SHOBHIT UNIVERSITY(MEERUT) AN INTERNSHIP EXPERIENCE REPORT BY DEEPIKA GOYAL ROLL NO.-MRT07UGBEC057 B.TECH (ELECTRONICS & TELECOMMUNICATION) BATCH (2007-11) INTERNSHIP WITH SIEMENS Ltd. UNDER THE GUIDANCE OF Mr. MUJAHID ALI (SENIOR MANAGER- TRANSPORT SYSTEMS) DURING JANUARY-MAY 2011 Preface Each and every report is prepared with a purpose. This report is also prepared focusing on interpreting the relevant information of my Internship training. This report aims at providing brief details about an ongoing project in the company regarding the remote monitoring of locomotives. The project report focuses on exploring ways to implement the various innovations taking place in the Locomotive industry. How these locomotive functions? What types of innovations have been brought in the Locomotive industry? And most importantly what happens when some problems bother these locomotives & how to solve these problems? This book has been prepared to provide the answers to all these questions and also discuss the various upcoming technologies. All the facts and figures mentioned in this report are non-manipulative, true and best of my knowledge. The diagrams and explanatory text in each section provide definitive, irrefutable knowledge about the locomotives. This internship report will provide answers to the few of the existing questions of the railway industry. This report also includes the detailed profile of the Siemens Ltd. as per the various sources within the company itself. It is hoped that this book will be able to answer all the questions of the given context. Finally, the successful completion of this project is attributed to my colleagues & my mentor Mr. Mujahid Ali.. The internship training in Siemens Ltd. was the great learning experience both at my academic & professional level. Looking forward to the reply of my readers and teachers that has always been a great source of inspiration and motivation for me. ACKNOWLEDGEMENT It is my proud privilege to acknowledge with respectful gratitude & heartiest thanks to Mr. AMIT GUPTA & the entire staff at Siemens Ltd. for extending their utmost cooperation to me in making this project. I received full guidance & encouragement at every step during the course of my training. I was given enough opportunity & resources to conduct full study on my project. I am overwhelmed to receive such a cooperation & support from everyone & I am grateful to everyone for that. This report has been written by me and has not received any previous academic credit at this or any other institution. Last, but not the least, I would like to thank all the members of Siemens Ltd, Transportation Systems division who have helped me to make this project a success. (DEEPIKA GOYAL) . ABSTRACT The primal objective of this project has been to implement the remote monitoring on locomotives by achieving synchronization of the control signals sent by the shed staff and those received by the trailing (faulty) locomotive. 3 distinct objectives were to be accomplished. First. the operation and functioning of a locomotive. This device is finally proposed and referred to as REMMLOT (Remote monitoring & management of locomotives & trains). had to be understood. a device which satisfies the operational requirements of the product under design was found and studied. To achieve this. in particular diesel locomotives (also called ALCO locos). Thus. hardwiring the locos is not feasible. . based on the above chosen communication protocol. This synchronisation is required to control various equipments on the locomotive and to provide locomotive fault diagnostics. Third. Second. an alternative wireless communication device (preferably a Wireless modem) needs to be selected which would send the control signals over the space to the trailing loco and receive the acknowledgements. For synchronization to be achieved. since a gap of at least 1000 meters separates the shed and trailing loco. it is necessary that the critical processes in both the shed as well as the trailing (faulty) loco needs top be simultaneous. TABLE OF CONTENTS • INTRODUCTION • COMPANY’S PROFILE • INTERNSHIP EXPERIENCE (MAIN REPORT) • APPENDICES 5 9 21 55 . . would go a long way in enhancing passenger safety & comfort as well as vastly improving the utilization of the existing infrastructure of Indian railways. relay based interlocking. the demands of transportation & in general. In the vast country like ours. with an increasing population & fast growing economy. In this context the microprocessor used in the locomotive control promotes safety and improves flexibility for the operation of Railways. Indian railways are under continuous pressure to continuously enhance & improve the comfort quality of rail services. Siemens has constantly supported the Indian railways by timely introduction of state of the art technologies adapted to suit the local environmental conditions & strives to be a high quality and reliable partner in their efforts. To meet this. Indian Railways is committed to provide safe and efficient transportation system. but it soon gained the first place in the movement of a large quantity of men and material over long distances. . Siemens has played a pioneering role in the introduction & installation of railway signalling systems all over the country viz. track circuits & motor operated point machines. Siemens has now brought their systems & products to the doorstep of Indian railways. rail transportation in particular have increased significantly. microcomputer based axle counter systems and point machine with external clamp locks systems.INTRODUCTION Transportation has been a basic need of human beings since the dawn of civilizationwhether it was to carry big stone blocks for the pyramids or air-lift the first man to the moon. These include remote fed audio frequency coded jointless track circuit. they have embarked upon a massive technology up gradation & modernization of passengers & freight amenities. Rail transportation came at a very late state. Today. This data is in turn made available for viewing by railway staff through a secure password protected internet website. It is. Such vehicles would substantially mitigate the problems of urban transportation in Indian cities with minimum maintenance and wear & tear.In keeping with the modernization program of Indian railways. provide online data from various sources & fault-diagnosis capability. REMMLOT is a network-oriented system connecting microprocessor locos in the field with centralized server based management system through CDMA and/or GSM network communication. WDG3A and WDM3D locomotives. siemens has already diversified into the areas of rolling stocks. Siemens is the largest supplier of light rail vehicles in the world. The overall system is given the acronym REMMLOT (remote monitoring & management of locomotives & trains) for convenience & identification. commonly known as ALCO (American locomotive company). Further it was decided to fit Remote monitoring & management on Alco locomotives. DLW is manufacturing 100% ALCO locomotive with microprocessor based control system provides an ideal platform for future requirements. therefore. With the increased use of microprocessor based control systems. This data from the microprocessor control system along with GPS location information will be transferred at regular intervals to a central database using commercially available CDMA & GSM cellular networks. necessary to have a method of making this data available to shed staff or anyone else online. REMMLOT consist of -: . are being fitted with microprocessor based control system which can control the various equipments. overhead centenary & long distance transmission lines as well as power supply. the maintenance personnel of sheds (the place where locomotives are attended) are able to get more information about the locomotive which becomes normally available to the shed staff only when the locomotive returns to the shed for scheduled maintenance. Siemens is also geared to take projects for urban transportation. Now-a-days. 1) Locomotive and train management system (LTMS) 2) Locomotive remote monitoring system (LRMS) Brief working of REMMLOT The entire REMMLOT system is clearly divided into locomotive remote monitoring system (LRMS) and locomotive & train management system (LTMS). data memory. Software hosted on the locomotive and train management server will receive all data transmitted by a locomotive remote monitoring system & store data in a database management system. Both systems shall seamlessly provide locomotive information remotely. It will interface with microprocessor control system & communicate with LTMS through commercially available CDMA and/or GSM network. GSM network interface card with antenna. Application software will interpret this data already acquired & stored in database management system. GPS receiver with antenna & other appropriate interfaces. Locomotive remote monitoring system connects to this web address through a GSM or CDMA network and transmits locomotive health status. LRMS shall consist of a microprocessor control system interface. . • Locomotive and train management system (LTMS) It is a centralized server hosted on the internet for entire Indian railways & has a static IP address from which it can be accessed. CDMA network interface card with antenna. Overall