DEPUTATION REPORT OF

INSPECTION & TRAINING QF

ELECTRONIC RAIL CORRUGATION AND WELD MEASUREMENT SYSTEM

FROM 02-07-2007 TO 07-07-2007

MIS PUT "GRAW" sp. z 0.0. - GLIWICE, POLAND /--- ----

ASHISM BANSAL, DIRECTORfTMfRDSO 0

(REPORT NO. TM - 113) 2 Cr, 0

AUGUST 2007

TRACK MACHINES & MONITORiilG DIRECTORATE RESEARCH DESIGNS AND STANDARDS ORGANISATION

LUCKNOW-22601 1

to.\* u 1 3."' ' 6]bQ-, MIXISTRY OF RAILWAI'S ,..... ..... -.---- RAILWAY R n R D

No.2007/E(O)tii14!?0 Sea. Uull~i. dated OJ.06,2OUi

Sub: Deputalio~l of Shri Asllish Bansal. Director (TM)/RDSo to ~'olaml .....

Ref: This Ministp's lctlcr ofc,cn mln~ber daled 28.0?.?00;.

Paragrnph Z of this Ministr).'~ lcner quotcd above on the subject tnestioscd rllay be subslilulcd by the following :

"The period of deputation \-ill be s i x days excluding transit timc. from 02.07.2007 to 07.073007".

2. Al l othcr terms and conditions o f the deputation rcrnain unchanged

3 This issues with thc concurrence ofthe Finance Direclorate ofthc Millistry or Railways. +,', ,.

IN. Sodan) Deputy Secrclsry (D)iRailway Board.

No.2007/E(O)IU14i20 Copy forwarded to :-

New Dclhi, datcd 4.06.2007

The Rincipal Director of Audit. Nonhcm Railway New Dclhi and Dy.Cornptmller & Auditor General o f India (Railways), R w m No.224, Rail Bhavan. New Delhi.

for Financial Commissioner. Railways

New, Delhi. datedL/ .06.?007.

I. Ministry of Finance. Depn. of Expenditurc.Nonh Block, New k l h i . 2. Ministw of External Affairs, South Block. New. Delhi. 3. F im Seorelar);fDy.Roilua). Adviser. Embassy oilndia, UI. Rcjtalxa 15. Flats 2.7. 0:.

516, Warsaw. POLAND. Accommodation and lrnnspon may be bwked for the oflicer on request and debit raised against the Exec.Dircctor (Fin.mDSO. Lucknotv.

4 Shri Ashish Bansal. Director (TMYRDSO 5. Executive Director (Fin.)/RDSO. "f 6. P.O. G(Aa). Cash-l.F(E)ll. F(Foreign Exchange). ERB-I, and E('Trg.)Rr. . . nl

RIy Bd. ,, I , , . ..(*-.' LO )*N' ~otnon) o

Deputy Secretary (D)/Railway Hoard.

vii) Internal Travel : Suitable t&spo~l appropriate to stalus may be arranged for the oficcr on q u e n for oficial journey, and debit raised agninn Evcwtive Director (Fin.)/RDSO.

5 . The expenditure on the deputation oithe o f i m will be chargcd lo h e head to which his pay and allowances are charged. Post held by Lhc oficer will no! be filled up during cl~e petiod of his depulalion.

6. The release of foreign exchange on account orpersonal incidentals will be regulated in terms of lllc Minisuy of Finance (Depn. oi Economic Affirs)' 0.M.Na. F.13EC194 dated 22.3.94 a ~ d 8c amendcd from time to tirnc. -

7. Entitlements of lhc ofliccr may k paid to. him in US dollars in India and no pul Ulcreaishall be paid to him by the mission abroad.

.. 8. This issues with the wncurrencc of thc Finance Directorate of the Ministry of Rniluay.

v$Ft4' . Soman) Depufy Secretary (DWilwiy Board.

el. Exlracu of Min. of Finance ( D o n . ofExditurc) 's OM

No.~W~/E(O)NI~RO New hh, dated 28.02.2007.

Copy fonwded to :-

( I ) The Rincipal director ofAudiI, Nonhm Railway New Delhi

(2) Dy.Compmller & Auditor General of India (Railways), Room No.224, Rail Bhavah New Delhi.

dud@~ lo ; l ~ l *'a** ~.--+"

q , . $ q a T 1 . .

q 7 gt? b"...- 6 MLVISTRY OF RAILWAYS

t ..........---^ RAILW.&Y n n ~ n n So.Z00i/E(O)llIl4,'?0 Sew Ucll~i. dated 06.06.?007

Uinrlor Gcncral R.U.S.O.. I2t~ckamn. CORRIGENDUM

Sub: Depuralion of Shri Ashish Bansal. Director (TM)!RUSO in I1oland. ..--.

Rci : This Ministry's lcrrcr oicrcn nun~hcr dated 28.02.200:.

Pan$raph 2 ofthis Nlinislq's lcner quoted above 0s the subject met~~io~led allay be subslitt~tcd by the follow~ng :

T h e pcriod of deputalion will be six days excluding transit time. from 02.07.2007 to 07.07.2007".

2. Al l other terms and conditions of the deputation remain unchanged.

3. l h i s issun wilh the concurrence ofthe Finance Directorate of the Ministry

Deputy Secrelaq (D)&ilway Board.

No.2007/YO)IU14RO Copy forwarded to :-

New Delhi. datcd4.06.2007

The Rincipal Director of Audit. Nonhcrn Railway New Delhi and Dy.Cornptroller & Auditor General of India (Railwap), Room No.224, Rail Bhavan, N m Delhi.

6%- for Financial Commissioner. Hatlwayr

No.2007/E(O)lY 14n0 Copy to:-

Neu, Delhi. daledv .06.2007.

I . Minissty of Finance. Depn. oiExpenditurc, Nonh Block, Ncw h l h i . 2. Ministry of External Aifain, South Block. New. Delhi. 3. F i m Swrctary/Dy.Railu,ay Adviser. En~bassy of ledia, G I . Rej~ana 15. Flats 2.7. 01.

5 16. Warsaw. POLAND. Accom~nodaliun and tnnspon may be booked Tor the oficcr on rcqtlcst and debit raised againu the Euec.Director (Fin.YRDS0. Lucknow. Shri Ashirh Bansal. Direclor (TMYRDSO

5. Executive Direnor (Fin.)/RDSO. 6. P.O. G(Acc). Cash-l.F(E)Il. F(Forcipn Eschange). ERE-I. and E(rrg.)nr.

Rl? Bd. , ,

N. Suman) Deputy Secretary (I))/Rail~vay Ijoard.

*

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

RAILIVAY BOARD *******

4 0 W O q l O R 0 A m

No.2007/E(0)11/14/20 q, a') 4': a?w 6?;J9R *- New Delhi, dated 28.02.2007. ~ " O ? P .I7 zrc? a

Director General, i4te ...... ......... - -- R.D.S.O., Lucknow.

Sub: Deputaiion of Shri Ashish Baasal. Director (7M)IRDSO to Poland. ---

Sanction of the President is hereby communicated to the deputation of Sh.i Ashish Bansal, D i r d o r (TM)IRDSO (in the pay scale of Rs.14300-18300f-) lo Poland, to carry out inspection of Electronic Rail Corrugation and Weld Measurement System being procured from MIS. Agromach Spares Corporation.

