Project of Synopsis

On
“ RAILWAY CRACK TRACK DETECTION”
Submitted in the partial fulfillment of requirement for the award of the degree
BACHELOR OF TECHNOLOGY
In
Electronics & Communication Engineering
(ECE-4th year)
Submitted by:- Submitted to:-

RAHUL HARIJAN (1875131028) Mr. ARVIND MADDESHIYA

VIKAS KUMAR (1875131042) (ECE- Asst. Prof)

UPDENDRA SAHANI (1875131040)

ANCHAL GUPTA (1875131014)
KAJAL GUPTA (1875131017)

KIPM College of Engineering and Technology, GIDA – Gorakhpur

Dr. A P J ABDUL KALAM Technical University, LUCKNOW
Session: 2021-22
 Contents
1. Introduction

2. Block Diagram

3. Components & Description

4. Advantages

5. Conclusion and Future Work

 Introduction
• One of the major causes of such rail accidents according to the statistics is crack developed in railway track,
which may occur either due to improper maintenance or antisocial activities. The high frequency of trains
and the unreliability of manual labor have initiated the cause for an immediate system to monitor the
presence of crack on the railway lines.
• This report proposes an efficient and cost-effective solution suitable for large scale application. The basic
objective of our proposed work is to develop a low-cost breakage detection system of railway tracks using
ultrasonic sensors and send the location information of the fault to the authorized personnel for further
action.
 Block Diagram

GPS
Module

Block Diagram of Proposed System

Circuit Diagram
 Components & Description
Ultrasonic Ranging Module HC - SR04
 
• An ultrasonic sensor is an electronic device that measures the distance of a target object by emitting ultrasonic sound
waves, and converts the reflected sound into an electrical signal. Ultrasonic waves travel faster than the speed of
audible sound (i.e. the sound that humans can hear). Ultrasonic sensors have two main components: the transmitter
(which emits the sound using piezoelectric crystals) and the receiver (which encounters the sound after it has travelled
to and from the target). In order to calculate the distance between the sensor and the object, the sensor measures the
time it takes between the emission of the sound by the transmitter to its contact with the receiver. The formula for this
calculation is D = ½ T x C (where D is the distance, T is the time, and C is the speed of sound ~ 343 meters/second). The
ultrasonic sensors which basically work on the distance measurement are used for crack detection. These devices
typically Transmit a short burst of ultrasonic sound toward a target, which reflects the sound back to the sensor. The
system then measures the time for the echo to return to the sensor and computes the distance to the target using the
speed of sound in the medium. The prototype vehicle is made to move in-between the tracks. From the center of the
vehicle to the tracks, the distance is maintained. Whenever this distance increases, it is determined that the crack is
located in that particular place. 
• The basic principle of work: 
• Using IO trigger for at least 10us high level signal 
• The Module automatically sends eight 40 kHz and detect whether there is a pulse signal back. 
• IF the signal back, through high level , time of high output IO duration is the time from sending ultrasonic to returning.
• Test distance = (high level time × velocity of sound ~(340 M/S) / 2
HC SR04 Ultrasonic Sensor
 NEO 6M GPS MODULE
• The project robot has ability to sense locations with NEO-6M GPS Module
that can track up to 22 satellites and identifies locations anywhere in the
world. It may serve as a great launch pad for anyone looking to get into the
world of GPS. They are low power (suitable for battery powered devices),
inexpensive, easy to interface with and are insanely popular among
hobbyists. 
• GPS receivers actually work by figuring out how far they are from a number
of satellites. They are pre-programmed to know where the GPS satellites are
at any given time. The satellites transmit information about their position
and the current time in the form of radio signals towards the Earth. These
signals identify the satellites and tell the receiver where they are located.
The receiver then calculates how far away each satellite is by figuring out
how long it took for the signals to arrive. Once it has information on how far
away at least three satellites are and where they are in space, it can pinpoint
your location on Earth. This process is known as Trilateration.
 Global Positioning System