functioning of the LRMS should itself be managed by microprocessor based hardware and embedded software. diagnostics related data & other operational data. • Locomotive remote monitoring system (LRMS) It is a rugged stand alone embedded system mounted in the locomotive and connected with the microprocessor through either serial or parallel bus. . the company he started grew from strength to strength in every field of electrical engineering. engineer and entrepreneur. As Werner had envisioned. and some insulated copper wire – he designed his own pointer telegraph. In 1846. inventions that helped put the spin in the industrial revolution. who was won over by its simplicity and reliability. pieces of iron. He entrusted the apparatus’ construction to a mechanical engineer.1 SIEMENS 1.1 History From a humble workshop to a global enterprise Siemens was founded in Berlin by Werner von Siemens in 1847. and set up a small workshop in a back . Telegraphen-Bauanstalt von Siemens & Halske. their company ultimately developed into a world – class enterprise with more than 80 billion pounds of global sales and 461. Werner von Siemens made the world's first pointer telegraph and electric dynamo. Johann Georg Halske. Johann George Halske.000 employees on all continents and from all cultures of the world. In Berlin in October 1847. opened their new company Telegraphen-Bauanstalt von Siemens & Halske in Berlin. 1847. On October 12. Werner von Siemens hit upon an idea for improving the Wheatstone telegraph. 160 years ago – Werner Von Siemens and his partner . Thus began a success story. As an extraordinary inventor. tinplate. the two men formed their own company. Using just simple means – cigar boxes. He was the man behind one of the most fascinating success stories of all time by turning a humble little workshop into one of the world's largest enterprises. From a modest garage workshop in Berlin. Siemens was responsible for building much of the modern world's infrastructure. From constructing the world's first electric railway to laying the first telegraph line linking Britain and India. It is present in the following continents:• • • • • Africa The Americas Asia Australia and Oceania Europe The company has around 4. This and the pointer telegraph marked two key advances on the road toward modern telecommunications.000 employees (in continuing operations) working to develop and manufacture products . Work in the fields of energy. transportation. A year later. With innovations averaging 18 a day. While Werner was a tireless inventor during his days. the company received a government contract to install a telegraph line between Berlin and Frankfurt/Main – the company’s first major success. energy and healthcare sectors. healthcare.00.2 SIEMENS AG Siemens AG (Berlin and Munich) is a global powerhouse in electronics and electrical engineering. Siemens today remains a relentless innovator. employing some 440. the design of the pointer telegraph was awarded a patent in Prussia. components and lighting has become essential parts of everyday life. reliability and internationality. 1. operating in the industry. A week after the company was founded. quality. it seems like the revolution Werner started is still going strong.000 people worldwide. Siemens is a global powerhouse with activities in nearly 190 regions. communications. Siemens has stood for technical achievements.building at 19 Schöneberger Strasse. information. For over 160 years. In 1847. innovation. Siemens has been synonymous with international focus and worldwide presence for 160 year.and tailor a wide range of solution for individual requirements. industry. Today. Siemens is today a technology giant in more than 190 countries. . Werner von Siemens developed a gutta percha press that made it possible to create seamless insulation for copper wire.design and install complex system and projects . 1. At the same time sub groups were converted into independent companies like Bosch.Siemens put strong emphasis on R&D with over 4500 employees engaged in this key activity and contributing to approximately 8% of the turnover. In addition to its electric generators and transformers business. followed by an English subsidiary in 1858. the electric train and the electric street light. “Siemens Brothers” built the world’s first public sector power plant in Godalming in the south of England. with zero carbon di oxide emission. Werner Von Siemens designed a pointer telegraph that was faster & more reliable than any other device of its kind. It did this. the electron microscope and cardiac pacemaker. Siemens used electricity to light up posch Berlin boulevard unter den Linden. Various Discoveries in the History of Siemens 1847 1925 1929 1932 1934 1950 1956 Founding year Enter the oven Fully electrified kitchens in Berlin First washing machine with heater Granddaddy of all electric cookers The Siemens automatic hotplate Laundry moves upstairs 1906 First against dust 1928 Washing in any position of the wash ‘copper’ 1930 First refrigeration comfort 1934 The “whispering” vacuum cleaner 1938 Rolling out the first compressor refrigerators 1950 Conserving energy through laundry spin drying 1960 The miracle of space in the . In 1884. Other innovations were world’s electric locomotive (1879) and the world’s first electric streetcar (1881).Gmbh. On an average Siemens spends DM 35 million a day on R&D centers in Europe and USA apart from Germany. since it was driven by hydraulic energy from the river Wey.The first national subsidiary was established in Russia in 1855. electronic automation and the world’s largest and most powerful Gas Turbine. The facility generated electricity for street lights. the company also began making steam turbines in the 1920’s. by the way.3 Short Portrait of Siemens: In 1847. Three core companies were combined to form Siemens AG [Aktiengesellschaft] in 1966 & reorganization in 1969 and then various segments – the precursors of today’s group were formed in the “Basic Organization Of Siemens AG”. In 1881. The history of Siemens is filled with technological milestones: the pointer telegraph and dynamo.SiemensHausgerate . Building Technologies. Mobility (See Siemens Mobility) and Osram Energy Sector (led by Wolfgang Dehen) . Motion Control.45 cm wide Washing at a higher level of environmental consciousness Increased savings for dishwasher Induction.1962 1969 1970 1973 1980 1984 1987 1989 The first universal built in cooker The fitted kitchen as a status symbol Oven carriage and pyrolytic self cleaning Coffee with more flavor and aroma Desire for kitchen harmony Home appliances say what they need Dishwasher . • • Industry Sector (led by Siegfried Russwurm) o Comprising six sub-divisions: Industry Automation. The simple way World Exposition EXPO 2000 in Hanover World’s easiest dishwasher refrigerator 1964 The first dishwasher 1970 Lifestyle of breakfast 1970 Laundry with total comfort 1976 Laundry drying. Klaus Kleinfeld after the scandal charges of bribery against Siemens.super easy .Laundry and savings 1998 Fully electronic . Gerhard Cromme is the current chairman of the supervisory board of Siemens AG. 2007. the company is divided into 3 sectors and a total of 15 divisions. Electrical cooking with the characteristics of gas Cooking zones with boiling over Into the next millennium. He succeeded Dr. He succeeded Dr. Industry Solutions. Heinrich von Pierer on April 26.4 Corporate Divisions a. Organization structure:- Since 1 January 2008. Management:- Peter Löscher (formerly of Merck) is the current president and the CEO as of July 1. b. 2007. everywhere 1981 Hot news about cooker developments 1985 Aqua –stop provides water damage protection 1988 0 degree c keeps freshness 1989 New laundry technology : AquaTronic scoop and shower water system 1994 World premiere of top basket dishwashing 1996 Aqua-sensor .EPS 1999 Contribution to the working atmosphere 2001 Succulent world –first 1990 1995 1997 1999 2000 2002 1. • Comprising six sub-divisions: Fossil Power Generation. Power Transmission and Power Distribution Healthcare Sector (led by Hermann Requardt) o Comprising three sub divisions: Imaging & IT. SIEMENS INDUSTRY AUTOMATION MOTION CONTROL INFRASTRUCTURE INDUSTRY SOLUTIONS MOBILITY OSRAM ENERGY FOSSIL POWER RENEWABLE ENERGY OIL & GAS SR EQUIPMENT POWER Tx POWER Dr. HEALTHCARE IMAGING & IT WORKFLOW & SOLUTIONS DIAGNOSTICS . Workflow & Solutions and Diagnostics o In addition two other organizations Siemens IT Solutions and Services and Siemens Financial Services were part of the group. Renewable Energy. Oil & Gas. providing services to the other divisions The following block diagram denotes the various divisions and sub-divisions of SIEMENS and its past achievements and its role in Global and Indian Industry. Service Rotating Equipment. Siemens remain a strategic hub for a large part of Siemens Businesses. while delivering value. systems and services into turn key solution across the life cycle of a project. the optimal utilization of power will remain the focal point. In the coming years as India emerges as the super power. Siemens ‘hi-tech’ approach in the field of power engineering and automation system. We have the capability in integrate diverse products. while Siemens IT Solutions and Services operates across all three Sectors. Industry and Healthcare Sectors.Our customer