2. The period of deputation will be sir days excluding transit time, fium 12.03.2007 to 11.03.2007.

3. The deputation will be governed by the terms and oonditions a contained in the Ministry of Finance @epartment of Expenditure's) O.M.No.19036n183-E-N dated 7.1 1 . I 984 and as amended from time to time.

4. The following expenditure may be incurred:-

i) Passage- As per entitlement indicated in the Annexure.

ii) Cash Allowance:-As admissible under extant order of the Ministry 01 External Affairs.

iii) Contingency: Contingemy expenditure of stationery, postage,telegra~ns, telephones, etc incurred in discharge of official duties may be allowed in accordance with the existing mles. rn

iv) Hotel accommodation: Suitable accomrnodetion appropriate to status & 0

may be booked for the officer on request and debit raised agaim Executive L . 0 Director (Fin)/RDSO, Luchow. 0

v) Excess Baggage: Official : As admissible.

vi) Airport W i s a fee: May be reimbursed as required.

1 . M i n i m orFinance, Depn. of Expenditure, North Block. New Dclhi.

2 . Ministry of External Affairs. Soulh Block, New. Delhi

3. First Secrclary/Dy.Railway Adviser. Embassy of India. UI. Rejlana 15, Flats 2-7.02-51 6, Warsaw, POLAND.

Accommodation and bansport ma). be booked for lhc oflicer on rcqucsl and dcbit raised against the Exs.Direc1or (Fin.)/RDSO. Lucknow.

7 4 . 4 A s h i s h Bansal. Director (lTd),O/RDSO

His attention is invirxl to instructions conmined in Lhe m e x u r c .

5. Executive D i m o r (Fin.)/RDSO.

6. P.0, G(Acc). Cash-I,F(E)II, Fporcign Exchange), ERE-I, and E(Trg.)Rr Rly Bd.

End: Extra& of Minof Finance (Depllof E x p c n d ~ t u ~ S s 0.M.No 19016/7/83-E.IV dated 7.1 l 1984. A~exure for itrm 4 only. 6''

Deputy Secrewy (DyRailway Board.

INSPECTION AND

TRAINING REPORT

INDEX

Details Page No.

Introduction 1

~esign and operation of Electronic Rail 6 Corrugation and Weld Measurement System

Operation of control system of device 7

The software for analysis and visualization of 29 measurement results

Verification of metrological properties of the 71 device

Format of measurement files 72

Technical data of Electronic Rail Corrugation 74 and Weld Measurement System

Calibration settings card 75

Annexure-I1 (Inspection Report)

Electronic Rail Corrugation and Weld Measyement System makes possible to estimate the waviness. The unaue &at!.i~ of t/ls gauge is that it can

wavy wear of tails ahng lengif~s greater than devire M y length, due to appliwtion of supetpsf&n a/sorithm whie measurements are mde. Due to this it a n & applied lo esbiM& wavy wear of tails not only within the %-ope of sho/t waves (0.034.3) m but alm of lengths d i n bk m p e of (0.3- 1) m and (1-3) m. lBis f&tule is addibbnal over and ahve the s, f iw@ns.

During the visit from 2"d to 7th July, in addition to training, discussion with the experts of M/s PUT "GRAW was done on the following issues: 1. Hardware details and assembly of the system. 2. Principles of operation 3. Software and report generation 4. Technical specifications of the system 5. Calibration procedure of sensors and the gauge at the manufacturing

stage 6. Points communicated vide TMM Directorate's E-mail dated 12.2.07,

letter no. TM/IM/35 dated 14.2.07, 19.2.07, E-mail dated 1.3.07 and 2.3.07.

Hardware details and assembly of the system: The Electronic Rail Cormgation and Weld Measurement system is composed of:

Body of measurement system including measurement heads and a drive Control system - measurements results recorder. Accumulator battery

a Battery charger Supply unit of recorder PC computer connection cable Gauge for measurement system control of the device Software, which makes possible to transfer measurement results to PC computer, their visualization and printout of measured profiles.

• User Manual Calibration p r & ~ l 0

r \ ,

Electronic Rail Cormgation and Weld Measurement system is adapted ;nu Ln to continuous operation within 8 hours without necessity to exchange or to

charge additionally the supply source. Measurement of consecutive rails is stored in recorder memory as separate files. Visualization of collected measurement results is ammplished also after bansferring them by RS232 interface to PC computer.

A frame is provided inside the body of the equipment. On this frame, the carriage is mount&, on which the two sensors are provided for capturing the vertical and lateral profile. This frame was available in the laboratory. The frame has connections with the outer body at 2 points only, which are at the

1.0 INTRODUCTION

Rail and weld geometry are dominant factors for track service life. A poor geometry leads to high dynamic forces and consequently to a rapid deterioration of track components. A substantial increase of forces develops due to relatively small geometrical deviations. Short wave irregularities are known as corrugation which lie in the wave band of 3 to 30 cm and amplitude 0.05 mm.

Corrugation causes excessive stresses on mils and creates roaring of rails. Corrugation needs to be identified and remedial measure of grinding is to be resorted well in time to avoid heavy gnndinglrenewal of rails involving heavy financial inputs.

During his visit to Paris to attend an "Interactive conference" on "Cost effectiveness and safety aspect of Railway back" organized by ERR1 on and gfh Decembet-98, ADGIRDSO had identified an equipment dwdoped by Esveld consulting services (BV) and known as "RAILPRF 1200 straight edge" which could be gainfully employed in Indian Railways for measurement of corrugation (vide W C - 2 dt 23.12.98). It was recommended to procure one set of the equbment for experimental use.

A work for procurement of RAILPROF 1200, corrugation measurement system was sanctioned in January-2000. The contract for procurement of Electronic Rail Corrugation and Weld Measurement system was awarded to MIS Agromach Spares Corpn., 194-D, Gaiwadi (Compound), Girgaum Road, Mumbai-400004, (Pnndpals - P.U.T. "GRAW sp. z 0.0. ul. Kamla Miarki 12, skr.6, 44-100, Gliwice, Poland) vide RDSOILucknow purchase order No. SP3/0058/TM/GT/2000/063 dated 09.05.2005 with a total cost of Rs. 8,77,500.00. The writer of this report was deputed by Railway Board to carry out inspection of the system vide Railway Board's letter no. r- 2007/E(O)II/14/20 New Delhi dated 28.02.2007 & 04.06.2007. Training was 2 also to be imparted in terms of clause 9.0 of Technical specifications. It in included tmining in lab, operation, hardware and software. o

Electronic Rail Corrugation and Weld Measurement system is provided for collecting digitised image of longitudinal rail pmfile consisting of short wave irregularities known as corrugatian, which lies in the wave band of 3 to 30 an. Similar measurement for welds is also to be done by the system along with measurements of their gauge face.

M/s P.U.T. 'GRAW" have developed a portable and light gauge which can measure the corrugation on rail/weld and straightness of welds. Measurements are executed touch less and in two planes at a time. Moreover,

end. This ensures-that the results are accurate, even if the outer body develops some knk or curvature during the lifetime of equipment.

This is explained f u ~ e r in 2.0 aild 34. Principles of operation: These have been discussed from 2.0 to 3.0. Software and report generation: This has been discussed in detail in 4.0.

