KERNEX MICROSYSTEMS A Presentation on Train Collision Avoidance System (TCAS)

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TCAS Project

• TCAS Development project was awarded to 3 Companies, as below :  Package A- 140 KM awarded to Medha  Package B- 70 KM awarded to Kernex  Package C- 40 Km awarded to HBL Exploring Depths of Knowledge

TCAS Project - location map

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Package B (Kernex Scope) - location map

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Main Objectives of TCAS

• Safety  Prevention of SPAD  Control of Speed at PSR/TSR  Facility of SOS  Prevention of Collision during NI Working • Operational  Simple Operation by Loco Pilot  Continuous Update to ensure no Loss of Line Capacity • Limited Trackside Equipment Exploring Depths of Knowledge

Major Sub-Units of TCAS

• Station Units located in stations • Loco Units located in locomotives • IBS/LC Units located in block sections • Centralized monitoring system • Test benches at Loco Sheds Exploring Depths of Knowledge

TCAS Block Diagram

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TCAS Architecture & Components

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Typical Deployment Plan

(GPS) Station TCAS Station TCAS Loco 1 RFID Loco 2 Loco 3

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Loco TCAS - Schematic

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Loco TCAS major Sub-systems

• Dual Microprocessor based control system, along with dual redundant radio modems, RF Tag Readers and GPS Receivers • Interface to the existing speedometer • Event Logging sub-system along with blue-tooth data uploading/down loading facility and redundant GSM I/F.

• Two Loco pilot Operation cum indication panel (LPOCIP) – for Loco pilot and Asst. Loco pilot • Braking interface unit (BIU) • Dual Isolated Power Supply unit Exploring Depths of Knowledge

Loco TCAS Architecture

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Loco TCAS – Architectural Features

• Two redundant Microcontrollers (MIE 1 & MIE 2) working in “2 out of 2” mode to achieve high level of safety.

• All modules are connected through redundant CANBUS.

• Two redundant Microcontrollers (MIE 3 & MIE 4) as communication processors. • Two redundant Microcontrollers for peripheral interface.

• Separate Event logger for major events logging and storing for 90 days.

• Two UHF full-duplex Radio Communication Equipment with hot standby and associated antennae:  Frequency for Transmission by Loco : 441.8 MHz   Frequency for Reception by Loco : 466.8 MHz Transmission by Loco for emergency (SOS) Communication : 466.8MHz

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Loco TCAS – Architectural Features ( Contd..)

• Dual Redundant GPS units are interfaced with Loco TCAS to get synchronization for TDMA as well as to act as standby when speedometer fails.

• Radio Antennae & GPS receiver antennae are permanently fixed on the rooftop of the locomotive and connected to the Loco Unit through RF cables. • Dual Redundant RF-ID readers for finding Track Identification Number (TIN) and Absolute location.

• Dual Redundant GSM/GPRS modems for health check and transfer of failures to CMS.

• Bluetooth device for data up-loading and down loading.

• USB port for Event down loading.

• Loco Unit interfaced externally with Braking Interface Unit (BIU).

• Multi level Braking system, with the help of a proportional valve.

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Loco Pilot Operation cum Indication Panel

• Two LP-OCIPs (Operation cum Indication Panel) provided for Loco pilot and Asst. pilot interaction with TCAS.

• Functions performed: 1. Speed indication in analog and digital forms 2. Display of immediate signal aspect 3. Target distance and movement authority in meters 4. Generation of SOS 5. Selection of Leading/ Non leading of loco 6. Light engine/ Formation selection 7. Display of system health Exploring Depths of Knowledge

Loco Pilot Operation cum Indication Panel

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Breaking Interface Unit (BIU )

• Based on Proportionate Valve – Brake pipe pressure will be proportional to the input voltage • Separate Light engine brake • Separate Dedicated valve for emergency brake • Does not interfere with the brake action of the Loco Pilot • No continuous leakage of air after achieving the required pressure .

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RF Tag placement in Station

To be provided by Ajaiah

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Station TCAS major Sub-systems

• Dual Microprocessor based control system, along with dual redundant radio modems and GPS Receivers • Event Logging System along with blue-tooth data uploading /down loading facility and redundant GSM Interface and OFC Interface.

• Station Master operation cum indication panel • Station yard layout and status panel (21”) • Dual Redundant Power Supply unit • Battery and Battery charger • 30 meter Tower for radio modem.

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Station TCAS Architecture

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Station TCAS Architectural Features

• Two Microcontrollers (MIE 1 & MIE 2) working in “2 out of 2” mode to achieve safety of desired functionality.

• All modules are connected through redundant CANBUS.