also know that they can rely on us to execute quality projects. Established in 1922. the technological dimensional role in making this happen. In generation distribution and control therefore. In fact. a world without electrical and electronic power.But its not only one . India’s rapid strides in the economic and technologies fronts would not have been possible without pragmatic policies and farsighted investments in electronic systems and electrical power generation. The Siemens group in India is a unique player in the field of electrical and electronics engineering. where it holds leading positions in the Energy. medical engineering and telecommunication will continue to provide synergy to the coordinated efforts to bring India closer to the frontiers of accelerated progress. While the sources of energy are being continuously explored to augment existing per generating capacities. which will dicta to a significant extent the scope and trends of India’s progress to meet the global changes. the optimal utilization of power will remain For more than 50 years.5 SIEMENS INDIA:INDIA. All this call for an integrated approach from all the sectors in achieving the total. Expert predicts that the demand for electrical energy will increase by leap and bound long after the close of the millennium. newer technologies will become overriding criterion. energy management. the pulse of a nation’s progress can be gauged from electricity flowing in the power lines. Innovation is our strength . it was incorporated as a company in 1957 and in 1962 was converted into a public limited company with 51% of its equity held by Siemens AG and the remaining 49% held by Indian shareholders. Siemens has been active in India.THE TECHNOLOGICAL DIMENSION It is difficult to envisage today.1. . While the sources of energy are being continuously explored to augment existing per generating capacities. Medical engineering and telecommunication equipments. Siemens grew out of response to this need. In the Energy sector. we provide the complete range of offerings. In Transportation. In Healthcare. HMT. we illuminate large stadiums and also manufacture small light bulbs. Drives and Automation. Besides associates and subsidiary companies have formed like: • • • • • • • Siemens Business Communications Systems Limited (SBCSL) Siemens Information System Limited (SISL) Siemens Communication Software Limited (SCSL) Siemens Public Communication Network Limited (SPCNL) Siemens Metering Limited(SML) Information Communication Mobile(ICM) Information Communication Network(ICN) Siemens with its global experience and expertise in the above sectors has helped to keep India in the frontline of International Technology. 30 representatives. Power system automation. 350 dealers and system houses . our expertise ranges from power plants to turbines and in the Industry sector. In all areas of our operation.Siemens long association in India began in the year 1867 when Werner Von Siemens personally supervised the laying of the first transcontinental telegraphic line between Calcutta and London. BEL. Siemens extensive network in India includes 10 manufacturing units. we build airports as well as contactors. First in a small way assembling switchboards at workshop in Bombay and Calcutta with products as varied as Switchgears. Railway signaling system. right down to safety relays. we execute complete solutions for . Siemens has played an active role in the technological progress experienced in the last three decades. Motors. 12 sales office. Siemens technology has been made available to the reputed Indian organizations in the form of collaboration agreements with BHEL. whereas in Lighting. ECIL and Mafatlal Industries to name a few. In the 60’s the nations expanding investments in the power generation called for a range of high quality electrical and auxiliary equipments.Being closely related to Siemens AG. Germany gives Siemens India access to the world’s latest developments in every field. we deliver complete high Speed trains. It enables customers to generate. Oil & Gas We offer customers in the oil and gas.6 billion.hospitals as also provide “in the canal” hearing aids. And.000 employees worldwide. in particular. the Sector generated total revenue of €25. solutions and key components spanning the entire energy conversion chain. .6 ENERGY Siemens Energy Sector is the world’s leading supplier of a wide range of products. They also help them produce. 1. convert and transport the primary fuels oil and gas. In fiscal 2010. plant-to-grid connections and other types of interfaces. They are the only manufacturer worldwide with knowhow.and gas-based electricity production and provide technologies for low-carbon fossil power generation.5 billion and profit of €3. process and energy supply industries a wide portfolio of products and solutions for the eco-friendly and resource-saving utilization of energy in areas such as the production and processing of oil and gas and the energy-efficient generation of electricity. They focus primarily on the requirements of energy utilities and industrial companies – particularly those in the oil and gas industry. transmission and distribution as well as for the production. solutions and services for power generation. Their exceptional solutions expertise is particularly striking in the area of interfaces: for example. We boost the efficiency of coal. Fossil Power Generation Our innovative technologies generate more electricity from less fuel. conversion and transport of the primary fuels oil and gas. the thread that connects all our businesses is Information Technology. Siemens Energy has about 88. transmit and distribute electrical power at the highest levels of efficiency. Siemens Energy Sector is one of the world’s leading suppliers of a wide range of products. products. They are the only supplier worldwide with comprehensive knowhow encompassing the entire energy conversion chain and. grid integration technologies and smart distribution systems linking grids to consumers. solutions and services in the field of energy technology. in plant-to-grid connections. And as the world’s No.7 INDUSTRY Siemens Industry Sector is one of the world’s leading suppliers of manufacturing. . efficient: we offer our customers a unique combination of automation technologies and industrial software spanning the entire value chain – from product design to service. flexible. installation. we have the solutions they need. industrial processing and heat and power generation industries. 1 supplier of products. with large-scale photovoltaic projects and with leading-edge technologies for solar thermal power plants. we enable customers to transmit power – for example. end-to-end systems. building and lighting systems. efficiency and flexibility. By continuously optimizing productivity. end-to-end products.Renewable Energy We’re steadily expanding our position in the dynamic renewable market – with innovative wind turbines that rank among the most reliable in the world. Power Distribution The prerequisite for sustainable energy management. These turnkey solutions cover project management. At Siemens. solutions for energy automation and services for electrical systems and networks. we’re increasing the economic and environmental competitiveness of our customers in the industry and infrastructure segments. applications and services for complete power trains and for all industry segments. commissioning. Our portfolio enables industry customers to slash time to-market by up to 50 percent. reliable switchgear and transformers. engineering and software. Industry Automation Fast. Power Transmission Leveraging our innovative strengths in low-loss power transmission. Energy Service Our broad spectrum of innovative products and services ensures plant reliability. and advanced power transmission systems. 1. energy efficiency and reliability are our customers ‘key requirements. transportation. systems and solutions for industrial and building automation as well as infrastructure installations are provided. Drive Technologies Productivity. We offer innovative medium-voltage components and systems. enabling them to gain the maximum benefit from their investments. green electricity from renewable energy sources like offshore wind farms – safely and efficiently. plant maintenance and training. our smart grid technologies increase the efficiency of energy systems. after-sales service. improved efficiency and optimal environmental performance for our customers operating plant assets in the oil and gas. LED systems and LED luminaries but also electronic control gear and light management systems. Industry Solutions We’re a leading provider of solutions and services for industrial plants and infrastructure systems. Diagnostics and Customer Solutions. reliable diagnosis. our integrated solutions for intermodal transport. pollution control and water management. traffic management. laboratory diagnostics. helping customers increase their competitiveness across entire lifecycles and Offering attractive solutions in the areas of energy efficiency. Imaging & IT Their innovative imaging systems are routinely used in hospitals and doctors’ offices. solutions and services for building automation. and on the other. knowledge processing – including information technology and systems integration. OSRAM