Technical specifications of the system: These have been discussed in detail in the inspection report, which is attached as Annexure-11.

Calibration procedure of sensors and the gauge at the manufacturing stage: Calibration procedure of RSG at manufacturing stage involves linearization of sensors i.e. the characteristics of sensors are acquired. A gmph between the voltage and distance is plotted and this information is stored in the device memory. The accuracy is better than 0.005 mrn and 0.001 V in their whole measurement range. Than the device is zeroed on a certified flat template. The zeroing is better than 0.03 mrn. Thus by ensuring that the sensor characteristic is better than 0.005 mm in the whole range and also that the zeroing is better than 0.03 mrn, the accuracy in the whole measurement range is ensured. At this stage all examinations are camed out of repeatability--both the laboratory ones as well as the field tests. After the gauge passes these tests then a second order template is made, which is provided with the equipment, with two grooves of about 1 mm and 2 mm. The digital characteristics of this device is obtained using the freshly calibrated RSG gauge and saved in the file delivered with the system software. The template is delivered with the instrument and the checkup procedure mnsists in measuring the template and the software carries out accuracy assessment automatically.

The Calibration procedure at the manufacturing stage and the Lab & Field Validation Scheme is placed as Annexure -I. Points communicatEd vide TMM Directmate's E-mail dated 12207, letter no. TM/IM/35 dated 14.207,19.207, E-mail dated 1.3.07 and 2.3.07: The remarks on these issues are as under:

S.No. 1.

2.

Item mentioned in letter/E-mail Confirmation regarding compliance of all the clause of the specification

For lab testing, accuracy to be measured by testing on a template with known defects and a13 On a rail with known defects (clause 5.1). The accuracy limit to be as per clause 3.1. Accuracy to be achieved for all the parameters i.e. straig9tness of welds in vertical plane, straightness of weld in horizontal plane and corrugation.

Remarks These have been discussed in detail in the Inspection report. As per 5.1, "Sample rail piece with known defects to be made available for chechng proper functioning of the system before testing." The template with known defects was made available in the lab. Thus it was complied.

5. RAM support- memory battery replacement procedure should be described in a:supplement to the User Manual.

2.0 Design and operation of Electronic Rail Corrugation and Weld Measurement System

The device is used to examine shape of running plane and side plane of rail head along section of 120 cm. Measurement is accomplished using touch less method by means of two measurement heads during their travel along measured rail surface. The device is composed of body with slide ways on which a caniage mounted with measurement heads as well as control system (of recorder) travels. The body is incorporated in metal casing, on which control system and battery is attdched while measurements are made. The task of control system is to record readouts of photoelectric converter and measurement heads as well as to control the carriage travel.

Position of heads is precisely established by manufacturer. Carriage travel with heads mounted on it along measured rail is made automatically after starting the measurement cycle. Proper guiding surfaces of casing provide correct reference planes of device body in relation to a rail. The carriage is moved by means of e l m ~ c motor furnished with a wrapping connector. Position of the carriage in relation to slide way is determined by means of photoelectric converter. Extreme position of caniage is signaled by two limit switches - left and right one.

Recorder body incorporates graphic display and membrane keyboard, which make communication possible with the microprocessor control system of Electronic Rail Corrugation and Weld Measurement System. By means of keyboard we can determine localization of weld in a track and we can specify any additional information supplementing the measurement results. After the measurement is completed, the measured profile and result of its estimation can be viewed on the display after selecting proper option of control system.

C\I After a series of measurements are completed their results are saved m

to PC computer memory to perform further analysis. This task is t.: accomplished by SOFTWARE provided together with measurement device. o The software used to analyze measurement results enables making plots of the whole measured profile of rail surface or its selected fragments, archiving the measurement results, their estimation as well as observation of wear progress. Moreover it is possible to print measurement protocols including estimation of straightness and waviness.

3.0 Operation of control system of device

Control system of the device mounted on Electronic Rail Corrugation and Weld Measurement System is supplied from externa! MiMH service-free accumulator battery. Batteries are protected against complete discharge. !!I case of too low voltage the control system disconnects the device. While transferring measurement results to PC computer the recorder is to supply using external power supply unit furnished together with device. On the front panel of control system there is membrane keyboard as well as ,graphic LCD display. Moreover, there are sockets to connect Electronic Rail Corrugation and Weld Measurement System and PC computer during transmission of measurement results. To control the recorder operation the keyboard is used which can operate in one of two modes: selecting the options and as alphanumeric keyboard.

Fig. 1. Keyboard and display of Electronic Rail Corrugation and Weld Measurement System control system

Data saved in recarder memory (6ntroller) are grouped in files created as a result of measurement sessions. Every new file is assigned a consecutive number beginning tiurn 0 (0 is assigned to the first file, the second is 1, etc.) Starting from this moment, a file is identified by its number. I n order to protect data and check integrity of information checksums are created for m

03 every file. Every measurement file in the recorder contains dab related to u-> running plane and side plane shapes. r r ,

0

3.1 Control system switching on - switching off

3.1.1 Power supply switching on (switching off) of device

Recorder system connected to device, battery attached: Switching on supply of the device and control system shall be accomplished atter pressing key OnIOff of recorder keyboard. After

end. This ensuresthat the results are accurate, even if the outer body develops some kink or curvature during the lifetime of equipment.

This is explained further in 2.0 a;ld 3.0. Principles of operation: These have been discussed from 2.0 to 3.0. Software and report generation: This has been discussed in detail in 4.0.

Technical specifications of the system: These have been discussed in detail in the inspection report, which is attached as Annexure-11.

Calibration procedure of sensors and the gauge at the manufacturing stage: Calibration procedure of RSG at manufacturing stage involves linearization of sensors i.e. the characteristics of sensors are acquired. A graph between the voltage and distance is plotted and this information is stored in the device memory. The accumcy is better than 0.005 mm and 0.001 V in their whole measurement range. Than the device is zeroed on a certified flat template. The zeroing is better than 0.03 mm. Thus by ensuring that the sensor characieristic is better than 0.005 mm in the whole range and also that the zeroing is better than 0.03 mm, the accuracy in the whole measurement range is ensured. At this stage all examinations are carried out of repeatability--both the laboratmy ones as well as the field tests. After the gauge passes these tests then a second order template is made, which is provided with the equipment, with two grooves of about I mm and 2 mm. The digital characteristics of this device is obtained using the freshly calibrated RSG gauge and saved in the file delivered with the system software. The template is delivered with the instrument and the checkup procedure consists in measuring the template and the software carries out accuracy assessment automatically.

The Calibration procedure at the manufacturing stage and the Lab & field Validation Scheme is placed as Annexure -I. Points communicated vide TMM Directorate's E-mail dated 122.07, letter no. TM/IM/35 dated 14.207,19.207, E-mail dated 1.3.07 and 2.3.07: The remarks on these issues are as under:

- S.No.

I.

- 2.

Item mentioned in letter/E-mail Confirmation regarding compliance of all the clause of the specification

For lab testing, accuracy to be measured by testing on a template with known defects and aljo on a rail with known defects (clause 5.1). The accuracy limit to be as per clause 3.1. Accuracy to be achieved for all the parameters i.e. straigCltness of welds in vettical plane, straightness of weld in horizontal plane and corrugabon.