• NEO 6M GPS MODULE chip measures less than the size of a postage stamp but packs a surprising amount
of features into its little frame. It can track up to 22 satellites on 50 channels and achieves the industry’s
highest level of sensitivity i.e. -161 dB tracking, while consuming only 45mA supply current. Unlike other
GPS modules, it can do up to 5 location updates a second with 2.5m Horizontal position accuracy. The u-
blox 6 positioning engine also boasts a Time-To-First-Fix (TTFF) of under 1 second. One of the best
features the chip provides is Power Save Mode(PSM). It allows a reduction in system power consumption
by selectively switching parts of the receiver ON and OFF. This dramatically reduces power consumption
of the module to just 11mA making it suitable for power sensitive applications like GPS wristwatch. The
necessary data pins of NEO-6M GPS chip are broken out to a 0.1″ pitch headers. This includes pins
required for communication with a microcontroller over UART. The module supports baud rate from
4800bps to 230400bps with default baud of 9600. 
• ESP 32 CAM MODULE: 

• The ESp32-CAM has a very competitive small-size camera module that can operate independently
as a minimum system with footprint of only 27*40.5*4.5mm and a deep sleep current of up to
6mA. ESP-32Cam can be widely used in various IoT applications. It is suitable for home smart
devices, industrial wireless control, wireless monitoring, QR wireless identification, wireless
positioning system signals and other IoT applications. ESP-32CAM adopts DIP package and can be
directly inserted into the backplane to realize rapid production of products, providing customers
with high-reliability connection mode, which is convenient for application in various IoT hardware
terminals. The ESP32-CAM is a full-featured microcontroller that also has an integrated video
camera and microSD card socket. It’s inexpensive and easy to use, and is perfect for IoT devices
requiring a camera with advanced functions like image tracking and recognition. The sample
software includes a sketch that allows you to build a web-based camera with a sophisticated
control panel. After you get the hang of programming the device you’ll find that it is very easy to
use. Not bad for a board that costs about ten dollars, including the camera. The ESP32-CAM
module has fewer I/O pins than the previous ESP-32 module we looked at. Many of the GPIO pins
are used internally for the camera and the microSD card port. Another thing missing from the
ESP32-CAM module is a USB port. In order to program this device you’ll need to make use of an
FTDI adapter. This will be described further on in this article. Here is the pinout of the ESP32-CAM
Module:
Pin Diagram of ESP32 –CAM
ARDUINO UNO:

• Arduino Uno is a microcontroller board based on the ATmega328P (datasheet

). It has 14 digital input/output pins (of which 6 can be used as PWM
outputs), 6 analog inputs, a 16 MHz quartz crystal, a USB connection, a power
jack, an ICSP header and a reset button. It contains everything needed to
support the microcontroller; simply connect it to a computer with a USB cable
or power it with a AC-to-DC adapter or battery to get started.. You can tinker
with your UNO without worring too much about doing something wrong,
worst case scenario you can replace the chip for a few dollars and start over
again. "Uno" means one in Italian and was chosen to mark the release of
Arduino Software (IDE) 1.0. The Uno board and version 1.0 of Arduino
Software (IDE) were the reference versions of Arduino, now evolved to newer
releases. The Uno board is the first in a series of USB Arduino boards, and the
reference model for the Arduino platform; for an extensive list of current, past
or outdated boards see the Arduino index of boards.
• The Arduino Uno board can be powered via the USB connection or
with an external power supply. The power source is selected
automatically. External (non-USB) power can come either from an AC-
to-DC adapter (wall-wart) or battery. The adapter can be connected
by plugging a 2.1mm center-positive plug into the board's power jack.
Leads from a battery can be inserted in the GND and Vin pin headers
of the POWER connector. The board can operate on an external
supply from 6 to 20 volts. If supplied with less than 7V, however, the
5V pin may supply less than five volts and the board may become
unstable. If using more than 12V, the voltage regulator may overheat
and damage the board. The recommended range is 7 to 12 volts.

