CHAPTER 1

INTRODUCTION

1.1 OBJECTIVE

In India rail transport occupies a prominent position in providing the

necessary transport infrastructure to sustain needs of a rapidly growing
economy. Today, India possesses the fourth largest railway network in the
world. However, in terms of the reliability and safety parameters, we have not
yet reached truly global standards. The main problem about the railway analysis
is the detection of cracks in the structure. Detection and maintenance of rail
defects are major issues for the rail community all around the world.

1.2 SCOPE OF THIS WORK

The overall aim of the present work is to make use of existing working
principle of a railway network to control automatic crack detection in railway
track with the help of Electromagnetic tomography and microcontroller using
Embedded system. To avoid accidents that occur in rail.

1.3 EMBEDDED SYSTEM

1.3.1 INTRODUCTION

A system is something that maintains its existence and functions as a

whole through the interaction of its parts. E.g. Body, Mankind, Access Control,
etc. A system is a part of the world that a person or group of persons during
some time interval and for some purpose choose to regard as a whole, consisting
of interrelated components, each component characterized by properties that are
selected as being relevant to the purpose.

1
 Embedded System is a combination of hardware and software used to
achieve a single specific task. Embedded systems are computer systems that
monitor, respond to, or control an external environment. Environment is
connected to systems through sensors, actuators and other I/O interfaces.

An embedded system is a microcontroller-based, software driven,

reliable, real-time control system, autonomous, or human or network
interactive, operating on diverse physical variables and in diverse environments
and sold into a competitive and cost conscious market.

An embedded system is not a computer system that is used primarily for

processing, not a software system on PC or UNIX, not a traditional business or
scientific application. High-end embedded & lower end embedded systems.
High-end embedded system - Generally 32, 64 Bit Controllers used with OS.

1.4 ELECTROMAGNETIC TOMOGRAPHY

Electromagnetic waves are named for the fact that they have both an
electric and a magnetic component. They begin when charged particles, like
electrons, vibration due to the various forces acting on them. The vibration of
charged particles result in an emission of energy known as electromagnetic
radiation. EMT, also called magnetic inductance tomography, is one type of
electrical tomography used to image cross sections of multiphase ow pipe in
industrial process.

The sensor of EMT system can generate AC magnetic eld by excitation

coils. The detection coils are mounted around the measured space can detect the
stray magnetic elds. Therefore, it is possible to use EMT to extract more
detailed information from rail than by the traditional eddy-current inspection
method. But in rail defect inspection case, the EMT sensor coils cannot be

2
installed as encircling the rail due to limitation of mechanical structure of the
rail track and relative facilities, including rail bed mounting clips and turnout
junction. To adapt the measurement condition, non-encircling sensor structure is
designed to meet the tomography excitation and detection requirements. The
sensor coils array is arranged as L-shape to cover the region of rail head corner
which is the contacting region of rail and train wheel. Therefore, it is possible to
use EMT to extract more detailed information from rail.

1.5 RELAY

Relay is a switch operated device. Relay contains two circuits they are
load circuit and control circuit, which is used in the application of ON and OFF
of a circuit by a low power signal or several circuits that can be controlled by
one signal. If there is any crack in the rail, it will open if no crack it will be in a
closed state. Relay is used to control the signal.

Fig 1.1 Relay

3
1.6 PIC MICROCONTROLLER

This section forms the control unit of the whole project. It is basically
consists of a microcontroller with its associated circuitry like crystal with
capacitors, reset circuitry, pull up resistors (if needed) and so on. The
microcontroller forms the heart of the project because it controls the devices
being interface and communicates with the devices according to the program
being written.

1.7 GENERAL PURPOSE OF EMT:

Electromagnetic wave can travel through a vacuum like in space. This

is possible because they are not vibrating in an actual material. They are
fluctuating in electric and magnetic field.

All electromagnetic waves move at the speed of light. In fact, physicists

use the word light to refer to any kind of electromagnetic wave even once that
cant be seen with our eyes. Every part of the electromagnetic spectrum have
multiple applications in our everyday lives, many of those application involves
technology.