We’re an expert partner offering customers energy-saving lighting solutions for all areas of modern life. Our portfolio includes not only lamps and optoelectronic semiconductor light sources like light-emitting diodes (LEDs).8 HEALTHCARE Siemens Healthcare Sector is one of the world’s largest providers to the healthcare industry. diagnostic systems and therapeutic technologies. security and power distribution. effective treatment and patient-friendly follow-up care. Clinical Products. They specialize in medical solutions based on our core competencies and innovative strengths: on the one hand. Their advanced IT solution – ranging from image review and . their hearing instruments business will be operated as a separate unit. treatment solutions and healthcare IT – rounded off by consulting and services. Their acquisitions in the field of laboratory diagnostics have made us the first integrated healthcare company to combine imaging systems. Mobility By networking transportation systems more effectively. we’re reorganizing our activities into four Divisions: Imaging & Therapy Systems. where they support physicians in early disease detection. fire safety. postal automation and airport logistics are making the movement of people and goods more efficient and ecofriendly.Building Technologies We’re the preferred partner when it comes to maximizing energy efficiency in buildings and protecting people and infrastructures. Our portfolio comprises products. 1. In the future. To leverage our market and growth potentials even further. There leverage of broad portfolio of products and services to develop integrated solutions that increase the clinical and economic value of their individual offerings.distribution to the management of entire data sets – is helping make healthcare more patientoriented. cutting costs in the process. they provide customers with solutions tailored to their specific needs. Workflows can now be designed more efficiently. open and transparent. . Workflow & Solutions Their aim is to accelerate the accurate diagnosis of the most common diseases and establish new worldwide standards for their treatment. Reflecting the local focus of healthcare delivery. . INTERNSHIP EXPERIENCE (MAIN REPORT) The internship with Siemens Ltd. was quite an informative & a great learning experience. The over-all exposure provided by the company was of source immense help to me both at academic and professional level. The learnings and the knowledge gained by me was somewhat different and epitaxy to my existing knowledge. § Getting Started . . . . Though the project allotted to me was not directly related to my field i.e. Electronics & telecommunication but yet it follows a strong background in electronics (eg.Microcontrollers) and various technologies of Telecom (CDMA, GPRS, GSM, GPS) too. The project basically deals with the implementation of remote monitoring system in the Locomotives. The locomotives, in this case, are typical ALCO (American Locomotive Company) based. Since the company’s major clients include Indian Railways (IR). So, it was indeed necessary that the developed software should be able to pass all the compatibility tests of the Indian locos. The Need for Remmlot Before moving to the details of REMMLOT, let us discuss about the need of introducing the concept of REMMLOT. A host of qualities are needed to meet the demands of local as well as global Locomotive Industry innovation along with the flexibility, world class quality, ability to integrate components and systems, skills to meet production deadlines and delivery schedules to meet long term engagements. Siemens ability to continually meet these expectations has prompted the Indian locomotive Industry to allow the Siemens transportation department to develop and introduce a system that can enhance the capability & functionality of the locomotives. This calls for the existing faultdiagnosis system to get replaced by more efficient and technically advanced system. Thus, a device needs to be installed that can work at a greater speed, overcoming all the deficiencies of the existing system. Therefore, a microprocessor based control system is provided that can actually enhance the capability of the locomotive. The presence of Microprocessor (RISC type µp) based control system (Microcontroller) in the locomotives, makes it possible to control various equipments on the locomotive, thus, feeding the loco with online-data from various sources & providing the fault diagnostics facility. These microcontrollers are installed mostly on latest technology WDM3D locomotives. With the increased use of these microprocessor based control systems, the maintenance personnel of sheds (the place where locomotives are attended) are able to get more information about the locomotive which becomes normally available to the shed staff only when the locomotive returns to the shed for scheduled maintenance & out of course repairs. It is, therefore, necessary to have a method of making this data available to shed staff or anyone else online without actually making the locomotive available to the shed staff. Thus, handling the fault from remote location without handling it personally. BASIC JARGONS AND DEFINITIONS USED IN LOCO INDUSTRY DLW BG IS IR IRS LRMS LTMS ALCO TCP/IP GPS GSM GPRS CDMA AAR SIBAS Diesel Locomotive Works Broad Gauge – 1676 m Indian Standard Indian railways Indian Railways Standards Locomotive Remote Management System Locomotive and Train Management System American Locomotive Company Transmission Control Protocol/ Internet Protocol Global Positioning System Global System for Mobile Communication General Packet Radio Service Code Division Multiple Access Association of American Rail roads Siemens Railway Automation System in India & neighboring countries] Y= meter gauge (1000 mm) [Normally at hills due to limited track space] Z= Narrow gauge (762 mm) N= Narrow gauge (610 mm) Standard gauge = 1435 mm § [Most common in whole Europe & US] A Rail Gauge § POWER SOURCE: Basic energy source for Locomotive Ü Ü Ü AC Diesel Dual power AC/ DC.BASIC LOCO TERMINOLOGY § GAUGE: Distance between the rails. W= Broad gauge (1676 mm) [Max. DC Ü DC § LOAD: As driven by locomotive. [ M= Mixed traffic P= Passenger G= Goods S= Shunting . of unpowered wheel sets § TRACTIVE EFFORT: The force exerted by the Loco at the wheel rim of Locomotive before the wheels slip out of control and is usually expressed in pounds (lbs) or kilonewtons (KN).U= Multiple Unit (EMU/DEMU) ] § WHEEL ARRANGEMENT : No. M= mass of the Locomotive) . of powered wheel sets / No. TE= µ. M (where µ = Coefficient of adhesion. Because of the friction of the mechanical parts of the drive and some wind resistance. In the metric system. P= (F*D) / t (Where P is the power. § WHEEL SLIP: The phenomenon caused on a locomotive or power vehicle by over applications of power to the drive system relative to available adhesion. § WHEEL SLIDE The synonymous with skidding and usually caused by over-braking during poor adhesive conditions.1 and 0. F is the force. the drawbar pulls lesser than tractive effort (TE). it is calculated as the power (in watts) needed when one Newton of force is moved one meter in one second. It is denoted Greek letter µ and may vary between 0.One horsepower is the work involved by a horse in lifting 33. § DRAWBAR PULL The force transmitted to the coupling between the locomotive and the train. It is expressed as Horsepower (hp) or KWatts.000 lbs to one foot in one minute. It can cause damage to the electric motors and to the rails. D is the distance & t is the time.§ COEFFICIENT OF ADHESION: The factor used to determine the maximum tractive effort which can be applied by a locomotive under a given rail conditions before slipping occurs. It is a common cause of wheel damages it produces a flat spot on the wheel where the skid has occurred.4.) . § POWER It is defined as the rate of doing work. . § WHEEL ON RAILS The arrangement of wheels on rails is a very systematic and deliberate arrangement. flanges & track. power needs to be increased. Flanges are only the last resort to prevent the wheels from derailing. A low speed and a high drawbar pull can produce the same power as high speed and low drawbar pull.A SAFETY FEATURE. rails. Coning. It consists of Axle. The flanges should not touch the rails. To achieve higher Tractive effort and high speed.One Horsepower equals to 746 watts.The inner wheel uses the outer edge of its tyre to reduce the distance travelled during the passage round the curve. electromagnetic induction and radio frequency interference. monitoring and protection functions. vibrations. . Overview The microprocessor-based locomotives control systems shall provide extensive control. dust. which contains • Excitation of main alternator and auxiliary generators (battery charging) • Engine Control including Cranking • Propulsion including Transition • Auxiliaries control (Switching of fuel pump Motor) • Electro dynamic braking (EDB) • Wheel slip/ slide control of electric traction • Safety alarm and indication • Data logging and fault-diagnosis Working Conditions The microprocessor based control system is required to work in very hazardous environment having oil.EXPLORING LOCOMOTIVES Let’s discuss about the locomotive control system first prior to the discussion of the REMMLOT. high temperatures & humidity combined with high levels of electric surges. DC Motors / AC Motors Control devices: .LOPS/ LWS/ OST/ PCS Information devices: .Alternator / Transformer Traction drives: .Diesel Engine / Catenary Voltage / Steam Engine Secondary mover: .Control desks Safety Devices: .Locomotive Internal Architecture The locomotive consists of the following equipments: Prime mover: . Microprocessor based control system (currently in use) . Static excitation control system. E-type Excitation system. Some of the examples of the control system are as follows: 1.