Remarks These have been discussed in detail in the Inspection report. As per 5.1, "Sample rail piece with known defects to be made available for checking proper functioning of the system before testing." The template with known defects was made available in the lab. Thus it was complied.

The p d u r e for calculation of accuracy has been dixussed above. The achievement of accuracy for running and side profile ensures that the accuracy is achieved for all parameters, as they are derived from the basic profile. This has been complied.

The system can measure the lip flow reliably within it's measuring range. The mechanism of measurement is the same as that used for measuring the running and side surfaces. These have been enumerated in detail in 3.9.3.

Maximum memory size is 250 measurements; the display shows the volume

memory occupied, the rest is free memory: Stored data can be deleted on confirmation by user. This has been explained in detail subsequently. All these reports are generated. This has been explained on subsequent pages. No indices are available on IR at p e n t . such a type of inmment is also being procured for the lst time on IR. IndexIIndices could be incorporated on the basis of fnrm~~lan nrnvkLdm tho

3.

4.

5.

6.

7.

-

For repeatability, two measurements on a rail / rail piece to be taken and the maximum deviation should not exceed 50 micron (dause 3.2).

System should be able to record reliably the rails with lip flow. Mechanism for this to be explained

The results, both graphical and digital, being shown after each measurement may be enumerated.

It may be confirmed that the system has the facility to show memory used and available. Also the stored data should able to be deleted o n o f confirmation by user.

The follows reports are to be generated:

i) Comparison of two test reports showing improvement or deterioration,

ii) Generate exception report from stored data and alculation of various indices.

iii) Graphical output of test results from stored data.

corrugation amplitude, grinding index and welding index. The Exception report should contain values of all the above parameters and the Graphical report should contain the graphical

on of all the above

11. Evaluation of ImprovementjDeterioration improvernentjdeterioration can be evaluated.

The following features have been provided over and above the specifications: i. It can estimate wavy wear of rails along lengths greater than device

body length, due to application of superposition algorithm while measurements are made. Due to this it can be applied to estimate wavy wear of rails not only within the scope of short waves (0.03-0.3) m but also of lengths within the m p e of (0.3-1) m and (1-3) m.

ii. Average wave length and mean amplitude of corrugation can be seen -I on the display after the measurement. c3 u->

L n The firm was asked to make the following modifications in the system: o

1. "RLY ZONE" and "Division" should also be added as identification inputs to the measurement made.

2. "Rail" on the right side is indicated as "P" in the controller display. This is to be corrected.

3. Time setting for the measurement has to be provided. 4. Serial number of the device does not match with the serial number

displayed in controller. It is to be corrected.

5. RAM support* memory battery replacement pmedure should be described in a:supplement to the User Manual.

2.0 Design and operation of Electronic Rail Corrugation and Weld Measurement System

The device is used to examine shape of running plane and side plane of tail head along section of 120 cm. Measurement is accomplished using touch less method by means of two measurement heads during their travel along measured rail surface. The device is composed of body with slide ways on which a carriage mounted with measurement heads as well as control system (of recorder) travels. The body is incorpotated in metal casing, on which control system and battery is attached while measurements are made. The task of control system is to record readouts of photoelectric converter and measurement heads as well as to control the carriage travel.

Position of heads is precisely established by manufacturer. Carriage travel with heads mounted on it along measured tail is made automatically after starting the measurement cycle. Proper guiding sutfaces of casing provide correct referene planes of device body in relation to a rail. The carriage is moved by means of electric motor furnished with a wrapping connector. Position of the carriage in relation to slide way is determined by means of photoelectric converter. Extreme position of carriage is signaled by two limit switches - left and right one.

Recorder body incorporates graphic display and membrane keyboard, which make communication possible with the micropmsor control system of Electronic Rail Corrugation and Weld Measurement System. By means of keyboard we can determine localization of weld in a back and we can specify any additional information supplementing the measurement results. After the measurement is completed, the measured profile and result of its estimation can be viewed on the display after selecting proper option of control system.

m After a series of measurements are completed their results are saved rn

to PC computer memory to perform further analysis. This task is >; accomplished by SOFTWARE provided together with measurement device. The sohare used to analyze measurement results enables making plots of the whole measured profile of tail surface or its selected fragments, archiving the measurement results, their estimation as well as observation of wear progress. Moreover it is possible to print measurement protocols induding estimation of straightness and waviness.

3.0 Operation of control system of device mm~l system of the device mounted on EleWniC Rail armgauon

and Weld Measurement System is supplied from aternz! NiMH se!v icefe accumulator battery. Batteries are protected againa mmplete d i x h a ~ e . In case of tm low voltage the control systeN~ disconne- the device. While transferring measurement rewltr to PC mmputer the recorder is to w p p l ~ using external pwer supply unit furnished together with device. On the fmnt panel of mntrol system there is membrane keyboard as well as glaphic LCD display. Moreover, there are rake& to connea El-nic Rail Mrugation and Weld Measurement System and PC computer during transmision of measurement ~ I B . To mntml the remrder opemmn the keyboard is used which can o~erate in one of two modes: selecting the options and as

Fig. 1. Keyboard and display of Electronic Rail Corrugation and Weld Measurement System control system

Data saved in recorder memory (Controller) are gmuped in files created as a result of measurement sessions. Every new file is assigned a consecutive number beginning from 0 (0 is assigned to the first Me, the semnd is 1, etc.) Starting fmm this moment, a file is identified by its number. I n order to protect data and deck integw of infomafan checksums are created for every file. Every measuranent file in the remrder mntaim data related to

u-l

running plane and side plane shapes. ~n 0

3.1 Control system switching on - switching off

3.1.1 Power supply switching on (switching off) of device Recorder system c o n n e d to device, battery attached: Switching on supply of the device and control system shall be accomplished after pressing key On/Off of recorder keyboard. After 7

-- -- - - -..-..v~y-me device . . 5 "'me content, ,

Fig. 2 Signaling the initializatim memov mntent th

e recorder. me mesage is be acefled USinQ * or + key and kbe me mmsu-nb the GJibmtim value indudd in me wng

of the devie are to be

entered. kavin0 default parameten causs bulb "leasuremen&. The GSC? of frequent apmdng UM probably proves that ba&v su~of i i , ,~ me UM me memv initialinn

mOv supply is discharged. me

is loam On elm.c board O f 4 W r d e r ad is a m b l e a&r dismantling its casing, . If Cheing of the device erameterr is c o ~ p l ~ ~ succes~Hy the 'ntqdv of eveV file with measurement results is ,-he& in Detecting the error muses:

W Sep. Of me and an files Of numben higher than mis one Dis%"ng the m n h d message of the content:

fig 3 Signaling the detecfed e m in file m n g

where n - number of 6ulty file. . The message is to k accepted using 4 or + k e . Frequent appearing

of such message manifests lo:v beer;. conditian that supports RAM memory or faulty of control system aild should be discussed with service.

Current date (14105)

Fig. 4. Entering the present date

The last a g e of initialization of the device is entering the present date. Date is entered in three fields: day, month and twa last digits of year. Selection of a field to be edited is accomplished using keys: C or + and then $I. Interruption or leaving the mode is performed by pressing + key. The value is entered using digital keys. Edition is complete after pressing + key. A screen with options of the highest level of menu of the device is then displayed. On date edition screen, the serial number and manufacture year of the device is displayed. This information, limited with brackets, is inserted on the right of the upper display line.