• Two redundant Microcontroller (MIE 3 & MIE 4) working on for radio communication and display. • Event logger for major event logging and storage for 30 days • Two UHF full-duplex Radio Communication Equipment with hot standby and associated antennae   Frequency of Transmission by Station : 466.8 MHz Frequency of Reception by Station: 441.8 MHz • Two GPS units are interfaced with Station TCAS • Radio Antennae & GPS receiver antennae are permanently fixed on the preinstalled 30 mtr towers. • Two GSM/GPRS modems for transfer of failures to CMS.

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Station TCAS Architectural Features ( Contd..)

• Station-OCIP (Operation cum Indication Panel) provided for station master.

• Existing fail safe signal, point status relay interface contact input reading.

• 21’’ LCD monitor for yard display. • Bluetooth device for data Transfer.

• Battery with battery charger cum power supply to provide up to 24 hrs.

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IBS/LC TCAS

• Intermittent block Station/ Level crossing gate TCAS is similar to Station TCAS Unit, but with less no. of Inputs / outputs.

• No user interface • Acts like a base station Exploring Depths of Knowledge

Centralized Management System

Railnet GSM Network Loco 1 Web Reports Loco 2 Loco 3 Central Management System Web Reports LAN Network Station A Station B Station C Station N Exploring Depths of Knowledge

Station/IBS/LC TCAS - Schematic

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Trackside RFID Tags

• RFID Tags Provided at  Start/End of TCAS Territory  One Kilometer on Straight Track  At Turnouts to detect diversions and Infringements  Block Entry – foot of Last Stop Signal  Station Entry – at the end of the Block Overlap at the Station  Foot of Signal • Each Location with Pair of Tags for Redundancy • Rigid Fixture with Clamps on Sleepers Exploring Depths of Knowledge

TCAS System Functions

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ATP Functions

•In-Cab Signaling •Detection and Prevention of SPAD •Display of Distance of Signal and Movement Authority •Loop Line Speed Control •Speed Control at PSR/TSR

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Collision Prevention Scenarios

• Prevention of Head-On Collision • Prevention of Rear-End Collision • Prevention of Collision due to Unusual Stoppage in Block Section • Detection of Train Parting with External Input • Manual SOS Generation Feature in Station TCAS • Manual SOS Generation Feature in Loco TCAS • Detection of Roll back Exploring Depths of Knowledge

Supporting Functions

• Full Duplex Radio Communication • Location with RFID and Existing Tachometer • Automatic and Manual Brake Test • No Database in Locomotive TCAS Unit • Automatic Train Length Measurement Feature • Station to Station Communication for Additional Layer Block Protection Exploring Depths of Knowledge

Modes of Operations

• Normal Mode • Controlled Mode (when any vital system fails) • Restricted Mode (15 Kmph operation) • Staff Responsible mode (Manual mode) • Coupled / banking operation • Trip and Post Trip Modes • On-Sight Mode • Reverse Mode (to move in reverse direction) • Shunting mode Exploring Depths of Knowledge

Features of TCAS

• Full Duplex Radio Communication • Location determination with RFID and existing Tachometer • Automatic and Manual Brake Test • No Database in Locomotive TCAS Unit ; hence operation, handling of yard layout changes will be easy.

• Automatic Train Length Measurement Feature • Station to Station Communication for Block Protection (as additional layer) • Time synchronization of complete network through GPS Exploring Depths of Knowledge

Features of TCAS ( Contd..)

• Handling of New Train Formation • RFID based Track Id & Location Determination • Multi Level Braking Interface • Provision of Controlled Mode (Manual mode) Operation • TDMA based Communication protocol • Startup/Online Diagnostics • Event Logging • Central Monitoring through GSM / GPRS network for maintenance • Data up-loading & down loading through ‘Bluetooth’.

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Environmental Specifications

• Operating Temperature: -10 to +70 deg. C • Relative Humidity : 95% (non-condensing) • Vibration : 3 g for Loco; 2 g for Station & LC • Mechanical Shock : 20 g peak for 11 msec. (non-operating) • Bump : 40 g peak in packed conditions • MTBF (Planned)  - Loco unit: 20,000 hrs  - Station Unit: 60,000 hrs Exploring Depths of Knowledge

Present Status

• Installed Station TCAS in Nawandgi and Kurukunta stations • Installed Loco TCAS in one electric and one diesel loco • KMIL participated in several field trials to study / verify • Radio communication • RFID readers and tags • Inter-operability with other vendors equipment between stations Tandur, Mantatti, Nawandgi and Kurukunta. • Various control logics including SPAD • Prototype testing completed. (Same was used for site trials since Jan 14.) • Independent Safety assessor (ISA) clearance for Hardware design completed.