-LED’s / Display Control consoles: -Control panel Auxiliary controls: -Battery charger/ Auxiliary drives etc. There should be central coordinator to control and monitor all these equipments/ devices/ machines. This requirement calls for automated control system. 3. 2. e. Ü Auxiliary Generator: . Locomotives used to operate passenger trains are equipped with an auxiliary generator.Description Ü Diesel Engine: . on the train. heating. . lighting.5 sec of governor) from the 1st notch to 4 th notch and 6 sec per notch above 4 th notch.e. This provides AC power for hotel load i. air conditioning and dining facilities etc. Ü Main Alternator: . It consists of 16cylinders and is capable of delivering 3100HP of power.Loco main components.It is an electrical machine converting the mechanical power obtained from the Diesel engine into three phase electrical power for traction i.Electrical machine utilizing mechanical power from Diesel engine to convert to electrical DC power for battery charging. The ramp up rate for the Diesel engine has been programmed as a total of 5 seconds per notch (including 2. for moving the locomotive by providing supply to the traction motors.It is the main source of power on board the locomotive. Ü Battery:-DC power source on the locomotive to serve auxiliaries on board the locomotive. speedometers. Ü Locomotive Control Unit (LCU): -Microprocessor based system that manages complete locomotive control with reading various commands from the locomotive operator. Ü Control Stand :. voltage and current meters and other notches and controls which need to be operated manually by the Driver. engine control switch. Ü Rectifier: -This circuit converts three phase electrical power from the Main Alternator to DC electrical energy for traction motors.Electrical machines converting electrical energy to mechanical energy for moving the locomotive. Ü Drive Shaft: -The main output from the diesel engine is transmitted by the drive shaft to the alternator at one end and the radiator fans at the other end. Ü Gear Box: -Drive to the fan is through a gearbox to change the direction of the drive upwards. .This is the principle man-machine interface. Its flow is regulated by temperature. Ü Truck Frame: -This is the part carrying the wheels and traction motors of the locomotive. control electrical breaking and fault diagnosis. managing the movement of the locomotive. it consists of the main controller handle. Ü Sand Box: -The locomotive carries sand in the sand box to assist adhesion in bad rail conditions and to prevent slipping of the wheels. both inside and outside the locomotive. pressure.The air for cooling the locomotive’s motors is drawn in from outside the locomotive through air intakes and filtered to remove dust and other impurities. Ü Traction Motors: .Ü Air Intakes: . The WDG3A locomotive consists of 6 traction motors. The ON/OFF control is done by Pulse width modulation (PWM). A transistor working in switching mode in turn controls field of the exciter. Reg. The AG and the exciter are used as motors powered by 64 V batteries for cranking the engine. An auxiliary generator driven by a gear train mounted on traction alternator provides power for electrical auxiliaries and also charges a 64 V battery floating across it. The output of the auxiliary generator is regulated at 72±1 V. The traction alternator field is excited by a DC exciter. Gen. Power level of the diesel engine is set through a master controller which has eight settings called ‘notch’. . The exciter is driven by alternator shaft by a gear train. Reg. Drivers Display Aux. which is directly connected across the alternator field. M M M Traction Motors DC M M M General overview of locomotive main components A diesel electric locomotive is driven by DC series traction motors mounted on all the driving axles independently. M/G Cranking M/G Exciter Main. A traction alternator that is directly driven by a diesel engine supplies electrical power to these motors. The traction alternator field is controlled by control system through excitation control of exciter.WORKING OF LOCOMOTIVE Main Alternator G Master Controller Diesel Engine Governor ~ Rectifier Brake Resistors Locomotive Control Unit Battery Aux. Each notch has a fixed rpm and power level. the auxiliary generator and the exciter are used as motors powered by 64 V batteries.e. Wheel slip is detected by comparing voltage across a slipping motor to a non-slipping motor through a Wheatstone bridge circuit. The locomotive controlled by the LCU is designed to be operated in the following scope: • Single Unit • Multiple Unit (Master) • Multiple Unit (Slave) • Test Run without Traction Motors (Stationary with load box in shed) • Micro-controllers supported by Siemens • KM-DIREKT . The brake system may be either pure air brake or pure vacuum brake or dual brake (i. The unbalanced voltage energizes a wheel slip relay that causes reduction of alternator excitation through PWM to reduce the traction output to wheel through wheel slip control mechanism. During dynamic braking. field weakening is also done to increase the loco speed. There are three such pairs of motors connected in the above manner energizing three wheel slip relays.At defined loco speeds motor transition (changing the traction motor combination from series parallel 2S3P to parallel 6P) is done by control system to increase the loco/train speed. The motors now work as separately excited generators and the current generated is dissipated in the resistor grids. For cranking purposes. In passenger or mixed type locomotives. These locomotives have a pneumatic brake system. the traction motor fields are disconnected from the motor armatures and reconnected in series across the traction alternator. provision of both the vacuum and air brake). This has called for the replacement of KM-DIREKT with a new and improved technology that has brought a revolution in the Locomotive industry.It is a microprocessor based control system for rail vehicles which provides extensive diagnostic functions and high availability. This system was named as SIMCONTROL. The system is configured modular out of a central processing unit and different functional cards in a 19’’ rack with application specific backplane wire-wrap wiring. Since this system cannot afford to work in very harsh environmental conditions of the Locomotives (as discussed above) so the system is modified and replaced by a system that can sustain extreme locomotive conditions and moreover. this technology became very obsolete and is hardly have any scope in the international market. KM-DIRECT • . Battery Charging Regulation . From the functional point of view. SIMCONTROL is complete successor of KM-DIREKT with just a few architecture differences.Diagnosis .Propulsion Control including Transition & Reversing .• SIMCONTROL A SIMCONTROL is the new series of microprocessor based control system developed for 3100 HP WDG3A/WDM3D diesel electric ALCO locomotives by SIEMENS.Vigilance Control .Flasher Light Control A SIMCONTROL .Diesel Engine Cranking . The basic functions performed by KM-DIREKT system are also valid for SIMCONTROL system such as: .Excitation Control during Motoring & Dynamic Braking .Driver’s Display .Diesel Engine Speed control through Governor .Auxiliary Control . 2) The terminological difference between the representation of the cards in SIMCONTROL microprocessor based control system and existing KM-DIREKT system is as follows: S. . The existing KMDIREKT X48 Connector is retained as such in SIMCONTROL system. 1 KM-DIREKT SIMCONTROL 19” module rack with back plane 3 rack system (X. 4) The X-Connectors (X41/X42/X43/X44/X45/X46/X47) in KM-DIREKT system is replaced by XR-Connectors (XR1/XR2/XR3) connectors in SIMCONTROL. Y & Z) with back plane wiring which integrates the connector connected with interface functional circuit boards modules (IM-Y & IM-Z) CRH12 Central Computer CPU Central Computer 2 3 Wheel Slip & Slide control card Counter Module card designated as ‘X7’ & designated as ‘-A10’ ‘X8’ Power supply module for system Power supply module for system 24Volt 5Volt operating supply operating supply designated as ‘PSU-5’.v KM-DIRECT Vs SIMCONTROL The architecture comparison between the SIMCONTROL & KM-DIREKT is as follows: 1) Integrated Wheel slip & slide control in SIMCONTROL microprocessor against the separate K-MICRO compact – Wheel Slip & Slide Module in KM-DIREKT microprocessor. NO. designated as ‘-A90’ ‘PSU-6’ & ‘PSU-7’ 4 3) Integrated filter cards in AI cards for analog inputs in SIMCONTROL system as compared to KM-DIREKT system. LOCOMOTIVES SUPPORTED BY SIEMENS There are two types of ALCO Locomotives supported by Indian Railways that are being fitted with Microprocessor based control system .WDG3A and WDM3D.100 HP (3A= 3100 HP) WDM3D • • • • W. WDG3A • • • • W.Goods A.Mixed (Goods/Passengers) D.Broad Gauge D.300 HP (3D= 3300 HP) WDG3A (above) and WDM3D ALCO locomotives .Diesel M.Diesel G.Broad gauge D. diagnostics related data & other operational data.v Discussing REMMLOT REMMLOT is a network-oriented system connecting microprocessor locos in the field with centralized server based management system through CDMA and/or GSM network communication. Microprocessor ffff (RISC type) (RISC Via LAN ports Data logger unit (Ethernet) LRMS MODEM Web server Client • GSM/ CDMA • GPRS LTMS Physical set-up for REMMLOT . REMMLOT consist of two units -: 1) Locomotive and train management system (LTMS) It is a centralized server hosted on the internet for entire Indian railways & has a static IP address from which it can be accessed. Locomotive remote monitoring system connects to this web address through a GSM or CDMA network and transmits locomotive health status. It will interface with microprocessor control system & communicate with LTMS through commercially available CDMA and/or GSM network. 