Fig 1.2 Emt rail defect inspection

4
1.8 EXISTING SYSTEM

The existing track surveying systems have some limitations. It takes

more time and it is less accurate. Different methods have different limitations.
After many years of eld application practice, ultrasonic rail defect inspection
has been used as the most popular method because of its sufcient resolution
and application convenience. Nevertheless trains running speed, and running
interval time decreasing, the inspection speed limitation of the ultrasonic rail
defect inspection method makes it more difcult to meet the requirement of
railway industry. The highest reported eld application speed for the ultrasonic
rail defect inspection is <80 km/h. Inspection train is equipped with the
ultrasonic rail defect inspection system running at low speed can block the train
trafc, and therefore it heavily inuences the rail transportation efciency.

1.9 PROPOSED SYSTEM

Now a days crack detection in railway track is carried out with the use
of an electromagnetic tomography. When compared to before, this project uses
less number of coils and also a simple technique. The R&D department and
many places are trying to use these crack detection technique in railway track.
Hardware requirements are metal, signal post, pantograph, post for carrying
pantograph, train, DC motor, PIC microcontroller and battery, and software
requirements are MATLAB.

1.10 HARDWARE DESCRIPTION

The implementation of the project is with the help of hardware interface

to the software. The output of the hardware is viewed and analysed in the
remote station.

5
The hardware components used in the project are microcontroller, relay,
electromagnetic coil, motor, pantograph, transformer, regulator.

1.10.1 PIC MICROCONTROLLER

Peripheral interface controller

1.10.1.1 INTRODUCTION

The term PIC is the name given by microchip technology to its single
chip microcontroller. These devices have been phenonmenally successful in
market for many reason have grown in popularity over last decades ever sense
their inception into the market in early 1990s.PIC micros have grown to
become the most widely used microcontroller in the eight bit microcontroller
segment .The 16F877 is 40 pin IC. There are six ports in the microcontroller.
Namely PORTA, PORTB, PORTC, PORTD, PORTE. Among these ports,
PORTD, PORTC, PORTB contains eight pins, where PORTA contains six pins
and PORTE contains three pins.

The main factors that account for the popularity of PIC microcontroller are
following:

SPEED: When operated as its maximum clock rate, a PIC execute an

instruction at 0.2 microseconds.

INSTRUCTION SET: The instruction set consists of just 35 instructions.

INTEGRATION OF OPERATIONAL FEATURES: A PIC micros have the

features are POWER ON RESET and BROWN OUT protection which ensures
the chip operates only the power supply is within the specification. A watch dog
timer resets the PIC if the chip ever malfunction and deviates from its normal
operation.

6
SERIAL PROGRAMMING: PIC micros can be serially programed with two
pins, which bring down the complexity the cost of the PIC programmers
drastically.

HARVARD ARCHITECTURE: Apart from these features are reasons of

nontechnical nature like the availability of free development software, low cost
device programmers, and availability of free datasheets and application notes.

1.10.2 DC MOTOR

A DC motor is an electric motor that runs on direct current (DC)

electricity. In any electric motor, operation is based on simple
electromagnetism. A current carrying conductor generates a magnetic field,
when this is then placed in an external magnetic field, it will experience a force
proportional to the current in the conductor, and to the strength of the external
magnetic field. As you are well aware of from playing with magnets as a kids
opposite(North and South)polarities are attracts, while like polarities are repel.

The internal configuration of a DC motor is designed to harness the

magnetic interaction between a current-carrying conductor and an external
magnetic field to generate rotational motion. Every DC motor has six basic
partsaxle, rotor, stator, commutator and brushes. In most common DC motors,
the external magnetic field is produced by high-strength permanent magnets.
The stator is the stationary part of the motorthis includes the motor casing, as
well as two or more permanent magnet pole pieces. The rotor rotates with
respect to the stator. The rotor consists of windings, the windings being
electrically connected to the commutator.

7
1.10.3 SENSOR

1.10.3.1 PRINCIPLE

American National Standards Institute A device which provides a

usable output in response to a specified measured. A sensor acquires a physical
quantity and converts it into a signal suitable for processing (e.g. optical,
electrical, mechanical) Nowadays common sensors convert measurement of
physical phenomena into an electrical signal. Active element of a sensor is
called a transducer.

A sensor is a device that measures a physical quantity and converts it

into a 'signal' which can be read by an observer or by an instrument. For
example, a mercury thermometer converts the measured temperature into the
expansion and contraction of a liquid which can be read on a calibrated glass
tube. There are a lot of different types of sensors. Sensors are used in everyday
objects.