3.2 Selection of menu options Only four arrow keys are active in this mode; they are grouped on the

right side of the recorder. C - to the left moving the cursor to the previous option, * - to the right: moving the cursor to the next option, + -up: direct bansfer to higher level of menu, $I -down: selection of options pointed with cursor,

While selecting options large cursor is displayed. The highest level of recorder menu makes possible selection of.one of four options:

Fig. 5. Options of basic level of menu

Required option is to be ~el€fb?d navigating the cursor by means of C or + to the first character of dem-ption and acoepting selection with & key.

the keys: C as well as +. After selection is made we have to accept selection by pressing the key & again and then +.

The fad that the list is open is signaled by smaii cursor.

3.5 Controller menu tree

The controller menu tree is presented below with a brief description of the options.

Measurement

Write - measurement session including recording of measurement results in memory of device

Mileage - defining the mileage of measurement spot - numeric field Track - defining the track No - al@hanumeric field Rail - defining the course: left or right - List of value [L] OeR), [R]

(n0hrl Ok. - starting the measurement cycle

Dry Run - measurement passage without recording the measurement results Battery - displaying the accumulator charge condition Sensor - disolavinu the sensors readouts; additional keys -C as well as + . . -

cause shifting the carriage to t i e left or right,'respectively. O ~ t i o n

Route - entering the route ID Line number - line No - abhanumc fidd Line - name of line - alphanumeric M d SectionJStation - name of -on of line or a station - Alphanumeric field

Measurement - selectjon and defining the measurement parameters Step

5 mm - scanning distance - recording the measurement every 5 mrn 10 mm - scanning distance - recording the measurements every lOmm

Set - selection of limitation set for assessment Top surface - parameters for rolling surface - item to be selectw'

Track (Fast, Main, Other) - set of limitations for estimation of rolling surface

Selection consists in pointing the required element using pulsating k cursor (keys C +) and then pressing key +. c3

Side surface - parameters for lateral surface - ifem to & s e W 0 Lo Tracks : Main tracks, Other tracks - set of limitations for 0

estimation of lateml surface. Selection consists in pointing the required element using pulsating cursor (keys +) and pressing key +.

Limits - defining the limitation sets Top surface - defining the boundary values for rolling surface

assessment Tracks : Fast, Main, Other - selection of limitations set being defined

Above rail - Convexity of the @I Faulty - setting the faulty l&e! within the scope e.ln?m up

to 0.9mm - numeric field Dangerous - setting the dangerous leve! within the scope

0. lmm up to 0.9mm - numeric field Below rail - Concavity of the rail

Faulty- setting the faulty level within the xope O.lmm up to 0.9mm - numeric field

Dangerous - setting the dangerous level within the xope 0. lmm up to 0.9 mm - numeric field

Side surface - defining the boundary values for lateral surface assessment

Main tracks, Other tracks - selection of limitations set for track Track narrowing -

Faulty - setting the faulty level within the scope 0. lmm up t00.9mm - fidd

Dangerous - setting the dangerous level within the scope 0. lmm up to 0.9 mm - n u m c field

Track widening - Faulty - setting the faulty level within the scope 0. lmm up

to 0 . 9 m - f l ~ r n r i ~ field Dangerous - setting the dangerous level within the scope

0. lmrn up to 0.9 mm - numeric field Ruler -the base for assessment and displaying the straightness graph -

i m s to be seI&&. After the required value is selected (keys C +) press the ctr key.

Ruler length: l m - graph displayed on 1 m base 1.2 m - graph displayed on 1.2m base.

Other options - additional information which identify the measurement Operator - operator code - 4 character alphanumeric field Date - updating the measurement date and displaying the serial number of

device Current date (14105)

12.11.2005 Rail type - description of rail type - 5 characteralphanumeric field

Communication - including communication mode for transmitting the measurement results to the computer

File - measurement results management Viewer:

File viewer: file - max:xxx - displaying the diagram and assessment for

measurement of given number. Max number of file in memory is displayed.

Deletion - deleting the measurement result from recorder memory Remove file:

12

Removing file ... file :- max:xxx - erasing the measurement file of given number

Clear data memory: - erasing all measurement files from memory Removing ... Press [C] key

3.6 Description of controller parameters All parameters, which can be changed by user, can be divided into two

groups: Parameters connected with making measurement, Parameters connected with assessment and displaying the measurement results,

Additional group of parameters connected with calibration of device is hidden against accidental alteration and is directly unavailable.

3.6.1 Parameters connected with performed measurement These parameters define the measurement process, the subject of

measurement as well as they contain data identifying the place and measurement time. They should be updated before starting the measurement session every time.

3.6.1.1 Measurement step Measurement step determines the distance between consecutive points

of a rail. It can be equal 5 or 10 mm and can be changed selecting option Options->Medsurmnt->S&p. However, single measurement section is 1.2 m long. Because the device saves measurements carried out while caniage travels in both directions, th'us quantity of performed measurements equals 480 or 240 points. Selection of 5 mrn step gives more precise assessment of short waviness.

3.6.1.2 General parameters identifying the measurement These are values, which are common for a series of measukments.

They are to be defined before measurement session is started: route ID: o number of line, 4 alphanumeric characters, (Opmns-> Route-,

Line number), o name of line, 20 alphanumeric characten, (Optjons ->Route-

>fine), this parameter can be edited then using analysis programe

o name of line section or station, 16 alphanumeric characters, (Options->Route-> Mon/Station), this parameter can then be edited using analysis programme

operator's ID, 4 alphanumeric characters, (Options ->Other options- >Operat@ Type of measured rail, 6 alphanumeric characters, (Options -> Other Options ->Rail type)

13

Measurement date: day, month and two last digits of year. Updated every time during controller initial~zation (switching 'on) or after selecting the option (Options -> Other Option->Date). On the r~ght upper line of update screen the serial number and manufacture year of the device is displayed.

3.6.1.3 Precise parameters identifying the measurement These values are characteristic for measurement executed at present.

They are to be updated before every measurement cycle is started. Menu which allows alteration of these parameters, appears after measurement session is started (Measurement-> Writ):

Mileage of measurement place, number, 8 characters (including deu'mal point ) Track number, 3 alphanumeric characters, Rail, selection from the list: L (left), R (right)

3.6.2 Parameters connected with estimation and displaying measurement results

These parameters indude allowable deviations for straightness assessment as well as assessment base. They are connected with measurement analysis (option: R/e+ Hewed.