2) Locomotive remote monitoring system (LRMS) It is a rugged stand alone embedded system mounted in the locomotive and connected with the microprocessor through either serial or parallel bus. With the stated operating system and service conditions and requirements. An addressed secure mode is also available. Pheonix. Whilst the RF modem is simple to use it is also highly adaptable and can be used in a wide variety of applications. This modem should support either of GSM or GPRS technology. Since each instruction type that a computer must perform requires additional transistors and circuitry. RS 232/485 Radio Modem by TYPHOON The RF solutions typhoon RF modem provides fast and reliable wireless data communications at an extremely competitive price. some of the wireless modems that were selected are: Typhoon. a larger list or set of computer instructions tends to make the microprocessor more complicated and slower in operation. Trio-DATACOM and Siemens. Keeping this aspect in mind.Understanding the Set-up • RISC type microprocessor: RISC (reduced instruction set computer) is a microprocessor that is designed to perform a smaller number of types of computer instructions so that it can operate at a higher speed (perform more millions of instructions per second. The RF modem is configurable as a ‘transparent’ wireless serial point-to-point link reproducing the function of a half duplex serial cable. . in case of Remmlot. or MIPS). • Modem: The modem used. Moxa. The following product was found to be suitable and hence was chosen for further study. a search for compatible modem that could be used for the remote monitoring of loco was initiated. is a wireless modem that can be perfectly placed between the LTMS and LRMS. 6 cm 2.2 cm 19.Typhoon Modem Salient features: • Wireless half-duplex radio modem • RS232 and RS485 serial interfaces • RF power up to 500mW (+27dBm) • Range up to 4 km • Radio Baud Rate up to 38.4kbps • Serial baud rate up to 115.2kbps • Housed in a tough ABS enclosure rated IP68 • Multiple radio channel operation • Powered from 9 to 12 V DC • Internal LED indication of power and communications • Configurable with standard Hayes AT commands Modem Specifications: General Device Type Enclosure Type Width Depth Height Price Modem Interface Type Connectivity Technology Serial RS-232 / Bluetooth Wireless Fax / modem External 6.4 cm 9.96 pounds . 27ter. Operating Temperature Max.Bluetooth Miscellaneous Cables Included 1 x phone cable 1 x serial cable Power Power Device Software / System Requirements OS Required Microsoft Windows 98 Second Edition / Windows ME.9 pin D-Sub (DB-9) 1 x network .80 14.17.29.23.21.34. ITU V.external Min Processor Type Min RAM Size Environmental Parameters Min. ITU V. ITU V. ITU V. ITU V. ITU V. ITU V.4 Kbps External integrated Max Fax Transfer Rate Antenna Expansion / Connectivity Interfaces 1 x modem .32bis.90% .22.RJ-11 1 x serial . Microsoft Windows 2000 / XP Pentium II 64 MB Power adapter .RS-232 . ITU V.32. Bell 212A. ITU V. Operating Temperature Humidity Range Operating 0 °C 50 °C 10 . ITU V. ITU V.22bis.Max Transfer Rate Protocols & Specifications 56 Kbps Bell 103.phone line . the client may get the desired information about the locomotive and follow-up with the diagnosis process. • Client and web server: The LTMS basically comprise of these two sections. and CDMA). The client sends the request to the web server. Finally. The server acknowledges the request and collects the data to serve the client. The LRMS basically comprise of this unit independently.• Data logger unit: It is a section that collects and stores all the health data associated with locomotive. which means that mobile phones connect to it by searching for cells in the immediate vicinity. then sends it down a channel with two other streams of user data. It is connected with the microprocessor through either serial or parallel bus via ethernet ports. These two sections work in the same way as usual client-server model works. GSM uses a variation of Time Division Multiple Access (TDMA) and is the most widely used of the three digital wireless telephone technologies (TDMA. GSM. It controls the data that needs to be transmitted to the shed staff for locomotive diagnosis. GSM is a cellular network. GSM digitizes and compresses data. The server receives the request from the requesting client. GSM also pioneered a low-cost (to the network carrier) . each in its own time slot. It will interface with the microprocessor control system and communicate with LTMS through commercially available CDMA and / or GSM network via wireless modem (as specified above). • Best suited technologies: Ø GSM GSM (Global System for Mobile communications: originally from Groupe Spécial Mobile) is the most popular standard for digital mobile telephone system in Europe and other parts of the world. alternative to voice calls. GPRS enables packet data (the same as is used by an Ethernet LAN. GPRS utilizes up to eight 9. The GPRS core network provides mobility management.833Kb GSM: Technical details Ø GPRS The General Packet Radio Service (GPRS) system is used by GSM mobile phones. GPRS implementation requires modification of existing GSM networks. for transmitting IP packets. Mobile Frequency Range Multiple Access Method Duplex Method Number of Channels Channel Spacing Modulation Channel Bit Rate Rx: 925-960.2Kb. the Short message service (SMS.3 Gaussian Filter) 270. A GPRS connection is established by reference to its access point name (APN). The GPRS core network is an integrated part of the GSM network switching subsystem.05Kb or 13. The APN defines the services such as wireless application protocol (WAP) . GPRS supports both TCP/IP and X.g. It also provides support for WCDMA based 3G networks. mobile phone.25 communications.4Kb or 107. PDA or Laptop. The GPRS core network is the centralized part of the GPRS system.4Kb TDMA timeslots. which is now supported on other mobile standards as well.5G. because GSM is a circuit switched technology while GPRS is packet oriented. also called "text messaging"). for a total bandwidth of 72. session management and transport for Internet Protocol packet services in GSM and WCDMA networks.e. Tx: 880-915 TDMA/FDM FDD 124 (8 users per channel) 200kHz GMSK (0. WAN or the Internet) to be sent to and from a mobile station . the most common mobile phone system in the world (as of 2004). GPRS represents the bridge between 2G and 3G mobile telecommunications and is commonly referred to as 2. longitude. multimedia messaging service (MMS). Fixed/Mobile Circuit/Packet Max Bandwidth Range Frequency Host Network Definer Mobile Packet 107. GPS satellites broadcast signals from space that are picked up and identified by GPS receivers. day and night.2Kb Coverage area of host network Frequency of host network TDMA. GSM ETSI GPRS: Technical details Ø GPS The Global Positioning System (GPS) is a U. and timing services on a continuous worldwide basis. . Each of the loco is fitted with a GPS receiver and a communications system that relays our position to our Internet site on a real time basis. From there it is available to any interested party who wants to know where the loco is currently located and when to expect it. This provides better loco diagnosis & enhanced levels of safety. navigation. and the GPS receivers owned by users.S. short message service (SMS). control and monitoring stations on Earth.access. For anyone with a GPS receiver. Knowing the exact location of locomotives GPS has been a great benefit to our riders. space-based radio-navigation system that provides reliable positioning. The GPS is made up of three parts: satellites orbiting the Earth. and altitude) plus the time. anywhere in the world. Each GPS receiver then provides three-dimensional location (latitude. and for Internet communication services such as email and World Wide Web access. the system will provide location and time. GPS provides accurate location and time information for an unlimited number of people in all weather. GPS satellite around earth BASIC REMMLOT METHODOLOGY BASIC REMMLOT METHODOLOGY LOCO LOCO A SIEMENS B Remote Monitoring Overview . Features: • Transfer of position. technical staff. GPS and power meter module) is transferred to a central computer by GSM (in future. also by GPRS for faster data