1. Thermal sensors,
2. Electromagnetic sensors,
3. Mechanical sensors,
4. Motion sensors,
5. Car sensors.

1.10.3.2 ELECTROMAGNETIC SENSOR

An electronic device used to measure a physical quantity such as

pressure or loudness and convert it into an electronic signal of some kind (e.g. a
voltage)

8
1.10.4 PANTOGRAPH

A pantograph (or pan) is an apparatus mounted on the roof of an

electric train, tram or electric bus to collect power through contact with the
overhead catenary wire. It is a common type of current collector. Typically, a
single wire is used, with the return current running through the track.

1.10.4.1 INVENTION

The pantograph was invented in 1879 by Walter Reichel, chief engineer

at Siemens&Halske in Germany. A flat slide-pantograph was invented in 1895
at the Baltimore & Ohio Railroad.

The familiar diamond-shaped roller pantograph was invented by John Q.

Brown of the Key system shops for their commuter trains which ran between
San Francisco and the East Bay section of the San Francisco Bay Area in
California.

October 1903. For many decades thereafter , the same diamond shape
was used by electric-rail systems around the world and remains in use by some
today. The pantograph was an improvement on the simple trolley pole, which
prevailed up to that time, primarily because the pantograph allows an electric-
rail vehicle to travel at much higher speeds without losing contact with the
overhead lines.

9
 Fig 1.3 Pantograph

1.10.4.2 TECHNICAL DETAILS

The electric transmission system for modern electric rail systems

consists of an upper, weight-carrying wire (known as a catenary) from which is
suspended a contact wire.

The pantograph is spring-loaded and pushes a contact shoe up against

the underside of the contact wire to draw the current needed to run the train. The
steel rails of the tracks act as the electrical return. As the train moves, the
contact shoe slides along the wire and can set up standing waves in the wires
which break the contact and degrade current collection. This means that on
some systems adjacent pantograph are not permitted.

Pantograph are the successor technology to trolley poles, which were

widely used on early street car systems. Trolley poles are still used by
trolleybuses, whose freedom of movement and need for a two-wire circuit
makes pantographs impractical, and some streetcar networks, such as the
Toronto streetcar system, which have frequent turns sharp enough to require

10
additional freedom of movement in their current collection to ensure unbroken
contact. However, many of these networks, including Toronto's, is undergoing
upgrades to accommodate pantograph operation. Pantographs with overhead
wires are now the dominant form of current collection for modern electric trains
because, although more fragile than a third rail system, they allow the use of
higher voltages.

Pantographs are typically operated by compressed air from the vehicle's

braking system, either to raise the unit and hold it against the conductor or,
when springs are used to effect the extension, to lower it. As a precaution
against loss of pressure in the second case, the arm is held in the down position
by a catch. For high-voltage systems, the same air supply is used to "blow out"
the electric arc when roof-mounted circuit breakers are used.

1.10.5 VOLTAGE REGULATOR

A voltage regulator is to maintain the constant DC voltage level or the

voltage stabilizer. That is design to automatically stabilize a constant voltage
level. A voltage regulator circuit is also used to change or stabilize the voltage
level according to the necessity of the circuit.

Thus, a voltage regulator is used for two reasons :

1. To regulate or vary the output voltage of the circuit.

2. To keep the output voltage constant at the desired value inspite
of variations in the supply voltage or in the load current.

Here, In this project two voltage regulator are used.one regulator (7809)
is connects to an overhead line and another one (7805) is connected to the
microcontroller.

11
 Fig1.4 Voltage Regulator

1.10.6 RELAY

Relay is a electromagnetic switch. It consists of two circuits one is

control circuit and another one is load circuit. When control circuit is turned on
current starts flowing through a coil it generates a magnetic field that attracts
the armature and the load circuit is closed.

The relay has four parts they are Electromagnet, Movable armature,
Switch point contact, Spring .

Fig1.5 Control circuit

12
 Fig1.6 Load circuit

The normally opened relay, the contact is open when the relay is not
energized. And the other type is normally closed, here contact is closed when
the relay is energized.

The advantage of relay is that it permits a low voltage DC circuit to

control a completely separate high power circuit. Within a relay is a coil of wire
which generates the magnetic field when a current flows through it. The relay is
a system and is not a single circuit.

