10) mate
with them when the card modules are inserted in the unit. The motherboard also
provides access, through MS Couplers, to feed various inputs like channel inputs
from the tracks, power supply and trolley protection and to feed outputs to the EV
and the Supervisory Relays kept in the rack.

(m) Reset Relay:

This is mounted at the back of the Evaluator on the motherboard. A 67DP-
24-4C3 OEN Relay is mounted on this PCB with a mounting socket. This Relay
resets the System whenever required to do so.
 I. ELECTRONIC JUNCTION BOX (EJB)
The Electronic Junction Box houses PCB modules which are inter- connected
through motherboard. All the incoming / outgoing signals are terminated on
the MS Couplers (7 pin) mounted at the back of the junction box. Two types
of outputs are available from the EJB. The output of the EJB is sent to the
Evaluator either through a 4 wire or a 2-wire system.

(A) 4-WIRE SYSTEM:

In a 4-Wire System, two pairs of under ground cable are required to send
transition signal to evaluator for counting the dips. In this system there are
three PCBs consisting of common oscillator feeding to two transmitter coils in
series and two number of receiver amplifiers, one for each receiver coil. The
sequence of cards is, regulator and oscillator in first position, first amplifier in
2nd position and second amplifier in the 3rd position from left to right.

Detail of individual cards:

CARD No. 1:
Regulator / Oscillator Card. (Size: 200 mm X 110 mm)
This is a single sided PCB (size: 200mm X 110 mm), which generates 5 KHz
±20 Hz sinusoidal signal which is fed to the transmitter coils in series. The
output voltage is 60 V ± 10% (rms) and current supplied is 420 mA ± 10% in
the coils in series.

CARD No. 2:
Receiver Amplifier-1. (Size: 200 mm X 110 mm)
This is a single sided PCB of size same as that of card 1 and it rejects any
noise over riding in the signal by means of a two stage tuned amplifier. The
output of the receiver coil (1) is fed to the input of the amplifier. The output of
the amplifier is connected to the Evaluator and voltage is more than 1.2 V
(rms).

CARD No. 3:
Receiver Amplifier-2. (Size: 200 mm X 110 mm)
This card is exactly similar to card no. 2 and is used for receiver coil (2).

(B)2-WIRE SYSTEM:
In 2-wire system, a 4th card is inserted in the EJB, which converts the
frequency of the second receiver amplifier signal to 3.5 KHz with the use of
converters. Thus, 2-wire system is having output on 2-wire and consists of 4
cards, namely the regulator / oscillator card, the receiver amplifier card-1, the
receiver amplifier card-2 and 4W / 2W card. This is used in block working at
Advance starters only.

The sequence of cards is:

(i) Regulator / Oscillator Card.
(ii) Receiver Amplifier Card-1.
(iii) Receiver Amplifier Card-2.
(iv) 4W / 2W Converter Card.

II. RESET BOX

This box houses one 12 way PIRI terminal strip for terminating IN / OUT
signals. The indication LEDs of the reset box are fitted in LED holders and
projected to the front for indication. Green and Red indications are given for
track clear and track occupied conditions. The Yellow LED indicates co-
operative permission for resetting the Axle Counter.
 III. TRACK DEVICE ASSEMBLY
The Single Rail Track Device Assembly consists of two transmitter and
two receiver coils assembly, which are fitted with suitable mounting
arrangements on the rail camp, which in turn is fitted to the rails. The two
transmitter coils at each of the detection point are fed in series by a 5 KHz
sinusoidal signal from the junction box, which forms an electromagnetic field
across the receiver coils. The receiver coil in turn generates induced
voltage. The induced voltage drops to a minimum whenever there is an axle
between the transmitter and the receiver coils.

(a) Track Device Transmitter:

The transmitter coil is placed in a FRP housing and it is potted in place
by m-seal compound. It is fixed on the rail clamp on the outer side of the
rail. Each transmitter coil will be provided with a 10 meter, 24 / 0.2 PVC
cable.

(b)Track Device Receiver:

The receiver coil is housed in a composite aluminum fiber glass housing
and is potted in place by the means of an m-seal compound. The
receiver housing is fixed on the base clamp on the inner side of the rail.
Each receiver coil will be powered with a 10 meter, 24 / 0.2 PVC cable.

IV. POWER SUPPLY

A DC–DC Converter, feeds the Power Supply, to the Evaluator. The various
output voltage of the DC–DC Converter are as follows:

+ 5 V@ 5Amp. with ± 0.1% line & load regulation.

+ 5 V@ 5Amp. with ± 0.1% line & load regulation.
+ 10 V isolated @500 mA.
 The DC-DC Converter in turn derives its power from a + 24 V dc source i.e. a
battery bank.
The Junction Box (JB - 531) and the Reset Box (RB – 257B) are also
powered from + 24 V dc battery bank.
All the supplies have over current protection while 5V supply has additional
crow bar protection at 6.2 volts.

PRODUCTION TESTING & TEST PROCEDURE

The semi – conductor devices like diodes and transistors used are of high
reliability type. The other vital components like ICs mostly are the commercial
grade ICs which will undergo burn in at 60°C with dc power ‘ON’ for 72 hours.
This will eliminate the failure of critical components after the assembly of the
PCB.

Wave Soldering:
All the PCB’s assembly will be wave soldered for good reliability and also coated
with lacquer to withstand climatic conditions.

Inspection:
Each unit will be examined for proper workmanship, fitness, finish and proper
markings. Also each unit will be tested thoroughly as per the test schedules
mentioned in the test report before the final shipment.
 SPECIAL FEATURES
The Universal Axle Counter has the following special features:
a) PCB LAYOUT:
Better PCB layouts to have supply feeding and decoupling for better noise
immunity.

b) MOTHER BOARD:
The use of motherboard gives extra noise immunity as compared to back
panel wiring.

c) RACK:
The Evaluator is housed in a rack fabricated out of M.S. sheet. This gives
good noise immunity against electromagnetic interference.

d) SHIELDING:
The Rack is well shielded for better noise immunity. All the metallic frames
of the rack are interconnected to the main frame by means of 34 / 0.3 wire.
Shielded cables will be used in system, shield of which is connected to the back
panel of the Evaluator.

e) CARD INSERTION:
Each Card along with a module is guided separately.

f) CARD MODULES:
Each Card is provided with a module along with the identification label.

g) CARD POLARISATION:
Polarizing holes on the card modules and guiding pins from the Mother
Board side are used to provide card polarization to ensure correct card slotting.
h) MODULE TIGHTENING SCREWS AND CARD HANDLES:
Module tightening screws are provided to fix the cards along with the
module in the unit smoothly. By loosening, the cards can be removed from the
unit. Two card handles are provided on each module. The modules can be taken
out with the help of these handles.

i) COUNTS DISPLAY:
The Counts display is given on a PCB and mounted on the front panel
inside and is viewed through display viewing plate at the front panel of the
Evaluator.

j) EVALUATOR MARKINGS:
In each unit input /output labels, the supply, channel markings and trolley
protection A / B, C / D are marked.