transmission) and diverse user groups (sheds. Ü Locomotive Health data. etc.Explanation: Data from the vehicle (central control unit. faults. • Display of events (errors.as and when fault occurs Ü Life time counters data & trip data counters. operating messages. etc. Ü Locomotive GPS position co-ordinates .once every 10 to 30 minutes Ü Fault data with data packs.once every day Ü GPS location information only (optional) • Locomotive Health Data: It shall be transferred from microprocessor system to LRMS every 10 to 30 minutes. Each data packet shall consist of following parameters. diagnosis & other health data.) • Fault evaluation with notes on diagnosis • Loco position display (text & map) • Interface to SIBAS expert • Freely configurable data transfer including password & key ADDITIONAL REMMLOT FEATURES • Locomotive Data: LRMS shall interface with the microprocessor locomotive control system to receive the following data at the frequency mentioned.) can access the data via defined views. Ü Date and Time stamp Ü Notch position of Master controller Ü Speed of locomotive in kmph Ü Engine Lube oil pressure in Kg/cm2 Ü Engine fuel oil Pressure in Kg/cm2 Ü Engine temperature in 0C Ü Battery Voltage Ü Battery Charging/Discharging Current Ü Power Ground Leakage Current Ü Traction Alternator output Current • Fault data with data packets: These shall be transferred from the microprocessor control system to the LRMS as when a new fault occurs. The microprocessor control system also has a mechanism for resetting active faults. This packet will contain only date/ time stamp and GPS latitude and longitude. This information shall consist of date/ time stamp. • GPS location information: Though GPS location co-ordinates are part of the locomotive health data packet. fault description and fault data packs for three seconds before the fault and five seconds after the fault. • Life time data counters and trip data counters: These might be available in the microprocessor control system shall be transmitted from microprocessor control system to the LRMS once every day. fault code. GPS location coordinates. This information is accumulated since the commencing of the system. . Ü All of the above data shall be transferred along with a date/ time stamp and unique locomotive number allocated by Indian Railways. This is an optional data packet that may not be required. LRMS shall club this information with the next locomotive health data transfer. the LRMS shall using TCP/IP protocol to log into the LTMS system and transfer the appropriate data. • Communication with LTMS: LRMS shall communicate with LTMS using commercially available CDMA and/ or GSM network. Ü Fault data with data packets shall be transferred as soon as fault occurs. • Locomotive and Train Management System : . Ü GPS location data shall be transferred from LRMS to LTMS at an interval to be specified at a later time. • Communication Protocol: The LRMS shall transmit the various kinds of data mentioned earlier to the LTMS by making a data call on commercially available cellular network.LRMS shall place a new data call through CDMA or GSM network to communicate this information.• Frequency of data transfer: The following guidelines shall govern submission of exact details of the frequency at which the above data shall be transferred to LTMS database: Ü Locomotive health data shall be transferred every 10-30 minutes. Ü Lifetime data counters and trip data counters shall be transferred once every day. Once the data is placed. • Voice communication (optional): This feature may be optionally available to the locomotive pilot to make a voice call using the CDMA and/or GSM data cards being integrated into the LRMS. • LRMS Communication module: This software module shall have one internet interface that shall receive data from LRMS using TCP/IP protocol.This system shall comprise of one or more centralised high-end servers. After login and password authentication. • Database Management system: A reputed and reliable Database Management System shall be used for storing and retrieving the data. connected to the internet. The database management system should handle requests from the LRMS Communication module to store the data and the web application software to retrieve the data. The server(s) shall be hosted on the internet using a static IP address or a registered website (preferable). This communication module is only for receiving the data when LRMS sets up a data call and this module does not initiate a communication with LRMS on its own. • Web Application Server: An internet interface shall be provided for the Railway staff to log on to the LTMS website using secure login and password. menu driven web application software shall be designed and developed (preferably in MS-Excel) for LTMS website. This interface will be hosting web application software that will enable the user to view the data received from the LRMS system in various formats. an appropriate interface with the Database Management System shall be designed. . the user should be able to see the following data as well as formatted reports. the LRMS communication module shall identify the nature of data. For saving the data into the database. • Application Software: A user friendly. When data is so transferred from the LRMS. interpret it appropriately and save the data into a database. database management system and general website administration. Ü A list of alert messages filtered by Locomotive/ Shed/ Zone/ All Indian Railways and also by time period of consideration. an interface shall be provided for other websites or software modules elsewhere to acquire the GPS location data of specific locomotive. • GPS location Data interface: For future use. An appropriate mechanism should be available for adding/ removing members and restricting their access only to particular locomotives/ sheds/ zones. Indication should be provided if the fault is still active or not. Ü Detailed listing of Locomotive Health data with data/ time stamp and GPS Location details for a particular Locomotive. Ü Summary page for particular locomotive with summarized data of all above data. Ü Re-fuelling information for a particular locomotive with date/ time stamp.Ü A Summary list of all locomotives fitted with LRMS hardware. • Maintenance: The user should be responsible for the maintenance required for the web servers. • User Maintenance: Any user who wants to login into the LTMS website should be an Indian Railways authorized person. Ü Life-time counters data and trip counters data for a particular locomotive. Ü A Summary list of all faults on locomotives and also time period for consideration (from & to dates). . Ü Monthly totals based on life-time counters data. hardware application software. 130 micro Siemens per CM Max.55 0C • Altitude.6 mg/cm3 Atmospheric Condition Max. The dust content in air may reach as high as value as 1. conductivity. Temp Humidity -20 0C 10% (up to 100% in rainy season) Altitude Reference-site Max.2 cm above rail level) Annual Rainfall Dust Extremely dusty & desert terrain in certain areas. 70 0C (Sun) 47 0C (Shade) Min. inside engine compartment. PH value.8.. speed of locomotive (Withstand shocks & vibration) Interfacing 160 kmph For LRMS (via modem) For LTMS (via modem) Electromagnetic immunity range 9KHz – 80 MHz . Temp.ENVIRONMENTAL CONDITIONS Max.5 Sulphate. Max.7 mg /lit.160 m • Between 1750 to 6250 (in mm) • Able to run at 5 Km/hr in a flood water (10. conc.1200 m above mean sea-level • Ambient temp. of Chlorine – 6 mg/lit Max.47 0C • Temp. Phoenix. Since the Siemens’ major clients are IR (Indian Railways). the product should suitably work under the harsh & extreme conditions of the locomotive and moreover. Ø TASKS PERFORMED Since the project was about the remote monitoring of locomotives. Looking at the hardware part of the Project. GPS. . necessary to learn about these technologies in details. GSM. it should be compatible with GPRS & GSM technologies. TCP/IP etc.LRMS & LTMS. my contributed to the company and the novelty of the idea behind the project. As per our specifications.Typhoon.GPRS. etc) that could suggest us the most appropriate product suiting our requirements. These technologies feature the most significant part of my project. (for instance. The complete study carried out by me throughout the internship training includes developing a strong foundation in the area of Loco industry and proposing a mechanism for the monitoring and the diagnosis of locomotives. Moxa. a wireless modem was required for interfacing the two important locomotive units. It was therefore.).PERSONAL LEARNINGS AND EXPOSURE With the culmination of the project. so it was our responsibility to make the REMMLOT understandable to the IR people. following conclusions/ derivations can be made with regard to what I learnt. This requires frequent interaction with various electronic vendors (for eg. Moreover. These screen shots were developed using MS-Excel software. some telecom and networking technologies were also implemented that were significantly used during the course of my training. it was initially required to get familiar with the brief & basic knowledge of the locomotives. The organised & focussed approach begins with the most basic architecture of locomotive along with its all major components. . This calls for developing an