The admissible deviations are grouped into sets: three for rolling surfaces and two for side surfaces, in accordance with regulations applied by PKP (Polish Railways). Due to this fact it is possible to select proper deviations for various measurements without necessity of tedious editing the values. The name of sets applied suggest the scope of application:

Top surface: o F& in case of main tracks and basic main ones of admissible veloaty

greater than 160Wh, o Main: in case of main backs and basic main ones of admissible

velodty lesser than 16Olan/h, o Other: for other badts

Side surface: o Main back for main tracks and basic

main ones o Other Dauks: for other tracks

Within the scope of sets two types of deviations for every surface are defined:

Top surface: o Above tail -, i.e. maximum value of rail convexity in vertical plane, o Below rail -, i.e. maximum value of rail conmvity in vertical plane,

Side surfdce: o Tracknamwing -, i.e. maximum value of rail concavity in

horizontal plane, toward track narrowing. o Track widening -, i.e. maximum value of rail convexity in

horizontal plane, toward track widening. For every type two levels are specified: wrong and dangerous which

allow for distinguishing three situations: . the value under analysis is lower than the faulty level: no fault,

the value under analysis is greater or equal to the faulty level but lower than the dangerous level : the fault requires to be repaired, the value under analysis is equal to or greater than the dangerous level : the fault requires to be cut away,

By default, the values of all deviations are accepted in accordance with the values recommended for use in the PKP (Polish Railways).

In order tb edit the values of the deviations, select the option: Opf7ons- .Measurement->Limits Then, following the said description, navigating through the options of a lower level, display the required values. Edition is made by entering proper value within the scope from 0.0 up to 0.9.

In order to select a set for assessment of measurements, select the option : Op&ns->Maa?iumntf>9t->T~ sufice->Tmck: for the running plane or: Op&ns->Medwmnt->9tt>Side suIfae> Tmd: for the side plane respectively.

Then, point the cursor at the desired set of limits (keys +) and return tD the higher level of the menu (key +).

The ruler length defines the analyzed length of the basic profile. It can be selected either value: l m or 1,Zm. Selection is possible in the options : Option->Measumnt->Ruler

3.7 Course of measurement The measurement session is started by selecting the option --I

Measurement->W&. The screen appears as below, that allows edition of v the parameters that identify a single measurement: ~n ln

Mileage: 123.537

Fig. 6. Options of entering the parameters describing a single measurement.

After updating the parameters (Mileage, Track, Rail), select the option Ok and press &, to activate the measuring cycle. Bear in mind to enter earlier the correct general identification parameters described in section 3.6.1.2. (Line number, iine name, Section / Station, Operator ID, Rail type, Current date). Every cycle is recognized by withdrawal of carriage into original position (if necessary) which fact is signaled with suitable message on the display: This is basing of the carriage. Upon completion of that, the measuring cycle itself is started, and the following information appears on the display:

2.351mm.

Fig. 7. Appearance of the display during the measurement cycle

The inscription: Top sensor or Side sensur indicates from which sensor the measurements are taken to be displayed in the lower line of the display.

'1 11 The key 4 is designed to replace the sensor being the source of the displayed data (switching does not atTed the course of the measummenr).

At the right side of the top line there is a counter of the rmrded measuring points. Since the measurement data are recorded during passage of the carriage in either side, 480 measurements are recorded for the 5 mm step and 240 measurements for the 10 mm step, respectively. By referencing the counter readings to the total number of measurements it is possible to evaluate the progress of the measurement cycle. Termination of the measurement cycle is signaled by the message:

Next measurement?

Fig. 8. Selection: a single measurement - aggregating the measurements.

The annver NO completes the measurement. After checksums are n~ calculated and the file is dosed the submenu of the option Measurement is -a LO dis~laved. m . .

Selecting Yesenables performing the successive measurement cycle, 0

the results of which will be added to the current file.

I Start of meas. Remove last meas. Fig. 9. Selection: erasing the last measurement result from the file

I6

*

The intermediate option allows erasing results of the last measurement cycle fromcurrently created file. This may be necessary when the operator has to remove the device from the track during the measurement cycle. I n this case one has to erase measurement results of the last cycle, leaving previous ones intact. Selecting Remove last meas. option can do this. After erasing the data the system assumes the state making possible to resume measurements. Selecting the Smt of meas. option shifTs the system to the state in which it is possible to run the next measurement cycle. Pressing the key & activates the next measuring procedure. This mechanism permits for a continuous measurement of the sedions longer than the reference line of the device. These measurements are used for assessment of waviness.

Measurements of waviness of long sections are to be executed sliding the device along the rail (after current measurement cycle is completed) to direction of the arrow marked on the RSG casing by next 60un. Next measurement section should indude then a half of the previous section. Shifting by next 60 cm sections are to be executed using accuracy better than 5 mm. The length of so measured fragment of track is limited only by Qpauty of memory available of the recorder. However, the analysis module and waviness assessment is the limitation, which allows waviness analysis of a single sedjon of max length 41 m, at 5 rnm step, br 82 m in case of 10 mm measurement step.

3.7.1 The error messages related to the accomplishment of the measurement cycle.

During the measurement cycle a series of relationships that permit for asseswnent of the oorredness of measurements recordina are verified. Anv incorredness causes an immediate termination of measurement and generatio; of appropriate error message. Occurrence of faulty situations indicates measuring systems malfunction and should be discussed with manufacturer's service. Notification about a problem should contain also details of the content of displayed messages.

The key + is designed to cancel the error message from the display. Too low level of battery charge will result in disabling the 2 possibility to start the measurement cycle and to generate the

message: Battery discharged! Before continuing the measurements, 0 the battery must be recharged or replaced. I f battery voltage drops o below allowable value while measurement cycle is executed - the device shall switch off automatically.

3.7.2 Accomplishment of measurements of single sections

In order to accomplish the measurement of sbaightness or waviness of 1.2m long section we have to:

1. Connect the battery to the device, 2. Connect the control system to the device, 3. Turn ON the supply of the recorder - key 6 4. Set the general parameters of the measurement and the step of the

measurement: 5. Set the device on the rail so that side plane measurements sensor was

positioned between the rail of the track and after the device is shifted dose to the rail secure it using the knob. In case of measurement of welds a proper arrow shall p in t its center pint.

6 . Start the measurement session by selecting the option Measurement- > Wrie,

7. Update the detailed parameters that identify the measurement, 8. Run the measuring cyde by selecting the option Ok, 9 Upon completion of the measurement cyde, select the option No, lo. In order to a m p l i s h next single section measurement, go to item 5, Note:

While putting and shifting the straightness gauge to a rail pay attention to the fact whether large curvature rail shall not deform or damage lower parts of the device.

3.7.3 Accomplishment of measurements of long sections In order to accomplish the measurement of back section waviness of

length > 1.2m we have to: 1. Connect the battery to the device, 2. Connect the control system to the device, 3. Turn ON the supply of the recorder, key - dl 4. Set the general parameters of the measurement and the step of the

measurement: 5. Set the device on the rail so that side plane measurements sensor was

positioned between the rail of the track and after the device is shifted dose to the rail secure it using the knob

6. Start the measurement session by selecting the option Measurement- > write,

7. Update the detailed parameters that identify the measurement, 8. Run the measuring cycle by selecting the option 04 -f 9. Upon completion of the measurement cyde, select the option Yes, rt. Jn lo. Shift the device to the right (to proper arrow on the casing) by a half- Jn

0 length of reference line (60cm) using markers made on the rail. ~auracy of shifting should be~bette; than 5 mm.

1 1. Select the St& of m s S option or, in case when previous cycle had been interrupted, remove data of incomplete cycle (Remove lastmeas. option)

12. use the key + to start the next measuring cyde.

13. upon completion of the measurement cycle, select option Yesaad repeat steps starting from item 10 for the measurement of the : successive section, or No to terninate the measurement.