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Present Status ( Contd..)

• System documents under review by ISA.

• Soil test for Tower erection completed.

• Approval for Tower locations in stations and LCs from SCR obtained.

• Tower design with CPRI approval completed.

• Relay room wiring in Station- approval from SCR obtained.

• Unit level manufacturing in progress.

• Software documents under review by ISA.

• Software Functional logics developed and tested during site trials.

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TCAS Scenarios

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Detection & Prevention of SPAD

• Approaching Signal Aspect is Transmitted by Station TCAS to Loco TCAS • Loco TCAS Displays Signal Aspect on LP-OCIP • In case Driver fails to apply brakes to reduce the speed/stop the train, TCAS Applies brakes to stop the train. • On Change of Signal Aspect to green, brakes will be released Exploring Depths of Knowledge

In Cab Signaling

• Station TCAS gets inputs from Signaling and transmits the same to the approaching Loco TCAS • The Signal Aspect of the next approaching signal is displayed on the LP-OCIP • Movement authority is also displayed along with the signal aspect on the LP-OCIP • On Crossing the Signal, Next Signal Aspect and Movement authority is automatically updated on the LP-OCIP Exploring Depths of Knowledge

Display of Signal & Movement Authority

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Loop Line Speed Control

• Station TCAS gets inputs from Signaling and transmits the route Information to the approaching Loco TCAS • In case the route is set to Loop Line and the Loco Pilot does not apply brakes to achieve speed limit, Loco TCAS applies brakes to regulate to the Loop Line speed Limit • If Loco Pilot applies brakes, then Loco TCAS will not apply brakes as speed is monitored dynamically Exploring Depths of Knowledge

Prevention of Head-On Collision

• Two trains approach each other in Block section on the same Track is sensed.

• Station TCAS Transmits the HOC Condition to both Locos • Both Locos individually deduce HOC Condition based on Emergency Broadcast • Brakes are applied to both the Locos and brought to a stop Exploring Depths of Knowledge

Prevention of Rear-End Collision

• Two trains approach each other in Block section on the same Track is sensed.

• Station TCAS Transmits the REC Condition to both Locos • Both Locos individually deduce REC Condition based on Emergency Broadcast • Brakes are applied to the Rear Loco and brought to a stop Exploring Depths of Knowledge

Unusual Stoppage in Block Section

• One Train Stopped in Block Section either due to Derailment or for any other Reason is sensed by Station TCAS • Station TCAS Transmits the Unusual Condition to the other Loco entering the Block Section • Unusual Stoppage Emergency Broadcast also is sensed by the approaching Loco • Brakes are applied to the Approaching Loco and regulates to 15 Km/h • In case there is no obstruction, Loco Pilot can increase the speed after crossing the stopped Train Exploring Depths of Knowledge

Manual SOS from Station

• There is a provision on SM OCIP for generating emergency condition • SM can Press the Manual SOS buttons • All trains within the range of 3000m applies EB and stops • Loco Pilots of the trains can press the Manual Override and pilot the train at 15 Km/h • On Cancellation of Manual SOS in the Source Loco, Speed restriction is removed Exploring Depths of Knowledge

Manual SOS from Loco

• There is a provision on LP OCIP for generating emergency condition • Loco Pilot can Press the Manual SOS buttons • All trains within the range of 3000m applies EB and stops • Loco Pilots of other the trains can press the Manual Override and pilot the train at 15 Km/h • On Cancellation of Manual SOS in the Source Loco, Speed restriction is removed Exploring Depths of Knowledge

Prevention of Collision due to Train Parting

• Using External Sensor for Train Parting, Loco TCAS detects train parting condition • Train Parting Message is sent to the Station TCAS as well as transmitted in the Emergency Communication Slots • Any Loco TCAS approaching the Parted Loco TCAS applies brakes to regulate the speed to 15 km/h • Driver can look out for infringement and can go at full speed on crossing the Parted Train Exploring Depths of Knowledge

Train Length Calculation

• Loco Unit Stores its position and speed in FIFO • Station TCAS transmits the Start marker time stamp T1 to Loco TCAS (in millisecond accuracy) • Station TCAS transmits the End marker time stamp T2 to the Loco TCAS (in millisecond accuracy) • Based on the start and end time and the speed at which Loco is traveling, Loco TCAS calculates the Train Length Exploring Depths of Knowledge

Train Length Calculation Event “Start“ Train Length Event “End“ Event “Start“ Event “End“

Frame #n Frame #n+1 Frame #n+2 Frame #n+3 Frame #n+4

t (Start) t (END)

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Auto Brake Test & Manual Brake Test