organised series of screen shots that enable a beginner to handle the device with ease. the tasks I performed. not only did I get a clear understanding of the functioning of locomotives (in terms of the various processes involved as well as the electrical equipment details). colleague interaction. vendor interaction are some of my worth mentioning learnings in Siemens. Being a part of well-established company like Siemens Ltd. Moreover. I gained an adequate and detailed knowledge of the software. proved to be a great learning experience for me. The entire internship experience with Siemens was like an opportunity that one should definitely aspire for. . I also learnt a lot about various wireless communication protocols. The internship has not only helped me to polish my academic knowledge but has also refined & brushed-up my communication skills. the training experience with Siemens enabled me to gain an ultimate professional knowledge. In the term of the 4 months. I learned about the strength & importance of working in a team. Apart from this. Looking forward to work with accompany like Siemens in future. I understood the various leadership and management qualities that a professional should have. I learned how the academic world differs from the professional. since the screen shots of the device were prepared exclusively in MS. Not only this. proved to be a great learning experience for me. Briefly.The most interesting and informative task that I had performed was visiting the shed at New Delhi railway station that helped me to understand the Locomotive in a much better way and also gained bulk of fascinating knowledge about Indian Railways.Excel for the Indian railways. Ø ACHIEVEMENTS AND BENEFITS Being a part of well-established company like Siemens Ltd. Moreover. The responsibilities. The internship has not only helped me to polish my academic knowledge but has also refined & brushed-up my communication skills. This was something entirely new and adds to my skill set which will definitely help me later on in my professional life. tasks. Had learned the various technical subjects like Data communication networks. I was able to contribute an appreciable of it to the company.microprocessor. For eg. Having the sufficient electronics & IT knowledge.Ø CONTRIBUTION IN THE PROJECT With a vast reservoir of academic knowledge gained till the completion of my third year. will give it a head start in terms of documentation already done and the various problems encountered.. I made their database in the latest Oracle 9i which was earlier used to be in Ms-Excel. Analog Electronics. The various types of switching – packet. I was in a position to understand the company’s various technical concerns and make the company aware about the latest developments taking place in the various spheres. with regards to the comparison of communication protocols as well as the various products already available in the market which can be used to good effect. This enables the company staff to maintain and deal with the past and the present company records much more easily and efficiently. Siemens Ltd. Is about to embark on designing a solution for the remote monitoring of locomotives and the research done in this project. It gives me a sense of immense pride in contributing something to a prestigious company like Siemens. . microwave . circuit & message was another instance.DWDM technology in optical communication was one such thing. batteries. The IEC also manages conformity assessment systems that certify that equipment. These tests are identified by the standard IEC (Same as the one we use in engineering industry as IEEE). IEC may also refer to an "interexchange carrier" (a long-distance carrier).These tests are conducted on the equipments depending on various situations and conditions (as discussed briefly in the coming table). one has to undergo a certain tests which can suitably analyse and guarantees the proper functioning of these electronic equipments There are certain tests that are recommended and specified for the electronic equipments in railway applications. Ü Specification tests. The IEC is the world's leading organization that prepares and publishes International Standards for all electrical. IEC is an acronym for International Elecrotechnical Commission. The following are the tests conducted on the electronic equipments in Rail applications: Ü Routine tests.These tests are conducted on routine basis (within a week. Ü Type tests.APPENDIX-I (IEC Standards & Tests) Taking a broader glance at the conditions & specifications of the electronic equipments. month or may be a year). solar energy. transmission and distribution to home appliances and office equipment. These tests are optional and are rarely performed. semiconductors.These tests are performed on grounds of determining different specifications for the equipments. fortnight. systems or components conform to its International Standards. fiber optics. IEC standards cover a vast range of technologies from power generation. . nanotechnology and marine energy as well as many others. In telephony. electronic and related technologies — collectively known as Electrotechnology. 7 of IEC 60571 10.2. 5.4 of IEC 60571 10. 6.2.NO. Clause No.TYPE TESTS REQUIREMENT FOR ELECTRONIC EQUIPMENT S.2.9 of IEC 60572 10. 8.2.8 of IEC 60571 10. 2. surges and electrostatic discharge tests.6 of IEC 60571 Details of test Cooling test (Operating temperature) Dry heat test (Operating temperature) Supply overvoltages. 7. shock and bump test • Apart from the above standards applicable for railway industries. 4.2. there are various other standards associated with other industries.2.10 of IEC 60571 10.frequency cables Electrical relays Electrical installation of buildings Wiring colors Semi-conductor devices Optical fibers Hydro-electric power plant automation Uninterruptible power systems Infrared transmission of audio/ video signals .11 of IEC 60571 Transient burst susceptibility test Radio interference test Insulation test Salt mist test Vibration. 3. 10.2. of Standard 10. 1.3 of IEC 60571 10.2. IEC 60038 IEC 60076 IEC 60085 IEC 60096 IEC 60255 IEC 60364 IEC 60446 IEC 60748 IEC 60793 IEC 62270 IEC 62040 IEC 61603 Standard voltages Power transmission Electrical insulation Radio. An extensive idea about the peripherals attached to the KM-DIREKT and the various signals and conditions controlled by it was a prerequisite. The above given block diagram shows the microprocessor based control unit with its peripherals as it’s exists in the WDG3A locomotive.APPENDIX-II (Setting up of Test Bench) Broad Scheme with Microprocessor based Locomotive Control System To set up the test bench for the microprocessor based control unit one required to have a broad idea of the conditions that actually exist in a locomotive. . The test bench thus designed is a simulation of the conditions present in the locomotive such that the various quantities like temperature. The following shows the sequence in which the data appears on the Drivers Display.pressure and speed are sensed and calibrated as a measure of current and voltage as it is impossible to create real-time conditions in a lab. APPENDIX-III (Modems & Driver’s display) Ü As soon as the K-Terminal is powered up the following appears on the screen: Diagnostic and extensive informative data is viewed on a 4 line text display of the KTerminal placed in the drivers cab. . ) F4 F1 F2 F3 F4 Speed (rpm) (6 analog values) F1 F2 F3 F4 Temperature (6 analog values) F1 F2 F3 F4 Motor Current (6 analog values) F1 F2 F3 F4 F1 F2 F3 F4 F1 F2 F3 F4 F1 F2 F3 Tree structure of drivers display .Start Picture F1 F2 F3 F4 Diagnostics Parameter Input Display Parameters F1 F2 F3 F4 F1 F2 F3 F4 F1 F2 F3 F4 Diagnostics List (history) F1 F2 F3 F4 Diesel Engine (8 analog / 1 bin.) F1 F2 F3 F4 Generator (5 analog values) F1 F2 F3 F4 Traction Motors Auxiliaries (10 analog val.) F1 F2 F3 F4 F1 F2 F3 F4 Wheel Diameter Time K-MEMO Miscellaneous (2 analog / 6 bin. Ø PHOENIX Design Voltage Data Interfacing Data rates Frequency range Operating temperature range Relative humidity Light weight telecontrol tasks 8-30 V DC supply Voltage GPRS. CSD. GSM 1800 and GSM 1900 -30-65 °C 5-80 %. non-condensing Ø Trio.DATACOM Hardware Data rate Frequency Range Tx Power Mol ot n d iu a yvRs tiiei Sc te v e n r i P Srl ou wy e p p We g h i t Fully integrated radio. Some of these modems are listed below along with their specifications. Apart from Typhoon (that is used in the project) there are few other modems that could be used as an alternative. i on Vl 1 c 8 m ( 3 k g 1 -1c V) 6 d . SMS 9-way serial interface bit rates up to 460 GSM 900. modem and data multiplexer 4800 and 9600 bps 380-520 MHz 0.5W (+37 dBm) ð± b 1D n l iNra e folg b an a rbd y wi r ai t d td i G8K MS -11rD 1N dS Bf dA m 2 B I o n0a d.Wireless modem has played a crucial role in this project.MODEMS: .1 . 1 )10 73x mm 14( i2 6 9 . 8 x 7 95 H oR 5 t % 42 VC o 8 D 1 t 96u 22s 57 hr o . 2a Gt s 9/S8 0GM0 0 5 10 K.Ø MOXA Eeg u eoae xmp nd a ttir e de r nt t e p aa Sd nr ts d CTte Srot Dmi aR nn aa si s P e T r o x w Bt a e u r d We g h i t Do me in i s Oirti nt d Hmi py g e a u nl at V I g p t e o u MTFaua meble Bmr in ( nt f it) e w e s 70 -3 o 5 C t ° GMdR SaPS n G 1p 4s U o 4 0 b t . 3s o 1 2 0 b t 5 p g 1 5 ± 0 n3. x . 0 wt 8w0 Gt 01S 1a 09M S /0 M1 Et.