broken rail detector

8/11/2019 Broken Rail Detector

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The Ultrasonic Broken Rail Detector is designed toreliably detect breaks in train rails under allenvironmental conditions.

Whilst increasing operator efficiency and profitability,the Ultrasonic Broken Rail Detector is easy to install andmaintain, and requires no track modif ication.

The design of the system also makes it suitable for solarpowered, remote operation.

The system features special signal processing anddiagnostic techniques to ensure reliable operation andsection coverage up to 1000 meters.

ULTR SONIC BROKEN R IL DETECTOR

Overview


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Benefits to the client are:

Continuous monitoring for broken rails without human intervention.

Increased operational efficiency of the railway line.

Client will know where the break occurs (with a 1km resolution).

The system is designed to operate from solar power. It is not maintenanceintensive, requires no rail modification other than rail bonding for lightning andsurge protection, and is easy to install.


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3. System Descr ipt ion

3.1 General

The operation of the system is based on a simple transmit-receive

confirmation protocol. An acoustic signal is generated and inserted in the railat one location (transmitter), propagates along the rail, and is received at aremote location (receiver). The integrity of the rail between the transmitterand receiver is confirmed as long as an acceptable signal is received. Shouldthe rail develop a clean break between the transmitter and receiver, theinserted signal will not be received resulting in the generation of an alarm.

The Ultrasonic Broken Rail Detector consists of the following majorcomponents:

Transmitter Module

Receiver Module

Cabinet with Power Supply and Communication Equipment

Ultrasonic Transducer and Cable

Rail Clamp

Alarm Terminal

3.2 Principle of Operation

High voltage driving bursts generated by Transmitters are converted intoacoustic energy by the rail mounted Transducers, and propagates in bothdirections in the rail. Arriving at Receiver stations, the acoustic energy isconverted into electrical signals by the rail mounted Transducers. Thesesignals are filtered, amplified, and processed to ensure that only valid signalsare recognized.

The absence of a valid signal at a Receiver signifies a severely cracked orbroken rail in the specific rail section.

Transmitters and Receivers are interleaved. A specific Receiver receives

signals from both rail directions (up and down). To enable Receivers todetermine the direction from which acoustic energy originates, Transmittersinsert a burst train consisting of 5 pulses at a preset Burst Repetition Interval(BRI) into the left rail, followed by a sequence at a different Burst RepetitionInterval into the right rail. The BRIs are set differently at adjacent transmitters.Burst trains are repeated at a specific Interrogation Interval (II).


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To ensure that received burst trains from the Up and Down directions do notoverlap for extended periods at a specific Receiver, causing false alarms,adjacent Transmitters are factory set to different Interrogation Intervals (II).

Receivers measure the pulse intervals to identify the direction of the specificTransmitter station. For this purpose, Receivers are also individually set to

RightLeft

Right Rail

Left Rail

Burst Repetition

Interrogation Interval

Burst Injection Scheme


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3.4 Receiver Module Description

The Receiver consists of two separate analogue amplifier and filter circuitswhich generate triggers when received signals comply with the signaldiscrimination criteria, i.e. frequency, burst length, and amplitude. Triggers

interrupt the Processor which then executes interval timing routines. A CodeDetection algorithm is used to recognise valid burst trains, and to rejectspurious noise.

Rail mounted Ultrasonic Transducers are connected to the Module FrontPanel using coaxial cable and SMA front panel screw type connectors.

Receiver Board


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3.5 GSM Module

A custom GSM (cellular) is available to deliver the following alarm messagesto the Alarm Terminal:

Up Left Alarm (Up Left Normal)

Up Right Alarm (Up Right Normal)

Down Left Alarm (Down Left Normal)

Down Right Alarm (Down Right Normal)

Train Presence

Battery Voltage Low (Battery Voltage Normal)

Cabinet Door Open (Cabinet Door Closed)

Alarm status of a specific Receiver Unit can be polled via the GSM network.

GSM Module


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3.6 Alarm Terminal

A custom Alarm Terminal is available as a stand alone unit. The rail section

configuration is displayed with indication of broken rails, GSM communicationerrors, equipment failures, and sections booked out during repair actions.


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4. Intended Use

The Ultrasonic Broken Rail Detector is specifically designed to achieve acontinuous inspection of the rail status. In its current form a completeinstalled line can be scanned for rail breaks down to 3 minute intervals (called

the interrogation period), depending on train length and traffic density. On theOREX line in South Africa, the Interrogation Interval is set to 15 minutes toconserve energy consumed from the solar power supply system. The longestperiod for which a broken rail can go undetected, is thus equal to this settableInterrogation Interval.

Given the arguments above, it should be noted that the Ultrasonic Broken RailDetector is not classified Fail Safe, although many fail safe principles havebeen incorporated in order to detect and reveal most of the equipmentfailures. It is however conceivable that certain failure modes could occurwhich is undetectable and can cause the system to indicate that a section ofrail is intact, while an actual rail break could be present. Thus it is important tonote that the system is employed as a fast turn around inspection system withgreatly improved break detection reliability as compared to currently employedbreak detection methods.

Careful attention has been given to system and lay-out design to ensure thatequipment failures are detectable and will not manifest as false alarms. Withthe centre fed Transmitter configuration for example, a failed TransmitterModule will result in simultaneous signal loss in all four sections of railinterrogated by it. Such a multiple detection failure will be evident by

inspection of detection status at both adjacent Receivers and is completelyvisible at system level.

The Transmitter Module for example, employs an independent Transducervoltage monitor, which is used to detect a failed Transducer, cable orconnector. On detection of such a failure, the Transmitter automatically shutsdown, causing a multiple detection failure at both adjacent Receiversindicating equipment failure rather than false alarms. The Receiver alsoemploys techniques to reduce the occurrence of false alarms. Algorithms areemployed to improve detection reliability and to recognize the presence of atrain, which otherwise could cause detection failure due to interference with

the interrogation signals.

With this in mind, it should be clear that the RailSonic Ultrasonic Broken RailDetector system should not be used on its own to manage the risksassociated with broken rail detection. It should be used as a part of an overallbroken rail detection strategy on the railway. Procedures should be in place tohandle the detected broken rail incidents.

The repair action and the re-commissioning of such a section should all beintegrated into such a strategy. In the case of equipment failures, detectionwill be lost for that particular section and procedures should be in place to

initiate alternative detection mechanisms until system operation is restored.


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With current broken rail detection and management experience, RailSonic isin a position to assist clients withthe definition of a total broken rail management system incorporating theUltrasonic Broken Rail Detector.

5. Contact Details

Institute for Maritime TechnologyA division of Armscor Defence InstitutesP O Box 181Simons Town7995South Africa

Tel : +27 21 786 8100Fax : +27 21 786 3634Email : [email protected]: http://www.railsonic.com

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