The relay contain the diode that diode is always in reverse bias. When a
relay is switched off there can be a short lived high voltage spike of electricity,
which can damage sensitive chips and transistors in the circuit.

13
 Fig 1.7 Relay circuit

1.11 SOFTWARE DESCRIPTION

1.11.1 EMBEDDED C

Embedded C is a set of language extensions for the C Programming

language by the C Standards committee to address commonality issues that
exist between C extensions for different embedded systems. Historically,
embedded C programming requires nonstandard extensions to the C language in
order to support exotic features such as fixed-point arithmetic, multiple distinct
memory banks, and basic I/O operations.

In 2008, the C Standards Committee extended the C language to address

these issues by providing a common standard for all implementations to adhere
to. It includes a number of features not available in normal C, such as, fixed-
point arithmetic, named address spaces, and basic I/O hardware addressing.

14
 Embedded C uses most of the syntax and semantics of standard C, e.g.,
main() function, variable definition, datatype declaration, conditional statements
(if, switch, case), loops (while, for), functions, arrays and strings, structures and
union, bit operations, macros, etc.

1.11.2 ADVANTAGES

1. It is small and simpler to learn, understand, program and debug.

Compared to assembly language, C code written is more reliable and
scalable, more portable between different platforms.
2. C compilers are available for almost all embedded devices in use today,
and there is a large pool of experienced C programmers.
3. Unlike assembly, C has advantage of processor-independence and is not
specific to any particular microprocessor/microcontroller or any system.
4. This makes it convenient for a user to develop programs that can run on
most of the systems. As C combines functionality of assembly language
and features of high level languages, C is treated as a middle-level
computer language or high level assembly language.
5. It is fairly efficient. It supports access to I/O and provides ease of
management of large embedded projects. Java is also used in many
embedded systems but Java programs require the Java Virtual Machine
(JVM), which consumes a lot of resources.

Hence it is not used for smaller embedded devices. In Embedded we

need read/write data on given address, so in C its Easy to access and modify,
because of its pointer concept.

1.11.3 C COMPLIER

15
 C compiler is fully optimised for use with PIC microcontrollers. Built in
functions make coding the software very easy. Based on original K&R, the
integrated C development environment gives developers a fast method to
produce efficient code from an easily maintainable high level language.

1.11.3.1 CAPABILITIES

Arrays up to 5 subscripts Structures and Unions may be nested.

Custom bit fields (1-8 bits) within structures. Enumerated types,CONST
variables, arrays and strings. Full function parameter support (any number).

Some support for C++ reference parameters. Built in libraries for

RS232 serial I/O library, I/O, I2C, discrete I/O and precision delays. Integrates
with MPLAB and other simulators/emulators for source level debugging.
Standard Hex file and debug files ensure compatibility with all programmers.

Formatted Printf allows easy formatting and display in Hex or decimal.

Efficient function implementation allows call trees deeper than the hardware
stack. Access to hardware from easy to use C functions, Timers, A/D, E2, SSP,
PSP, I2C & more. 1,8, and 16 bit types. Assembly code may be inserted
anywhere in source and may reference C variables. Automatic linking handles
multiple code pages. Inline procedures supported; Linker automatically
determines optimum architecture or it can be manually specified.

Compiler directives determine if tri-state registers are refreshed on every

I/O. Constants (including strings and arrays) are saved in program memory.
Standard one-bit type (Short Int) permits the compiler to generate efficient Bit
oriented code. #BIT and #BYTE allow C variables to be placed at absolute

addresses to map register to C variables. Reference parameters may be used to

improve code readability and inline procedure efficiency. Both an Integrated

16
editor/compiler and a cmd line compiler Special windows show the RAM
memory map, C/Assembly listing and the calling tree. Interrupt procedures
supported on PCM. The compiler generates all start up and clean up code as
well as identifying the correct interrupt procedure to be called.

1.11.3.2 DESCRIPTION

This integrated C development environment gives developers the

capability to quickly produce very efficient code from an easily maintainable
high level language. The compiler includes built in functions to access the PIC
hardware such as READ_ADC to read a value from the A/D converter. Discrete
I/O is handled by describing the port characteristics in a PRAGMA. Functions
such as INPUT and OUTPUT_HIGH will properly maintain the tri-state
registers. The microcontroller clock speed may be specified in a PRAGMA to
permit built in functions to delay for a given number of microseconds or
milliseconds. Serial I/O functions allow standard functions such as GETC and
PRINTF to be used for RS-232 like I/O.