Arduino Diagram
MOTOR DRIVER SHIELD (L293D):
• The L293D is a dedicated module to fit in Arduino UNO R3 Board, and Arduino
MEGA. It is actually a motor driver shield that has full featured Arduino Shield can
be used to drive 2 to 6 DC motor and 4 wire Stepper motor and it has 2 set of pins
to drive a SERVO. L203D is a monolithic integrated that has a feature to adopt
high voltage, high current at four channel motor driver designed to accept load
such as relays solenoids, DC Motors and Stepper Motors and switching power
transistor. To simplify to used as two bridges on each pair of channels and
equipped with an enable input. A separate supply input is provided for the logic,
allowing operation at a lower voltage and internal clamp diodes are included. The
device is suitable for use in switching applications at frequencies up to 5kHz. The
L293D is assembled in a 16 lead plastic package which has 4 centre pins
connected together and used for heat sinking. The L293D is assembled in a 20
lead surface mount which has 8 centre pins connected together and used for heat
shrinking.
 
 Block Diagram of Motor Driver Shield

Motor requires more energy specially cheap motors since chip motors less efficient. The important thing we need is find out
what voltage require your going to use. some small motors are only intended to run at 1.5 volts but it is just a common to
have 6 ~ 12v motors. The motor controller on L294D shield is design to run at 4.5v to 25v. Most 1.5 ~ 3 volts motor will not
works on this shield. another thing you need is to figure it out how much current the motor will support? The L293D chip
support up to 600 mA per motor, with 1.2A peak current. Note ones you head towards 1A you’ll probably want to put a heat
sink on the chip, otherwise it will get thermal failure or burning out the chip. The motor shield can drive up to 4 or 6 DC
motors bi directional, it means that they can be driven forward and backward. The speed can also be varied at 0.5%
increments using PWM(Pulse with Modulation) this means that speed can be controlled. The motor connections are via two
screw terminals for each motor and labelled M1 thru M4. The centre terminal on the 5-pos terminal blocks are connected to
ground. The wiring of which lead of the motor connects to which terminal is somewhat arbitrary and relative to what we
consider forward vs. reverse motor operation. If the motor goes in the opposite direction that we expect, simply reverse the
wiring.
 ADVANTAGES
 
• It costs very less as compared to the existing system.
• Very accurate detection.
• All types of cracks inside the railway track and surface crack can be detected through NDT
ultrasonic sensor.
• The information is quickly transmitted to the receiver end through Wi-Fi and also stores the
data in memory.
• Accidents and Derailments will reduce.
• Online surveillance of railway track can be done through this model.
• By using this Autonomous vehicle for purpose of railway track inspection and crack
detection, it will have a great impact in the maintenance of the tracks which will help in
preventing train accidents to a very large extent.
• The regions where manual inspection is not possible, like in deep coal mines, mountain
regions and dense thick forest regions , this model can be very beneficial.
• It will also increase security of both rails and passengers.
• We can use solar panel in the robot to get rid of regular battery changing. 
• Enhance the percentage of efficiency
 CONCLUSION AND FUTURE WORK
 
• In this report, we have presented the Ultrasonic sensor based railway crack detection system. The crack
can be detected without only error. It does not give false output. The idea can be implemented in large
scale in the long run to facilitate better safety standards for rail tracks and provide effective testing
infrastructure for achieving better results in the future.
• By using this Autonomous vehicle for purpose of railway track inspection and crack detection, it will
have a great impact in the maintenance of the tracks which will help in preventing train accidents to a
very large extent. The regions where manual inspection is not possible, like in deep coal mines,
mountain regions and dense thick forest regions can be easily done using this vehicle. By using this
vehicle for the purpose of Railway track inspection and crack detection and automated SMS will be sent
to pre-defined phone number whenever the vehicle sensors detect any crack or deformation. This will
help in maintenance and monitoring the condition of railway tracks without any errors and thereby
maintaining the tracks in good condition, preventing train accidents to very large extent Railway track
crack detection autonomous vehicle is designed in such a way that it detects the cracks or deformities
on the track which when rectified in time will reduce train accidents.
• The proposed system can be used to detect the crack effectively and send the location of fault
accurately in minimum time to the predefined mobile numbers. The advantages of the proposed system
are that it has no noise, output is very much accurate and the cost is comparatively lesser than the
composite system. This system can be used both during daytime and nighttime. Solar panel can be
connected to power the system in place of rechargeable battery used for the purpose which would
make use of renewable energy sources.