14. in order to accomplish next successive measurement, go to item 5,

The files that contain results of more than a single measurement are automatically recognized during the transmission of the data to the PC by the software program for analysis and visualization. On the basis of saved measurements a single profile is generated of length:

L [cm] = 120 + (n-1)*60

where: L - length of the generated profile, n - the number of measurements, the results of which contains the processed file,

Fig. 10. Diagram of aaomplishment of waviness measurements of l o k sections.

I measurement 1 -

Note: While putting and shifting the straightness gauge to a rail pay attention

to the fact whether large curvature rail shall not deform or damage lower parts of the device.

measurement 2 measurement 3

...a*

measurement n

3.8 Transferring results of measurements to the computer.

- - ....... -

I

The results of measuwnents saved in the cache memory of the recorder of the device should be periodically sent to the computer. Due this fact it is possible to archive them and make a full analysis employing more V ) advanced tools. To this extent, the control unit has been equipped with a RS- * 0

V, 232C interface. On the other hand, device is provided with a "RSG" computer- aided software program for analysis and visualization furnished with integrated procedures that facilitate transferring data to PC.

The recorder is a passive element while data transferring is performed. This means that after communication is selected in the controller controlling the transmission is accomplished via software analysis program residing in the computer.

Transferof files is accomplished by means of a special protocol with implemented functions for verifying the corredness of the transmission and retransmission of erratic records. The transmission errors are signaled whilst the data are saved on the PC only in the event of a correct transmission. In order to facilitate the operation of the device, the parameters that define the transmission reside in the software.

Transmission procedure contains also additional functions that support data management in the recorder. Using these procedures selected measurement files can be removed from recorder memory as well as we can view their headings or parameters, which identify a measurement.

Before transmission is started the recorder is connected to RS port of the computer by means of the cable available in device. In case when the computer has only USB ports the proper converter USB->RS232 is to be used. Connect the recorder to power supply unit and select option Lbmmuniwtion. There will be displayed the following information:

Communication I Fig. 11. Communication mode.

Intemption or switching off communication mode in the controller is performed by pressing +. After selecting a proper option in "RSG programme, described in Section 4.4, management of communication and measurement file is accomplished on programme level.

3.9 Managing the results of measurements The results of the successive measurements are stored in the memory

of the recorder. After transferring them to the computer it is necessary to empty the memry space occupied by them. To this extent, there are provided two functions that enable for deleting any file or all files from the memory of the recorder. Deleting the files can be executed on programme lwel in option communication manager described in Section 4.4.5.

3.9.1 Deleting a single file from memory CD w In order to delete a file, select the options He->Deleebbn->Remove Ln

Ln data file. A diilogue window will appear in sum a case that enables entering the number of file:

Removing file ...

Fig. 12. Selection of a file to be removed

The number at the position rnax informs about the highest accessible number. Enter the number of the file to be removed. The key + initiates the removal of the file. The key + serves to return at the immediately higher level of the menu. After removal, all files with their numbers higher than the removed one will be so re-numbered to maintain their sequence i.e. their numbers are reduced by 1. After accomplishment of this operation, screen is displayed that allows entering the number of the successive file.

3.9.2 Deleting all files from memory

Deleting all files is possible after selecting the options File->Deletion- >Clear dah memory. In such a case, the demand for acknowledgement is displayed in the form:

Removing: Press LC11 Fig. 13. Confirming the attempt to cancel all files.

Pressing the key t it will cause deleting the contents of the memory of measurements and the return on an immediately higher level of the menu. The key + can be used to go back without file removal.

3.9.3 Reviewing the results of measurements

The results of performed measurements can be previewed using the option File- vie we^ Apart from the displaying of mil pmfile plots, the basic assessment whether the allowable deviations for the selected reference base were exceeded or not is also provided. Selection of this option is signaled by appearance of a dialogue window enabling entering the number of the measurement file:

File viewer: max:7

Fig. 14. Entering the file for the assessment

The number at the position max informs about maximal possible number that can be used. In position file enter the number of the file (from 0 up to max), which content is to be evaluated. The key + is designed to accept the number entered. The key + serves to return at the directly higher

level of the menu. For each plane of the measurement surface (running and side) there are available three plots:

Basic profile - this is the shape of measured running or side surface The trend profile - is a plot aeated of basic profile by averaging the measurements around the point of reference base *100rnm. Hence, the length of trend profile is lesser than basic profile by lOOmm at the beginning and 100 mm at the end. Waviness profile - this is a plot created of basic profile after subtraction of previously described trend

Switching between plots is made by pressing a key with suitable icon. The recorder graphic display is accomplished as matrix 32x128 pixels, hence the displayed plots have limited accuracy. The first 120 columns of horizontal axis corresponds to 120 an of measured section, whereas resolution in vertical axis is 0.13mm for scope *2mm, 0,06rnm for scope %lmm and 0,03mm for scope *0,5m. In addition, due to limitations of recorder arithmetic the calculations are made at acoJracy of 0.Olmm. The precise analysis of measured profiles can be achieved in RSG dedicated programme on PC computer. The analysis of waviness of measured long sections is possible only by means of PC. The letter inserted in the right upper profile of a plot determines the profile plane.

T- top (running) surfaa?: S - side surface Additionally, both the trend plots and the waviness plots are marked

with appropriate graphic marks placed before the plane letter.

Fig. 15. Plot of basic profile

Fig. 16. Plot of trend profile

Fig. 17. Waviness plot

Fig. 18. Results of assessment

To switch between the options the following function keys are used:

- displaying the plot of the basic profile

'C D' - displaying the trend plot 8 r, -

- displaying the waviness plot L-

- switching between the plots for the running and side planes (in the single plane version of the rail straightness gauge the profiles ch for the running plane are only available) w Ln

Lo 0

- switching between the ranges of the vertical plot. The following ranges are available: *0.5mm, *lmm as well as *2mm. They are switched over consecutively after every pressing the key.

' l,JTI - displaying the screen with the results of assessment of the profile 6 ,Jj Depending on the currenly displayed type, the following plots will

i be produced:

Basic profile: above rail (convexity), below rail (concavity) d u e s for the running plane or the values of widening or narrowing for the side plane, allowable deviations for faulty level and dangerous level and possibly the characters signaling an excessive faulty level "!" or dangerous level "*". Trend: above rail (convexity) , below rail (concavity) values for the running plane or the values of widening or narrowing for the side plane, allowable deviations for faulty level and dangerous level and possibly the characters signaling an excessive faulty level "!" or dangerous level "*". Waviness: above rail (convexity) , below rail (concavity) values for the running plane or the values of widening or narrowing for the side plane and the values of an average amplitude and average wavelength.

Additional explanation about the displayed results of assessment:

Rail-running surface --

1mm11 - 1.2 m J Above

Widening [mm]

Left. Roil - side surfoce

Norrowing 1-1

Track

Right Rai l side surfoce '/ 4////m

ABOVE RAIL - defining of the rail running surface deviation above the zero line linking ends of the measured profile, i.e., rail camber directed upwards

BELOW RAIL - defining of the rail running surface deviation below the zero line linking ends of the measured profile, i.e., rail camber dire-d downwards

Defect = Faulty

NARROWING -defining of the side mil surface deviation into the track narrowing direction

WIDENING - defining of the side rail surface deviation into the track widening direction

Example of the results of assessment:

.