The hardware serial transceiver is used for applicable parts when

possible. For all other cases a software serial transceiver is generated by the
compiler. The standard C operators and the special built in functions are
optimised to produce very efficient code for the bit and I/O functions. Functions
may be implemented inline or separate. Function parameters are passed in
reusable registers.

1.11.4 MPLAB

17
 MPLAB is a free integrated development environment for development
embedded applications on PIC and SPIC microcontrollers, and is developed
by Microchip Technology.

MPLAB X is the latest edition of MPLAB, and is developed on the Net

Beans platform. MPLAB and MPLAB X support project management, code
editing, debugging and programming of Microchip 8bit, 16-bit and 32-bit PIC
microcontrollers.

MPLAB is designed to work with MPLAB-certified devices such as the

MPLAB ICD 3 and MPLAB REAL ICE, for programming and debugging PIC
microcontrollers using a personal computer. PIC Kit programmers are also
supported by MPLAB.

MPLAB 8.X is the last version of the legacy MPLAB IDE technology,
custom built by Microchip Technology in Microsoft Visual C++. MPLAB
supports project management, editing, debugging and programming of
Microchip 8-bit, 16-bit and 32-bit Microcontrollers.

1.11.4.1 MPLAB X IDE

MPLAB X IDE is a software program that runs on a PC (Windows,

Mac OS, and Linux) to develop applications for Microchip microcontrollers
and digital signal controllers. It is called an Integrated Development
Environment (IDE), because it provides a single integrated "environment" to
develop code for embedded microcontrollers.

CHAPTER 2

18
 LITERATURE REVIEW

[1] The eddy current testing can be a practical technology for developing an on-
train real-time rail defect inspection system. It is because the eddy-current
testing has the advantage of non-contact operation, the speed of eddy current
rail inspection is not limited by the requirement of being in contact with the rail.
The inspection speed is only limited by the excitation and detection signals
transfer and the post signal processing speed. Therefore, by selecting the
optimized excitation frequency and using the fast signal processing device such
as Field Programmable Gate Array (FPGA), the inspection speed can easily
exceed 100km/hr. But here many number of electromagnetic coils are used.

[2] This project aims in designing railway track crack detection autonomous
vehicle using microcontroller, IR obstacle sensors assembly systems, which
detects the cracks along its path, the vehicle is also capable of monitoring the
location of the crack by using the GPS module and alerts through SMS
messages using GSM module. The central component of the whole system is a
PIC microcontroller. The vehicle is powered with the help of solar panel and
Lead Acid Battery assembly. The vehicle moves along the path of railway track
and IR obstacle sensors mounted on the vehicle front end will inspect the track
along the path. When any crack of deformation is detected on the track the
vehicle stops and the location of the track is identified and the location latitude
and longtitude coordinates in the form of short message service (SMS) to the
pre-defined number. But here the driver need to control the train.

19
[3] The inspection methods use different principles including sound, optic,
electromagnetic, thermal, and radiation. Different methods have different
limitations, after many years of field application practice, ultrasonic rail defect
inspection has been used as the most popular method because of its sufficient
resolution and application convenience. Nevertheless trains running speed, and
running interval time decreasing, the inspection speed limitation of the
ultrasonic rail defect inspection method makes it more difficult to meet the
requirement of railway industry. The highest reported field application speed for
the ultrasonic rail defect inspection is <80km/hr. Inspection train equipped with
the ultrasonic rail defect inspection system running at this low speed can block
the train traffic, and therefore it heavily influences the rail transportation
efficiency. And another popular rail defect inspection method is using the
inspection handcarts can only be used in between the trains running interval
time. For some busy lines, the interval time between trains falls
<10min.Therefore with the trains running interval time decreasing , inspection
workers are too busy and it is dangerous to move the hand cart on and off the
rail. Therefore, the railway service department urgently needs a new rail defect
inspection method to improve inspection efficiency.