• When Loco reaches a speed of more than 50 Km/h and is accelerating, Loco TCAS applies NB through Braking Interface Unit (BIU) • Speed is reduced by 20 Km/h • Based on the time taken, Deceleration constant (DC) of the train is calculated and stored for any future brake application. • Default DC is taken as 0.2 m/s 2 • Calculated DC is extrapolated for application of FSB and EB • Manual Brake Test is applied in Loco sheds to test the functioning of BIU Exploring Depths of Knowledge

TCAS Architectural Features and Safety Certification

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TCAS Architectural Features

• Two redundant Microprocessors/controllers (MIE 1 & MIE 2) working in “2 out of 2” mode to achieve safety of desired functionality • Two redundant Microprocessor/controller (MIE 3 & MIE 4) working on for radio communication and display. • Two full-duplex Radio Modems with hot standby and associated antennae • One GPS unit is interfaced with Loco TCAS to get time synchronization for TDMA as well as to act as standby when speedometer fails. • Radio Antennae & GPS receiver antennae are permanently fixed on the rooftop of the locomotive and connected to the Loco TCAS through RF cables. Exploring Depths of Knowledge

TCAS Architectural Features

Contd..

• Interfaced with two RF-ID readers for finding Track ID. • Interfaced with two GSM/GPRS modems for transfer of failures to CMS.

• Interfaced with two LP-OCIP’s (Operation cum Indication Panel) which are mounted on the Driver’s pedestal for easy access and visibility to the Driver. • Interfaced with Bluetooth device for data Transfer. • Loco TCAS interfaced externally with Automatic Braking Unit (ABU) for Normal Brake, Full Service Brake and Emergency Brake • Interfaced with 2 Field Input Modules (FIM) for Inputs. • Interfaced with 2 Field output Modules (FOM) for outputs. Exploring Depths of Knowledge

TCAS Architectural Features

Contd..

• Loco TCAS interfaced with existing odometer’s pulse generator to compute location data.

• Loco TCAS also interfaces with Inter-Cock Switch (ICS) to determine coupling / banking mode of train operations • Logging of eventlogs by eventlog module, which can be downloaded through Bluetooth.

• 1 Battery with battery charger to provide up to 30 min power backup. • 2 Hot Standby redundant power supply modules to provide power supply to all the modules of Loco TCAS Unit Exploring Depths of Knowledge

Safety Certification

• Independent Safety Assessor (ISA) done by ERTL, Kolkata • Hardware Design is Verified to provide required Safety • Software Design is Verified to provide required Safety • System is Validated Independently to ensure proper functionality • Design and Safety Documents are Verified to meet required Safety Level • On completion of assessment, Certification is done Exploring Depths of Knowledge

TCAS Radio Communication

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Radio Communication

• Full Duplex Communication • Stationary Units Transmit on Frequency ‘F1’ and Receive on ‘F2’ • Locomotive Units Transmit on Frequency ‘F2’ and Receive on ‘F1’ • In Emergency Situations, Loco Units also transmit in ‘F1’ and tune back to ‘F2’ for Listen. • Uses Time Division Multiplexing (TDMA) for Communication Exploring Depths of Knowledge

Communication Time Frame

Timeslot Position Marker 1 2 3 Tx by Stationary

(f1)

S1 1094 Bits ( Repeater/ End Cabin ) 1 M 5 7 Tx by Train

(f2)

Tx by Train ( Addl SOS/ Emergency Tx)

(f1)

45 4 6 55 56 6 6 6 8 7 2 75 7 9 8 1 S 4 M3 9 S 5 1094 Bits ( Repea ter/En d M4 Cabin 0 ) M4 4 S6 3504 Bits M4 5 S7 3504 Bits M5 3 M5 4 S 8 3504 Bits M6 2 M6 3 M7 1 MTP 2704 Bits S9 3504 Bits M7 2 M7 6 86 MR3 MR4 ME3 ME4 Exploring Depths of Knowledge

TCAS Position Determination

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Position Determination

• Loco TCAS is fitted with two RF Readers. • RF Tags are fitted on the sleeper • On Crossing RF Tag, Loco TCAS gets Absolute Position • From tachometer Speed, position is accumulated • GPS is used as fall back, in case of tachometer failure • Tag Crossed + distance traveled is Transmitted to Station TCAS • Station TCAS Calculates position of Train based on Absolute Position of Tag + Distance Traveled Exploring Depths of Knowledge

THANK YOU

Kernex Microsystems (India) Limited

‘THRUSHNA’, PLOT NO 7, A.P.I.I.C LAYOUTS HI-TECH CITY, MADHAPUR, HYDERABAD – 500081 Tel: +91-40-23113192-94, Fax: +91-40-23113191; URL: www.kernex.in

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