[4] The main problem about a railway analysis is detection of cracks in the
structure. If these deficiencies are not controlled at early stages they might lead
to a number of derailments resulting in a heavy loss of life and property. This
paper proposes a cost effective solution to the problem of railway track crack
detection utilizing LED-LDR assembly which tracks the exact location of faulty
track which then mended immediately so that many lives will be saved The
proposed system will overcome the limitations of both the traditional and the
current system that are using for detection of faulty tracks. In the current system
we dont get the exact location of the faulty track. We only receive latitudes and

20
longitudes of the location. In the proposed system we are using Gprs module so
that we can get the exact location of the broken rail track. In this proposed
system we are also using ARM7 controller which consumes low power and also
less cost. By using the ARM controller the analysis time of the proposed will be
reduced drastically. Before the start of the railway line scan the robot has been
programmed to self-calibrate the LED-LDR arrangement. It is necessary
because the LDR has a natural tendency to show a drifting effect because of
which, its resistance under the same lighting condition may vary with time.
After calibration, the robot waits for a predetermined period of time so that the
on board GPS module starts reading the correct geographic coordinate .

21
 CHAPTER 3
DESIGN OF CRACK DETECTION IN RAIL

3.1 WORKING MODEL

The working model of our project is based on the RAILWAY

ELECTRIFICATION SYSTEM AND WORKING PRINCIPLE OF SIGNAL
POST

3.1.1 RAILWAY ELECTRIFICATION SYSTEM

Railway Electrification System supplies electric power to railway trains

and trams without an on-board prime mover or local fuel supply .Electrification
has many advantages but requires significant capital expenditure. Selection of
an electrification system is based on economics of energy supply, maintenance,
and capital cost compared to the revenue obtained for freight and passenger
traffic. Different systems are used for urban and intercity areas; some electric
locomotives can switch to different supply voltages to allow flexibility in
operation.

3.1.2 TRANSFORMER

Electrical power transformer is a static device which transforms

electrical energy from one circuit to another without any direct electrical
connection and with the help of mutual induction between two windings. It
transforms power from one circuit to another without changing its frequency but
may be in different voltage level. The working of transformer is very simple. It
depends upon Faradays Law of Electromagnetic Induction.

22
 Actually, mutual induction between two or more winding is responsible
for transformation action in an electrical transformer. In this project, transformer
converts an 230V ac power supply to 9V for overhead line and 5V to
microcontroller and Relay.

3.1.3 RECTIFIER

A rectifier is an electrical device that converts alternating current (AC),

which periodically reverses direction (DC) , which flows in only one direction .
The process is known as rectification. . Physically, rectifiers take a number of
forms, including vacuum tube diodes, mercury-arc valves, copper and selenium
oxide rectifiers, semiconductor diodes, silicon-controlled rectifiers and other
silicon-based semiconductor switches. In this project, rectifier also used to
convert an ac to dc.

3.1.4 MAGNETIC COIL

Magnetic coil is placed inside the train and track for generating an
electromagnetic waves to detect the crack in the rail. If wrap a copper wire into
coils and run an electrical current through it, it will create a magnetic field.
When you put the train inside the coils, it causes an electrical current to flow
through the copper wire, which creates a magnetic field in the section of wire
coils right around the train car. This magnetic field has its own north and south
poles, which push the train along the track. In this project power supply is given
to the overhead line and an overhead line is given to a magnetic coil which
helps the run the train and also produces an electromagnetic waves.

23
3.1.5 RELAY

Relay is a switch operated device. It is act as a electromagnetic switch in

this project. And power supply is also given to the relay is shown in the block
diagram. If crack is detected in the railway track, the main operation of relay is
switched to the red signal. Else no crack is detected in the railway track, then
relay switched to the green signal. Relay output is given to the microcontroller
to control the signal post for changing either red signal or green signal.

3.1.5 SIGNAL POST

A signal is a mechanical or electrical device erected beside a railway

line to pass information relating to the state of the line ahead to train/engine
drivers (engineers in the US). Typically, a signal might inform the driver of the
speed at which the train may safely proceed or it may instruct the driver to stop.
But in this project, Signal post is a operated automatically which is controlled
by the microcontroller. Microcontroller gives only green signal to the train to
pass and the signal is turned to red when train passes the signal post This
happen because of the sensing box consists of relay near the railway track it will
senses the electromagnetic wave generated from the wheel of the train and
track.

24
3.2 ARCHITECTURE OF PROPOSED SYSTEM

Fig 3.1 Block diagram

An input 230V ac supply is given as a source, then step down

transformer and rectifier converts an ac power to dc power supply. And voltage
regulator for maintaining the constant voltage level. Here two regulators are
used. This power supply given to an overhead line of a train. The magnetic coil
is fixed to the train wheel and the track. When current pass to the magnetic coil,
that coil get energized. Then the electromagnetic wave is produced.

The relay is act as a electromagnetic switch and used in the application

ON and OFF a circuit by a low power signal or several circuits must be ON and
OFF a circuit by a low power signal or several circuits must be controlled by
one signal. Relay has four parts, they are electromagnet, movable armature
switch point contacts and spring. So this project the relay is fixed inside the
pillar for every 500m. The relay construction is connected to the railway track.

25
3.3 FLOW CHART

Fig 3.2 Flow chart

The power supply is given to the rectifier to convert the AC to DC. The
DC current is given to the voltage regulators(7809 and 7805). That supply
voltage is given to the micro controller and the other voltage is for magnetic
coil. The signal post is controlled by the microcontroller due to the program
dumped in that chip. If there is any crack in the rail the relay gets opened, the
signal port shows red signal and the train gets stop. If there is no crack the
controller gives green signal to the port.

3.4 CIRCUIT DIAGRAM

26
 Fig 3.3 Circuit diagram

The PIC micro controller has 40 pins. it consists of two 8 bit and one 16
timer. And also the serial ports, parallel ports, and five input/output ports are
also present in it. The input and output ports are namely PORTA, PORTB,
PORTC, PORTD, PORTD. the crystal oscillator input is connected to the pin
13 and the oscillator was having two capacitors . they are connected to the pin
14 and also the switches.

The PORTB pin 33 is connected to the regulator pin 2. the resisters are
also connected to the switches and the pin 19 and pin 21. The motor also
connected to the controller and it will be set for the forward and reverse
movement for the train. All the switches will be grounded.

CHAPTER 4

RESULT AND CONCLUSION

27
4.1 RESULT

In this project the automatic crack detection in rail using the

electromagnetic waves and signal indication has been done. Therefore if there is
no crack in the railway track, the magnetic coil wont get energized thereby
switching to the green signal. If the crack is detected, the magnetic coil gets
energized and switches to the red signal. The train motor is so controlled and
thus the train gets stopped.

4.2 CONCLUSION

The method has been proposed that can make use of the existing railway
system to control automatic crack detection in the rail. The electromagnetic
tomography system is used which helps in preventing the accident that occurs
due to the crack in the rail.

FUTURE SCOPE

28
 This method also can be implemented to control automatic railway crack
detection and in future , it can be developed to make a fully automated railway
system with solar panel and less power, cost efficient is also low.

APPENDIX

29
PANTOGRAPH

MODEL TRAIN

SIGNAL POST

30
CIRCUIT CONNECTIONS

EXPECTED OUTPUT

31
APPENDIX

32
void main()

TRISD = 0XFF; // setting PORTD AS INPUT

TRISB=0X00; // setting PORTB AS OUTPUT

TRISC=0X00; // setting PORTC AS OUTPUT

PORTB=0x00; // MAKE PORTB AS 0

PORTD=0x00; // MAKE PORTD AS 0

PORTC=0X00; // MAKE PORTC AS 0

while(1)

if(PORTD.F0==1 && PORTD.F2==1) // FOR MAGNETIC SWITCH

delay_ms(10);

PORTC=0x5a;

PORTB.F0=0;

33
 PORTB.F1=0;

else if(PORTD.F0==1 && PORTD.F2==0)

PORTC=0X5A;

PORTB.F0=0;

PORTB.F1=0;

else if(PORTD.F0==0 && PORTD.F2==1)

PORTC=0X5A;

PORTB.F0=0;

PORTB.F1=0;

else

34
{

delay_ms(10);

PORTC=0x0f;

PORTB.F0=1;

PORTB.F1=0;

while(PORTD.F0==0 && PORTD.F2==0)

if(PORTD.F3 == 0) // POST 1 LED CHANGE FOR FORWARD DIRECTION

delay_ms(10);

35
 PORTC=0X1E;

PORTB.F0=1;

PORTB.F1=0;

if(PORTC==0X1E)

if(PORTD.F0==0 && PORTD.F2==0)

if(PORTD.F7==0) // POST 2 LED CHANGE FOR FORWARD DIRECTION

delay_ms(10);

PORTC=0X5a;

36
 if(PORTB.F0==1 && PORTB.F1==0)

while(PORTD.F5 == 0) // LIMIT SWITCH FOR REVERSE OPERATION

delay_ms(10);

PORTB.F0 = 0;

PORTB.F1=1;

PORTC=0XF0;

} }

if(PORTB.F0==0 && PORTB.F1==1)

if(PORTC==0xf0)

while(PORTD.F6 == 0)

37
delay_ms(10);

PORTB.F0 = 1;

PORTB.F1=0;

PORTC=0X0F;

}} }

if(PORTB.F0==0 && PORTB.F1==1 && PORTD.F7==0) // POST3 LED CHANGE

FOR REVERSE DIRECTION

PORTC=0XD2;

PORTB.F0=0;

PORTB.F1=1;

if(PORTB.F0==0 && PORTB.F1==1 )

if(PORTC==0XD2)

while(PORTD.F3==0) // POST4 LED CHANGE FOR REVERSE OPERATION

PORTC=0X5A;

PORTB.F0=0;

38
 PORTB.F1=1;

if(PORTB.F0==0 && PORTB.F1==1)

if(PORTC==0x5a)

while(PORTD.F6 == 0)

delay_ms(10);

PORTB.F0 = 1;

PORTB.F1=0;

PORTC=0X0F;

}} }

}}

REFERENCES

39
[1] Z. Liu, A. D. Koffman, B. C. Waltrip, and Y. Wang, Eddy current rail
inspection using AC bridge techniques, J. Res. Nat. Inst. Standards Technol.,
vol. 118, pp. 140149, Feb. 2013.

[2]Komal B. Dandge Int. Journal of Engineering Research and Applications,

Vol. 4, Issue 11(Version - 6), November 2014, Automatic Broken Rail Crack
Detection, Scheme by Komal B. Dandge, Prof. G.R.Gidveer.

[3]Prof. P.Navaraja Assistant Professor, Electronic and Communication

Engineering, Mahendra Institute of Technology, Namakkal, Tamilnadu, India.
"Crack Detection System for Railway Trackby Using Ultrasonic and PIR
Sensor," ISSN 2348 9928 IJAICT Volume -1, Issue-1, May 2014.

[4]Robust Railway Crack Detection Scheme (RRCDS) Using LEDLDR

Assembly, Selvamraju, Somalraju, VigneshwarMurali, GouravSaha, Dr. V.
Vaidehi.

[5]Detection of Cracks and Railway Collision Avoidance System, S. Ramesh

2010-2011.

[6]A. Wilkinson, Long range inspection and condition monitoring of rails

using guided waves, presented at the Proc. 12th Int. Conf. Exhib., Railway
Eng., London, U.K., 2013.

[7]V.Radha, Sreedevi, V.Sandhya" An Innovative Railway Track Surveying

System for Accident Reduction" ISSN 2319-8885 Vol.03,Issue.44 December
2014, Pages:8907-8910.

40
[8]Wojnarowski, Robert John Welles, Kenneth BrakeleyKornrumpf, and
William Paul, "Electromagnetic system for railroad track crack detection
and traction enhancement".

[9]Journal IJAICT Volume -1, Issue-1, May 2014, ISSN 2348 9928,
CRACK DETECTION SYSTEM FOR RAILWAY TRACK BY USING
ULTRASONIC AND PIR SENSOR, Prof. P.Navaraja Assistant Professor,
Electronic and Communication Engineering, Mahendra Institute of Technology,
Namakkal, Tamilnadu, India.

[10]http://www.npeducations.com/2013/01/railwaytrack-crack-detection-
robot.html.

[11]An article on LED-LDR Based Railway Crack Detection Scheme on

internet open access articles.

[12]A. Pascale, N. Varanese, G. Maier, and U. Spagnolini, A wireless sensor

network architecture for railway signalling, in Proc. 9th Italian Netw.
Workshop, Courmayeur, Italy, 2012, pp. 14.

[13]A. Z Lorestani ,S. A Mousavi, R. Ebadaty, Monitoring RailTraffic Using

Wireless Sensor Network (WSN), IJCSET ,June 2012, Vol 2, Issue 6,1280-
1282.

41