( )

j (

n

u

!

*

A

A

m Lr? Ln 0

3.10 Checking battery charge level

widening of track - defines the rail side surface shape

narrowing of track - defines the rail side surface shape -

rail bent upwards -defines the rail running surface shape

rail bent downwards - defines the rail running surface shape - -

denotes exceeding the 'Yaulty - defect " value

denotes exceeding the "danger" value

amplitude value for waviness assessment - refers to rail side and running surfaces

wavelength for weld waviness assessment - refers to rail side and running surfaces

m e function of checking of the battery charge level is available after selecting options Measurement->Battery. The measured voltage at the battery terminals as well as assessment of the battery charge level are displayed on the screen:

Denotes that the rail side surface is bent into the track widening direction with the value of 0.14mm; whereas the boundary values are: "faulty" = O.2mm and "danger" = 0.6mm.

Denotes that the rail side surface is bent into the track narrowing direction with the value of 0.33mm; whereas the boundary values are: "faulty" = O.Omm and "danger" = 0.3mm. The ,*" symbol will be used: denotes exceeding of the "danger" value.

Denotes in the weld wavlness analysis that the maximum deviation in the direction of track widening is O.Olmm, deviation in the direction of track narrowing is 0.03mm, average wave amplitude is 0.05mm, and the average wavelength is 300mm.

2.

3.

Similarly measurement results will be reported during the assessment of the running surface, only other symbols will be used: U -rail bent downwards, A - rail bent upwards

( ) 0.14 mm Om2 1 Om6

X Om0 1 OA3*

( ) 0.01 A= 0.05 ) (0.03 A = 300

Discharged 6zv Fig. 19. Signaling the battery charge level

Two conditions are signaled: Discharged - the battery must be recharged before the use of the device or replace the set to use the charged one. Ok - the charge of the battery guarantees performing the measurement

Key + permits to return at the higher level of the menu. During execution of the measurement, the supply voltage is monitored. Too low level of the voltage will result in disabling the option of starting up the measurement cycle Measurement->WH&>Okor switching off the device while the measurement cyde is executed when battery capacity drops below admissible threshold.

Attention is to be paid to the fact that positive assessment of charging condition is not equivalent to long operation capacity. I n order to estimate correctly the preparation of the device for long-term operation, voltage value has to be 0 b ~ e ~ e d . The battery is fully charged if voltage is not less than 7.5V. NiMH Accumulator battery of capacity 4 Ah and of rated voltage 7.2V is used in the device.

Calling the options when the recorder is supplied fmm the power supply will result in displaying erratic readings.

3.11 Service functions of device recorder

3.1 1.1 Displaying the readings of the measurement heads

This function is used by manufacturer's service only, when required - the user has no need ever'to employ it. The function of displaying of the readings of the measuring heads is helpful at troubleshooting within the device. It enables displaying the values of the measuring signal and also to displace the caniage together with measuring heads along slide way. Selecting the option Measurement->Sensors starts this function. Sensor identifier and the measured value of the signal shall be displayed.

Fig. 20. Readings of the measuring sensor of the running plane

is designed to switch between the transducers of the running and side planes (in a single-plane rail straightness gauge this function is not provided). Key @ pennits to return at the higher level of the menu

The keys and .3 are designed to control the displacement of the camage together with the sensors.

3.11.2 Accomplishment of the "Dry run".

This function is used by manufacturer's service only, when required - the user has no need ever to employ it. Selection of the option Measurement- >D/y run enables the measurement cycle. All the elements of the cycle described are executed at the occasion of discussing the accomplishment of measurements except for the procedure of saving the results to the memory of the device. It enables carrying out a full test of the measuring arcuitry and the drive units of the device.

3.11.3 Updating the device settings.

This function is used by manufacturefs semce only, or by the user, a m replaang battery supporting the supply for internal RAM memory. After erasing of the RAM memory of the recorder, which is signaled by proper message during its initialization, parameters included in calibration setting card of the device described in section 8 have to be entered. These settings relate to vertical and horizontal measuring heads parameters as well as the divider of photoelectric transducer. Entering correct values of settings is to be executed as follows:

using f or + and JI keys point O@n ->b&asumntwith cursor, press and hold down blue (left) ylm key and then press selection key

JI.

Selection menu of settings type shall appear on the display: I I

Ranges Divider

Fig. 21. Selection of settings type

Option Range makes possible entering the Minimum and Maximum range for Top sudace sensor and Side su&e sensor. Option Divider is the field to set up divider value for internal photoelectric converter. Entered parameters always must have to be equal with values given in setting card of the device (see section 8). Entering wrong values causes faulty operation of the device.

3.11.3.1 Transferring the calibration corrections

This function is used by manufacturer's service only, or by the user, after replacing battery supporting the supply for internal RAM memory. In order to properly calculate the measured rail profile in the recorder it is necessary to have a series of values defined during the process of calibration of the device. These values are entered and saved in the memory of the device during the manufacturing process. In the event of failure loss of data memory content, which is signaled during the initialization of the device or re- calibration of the device, original parameters have to be saved. The original parameters are saved in the files induded in the software for analysis and visualization, whilst the program itself is fitted with special servicing functions that permit to transfer them to the device. Calibration of the device at the time of manufacturing is a p m s , which requires proper standards of known features to be applied.

Organization of calibration conections bansfer is similar to transmission of files containing measurement results. The recorder of the device is connected with the computer by means of RS accessory cable and the "RSG analysis programme is run. After recorder is actuated the hidden bansmission option in the control unit is started, by pnxeeding as follows:

Go to higher level of menu, Using + or + keys point option CMmuniwtion with cursor, Press and hold down blue (left) SHIFT key and then press opbon selection key 4.

Selection menu of corrections shall appear on the display:

V corrections

Fig. 22. Selection of a type of transferred correbions.

After selecting the type of corrections, the device goes in its ready-to- data-receiving condition what is signaled by the message: 7 I refeiving da ta... I e

Ln Fig. 23. A message about the transfer of corrections Ln

I C ) -. 0

A program residing within the computer controls the transmission session. In the main window of the programme press [Ctrl] [Alt] [V] key combination to update corrections for top plane and [Ctrl] [Alt] [HI combination for side plane. In displayed window the serial number and manufacture year of the device (two last digits of year) is entered. upon

completion of data transfer, the device automatically returns to the submenu of the selection of the type of corrections. Proper confinnation message shall be displayed on computer screen.

The correctness of the transmitted and received data is verified. In case of errors occurrence, which is signaled by an appropriate message, the transmission session must be repeated. The key + can be used to return at any moment to the submenu of the selection of the type of corrections.

4.0 The software for analysis and visualization of measurement results

The device is supplied with a special program with a set of functions for management of the results of measurements. The software enables:

Transmitting the files containing the results of measurements from the recorder to the PC, Displaying the plots for measured sections of the rail, Listing the basic parameters characterizing the measured profiles, Evaluating the straightness of the welds, Evaluatina the waviness of the section of the rail Printing the resufts of measurements and their assessment,

* Comparing the results The software program is supported by a PC with installed Windows 95

or higher and about 16 Mb free RAM. The program files occupy about 1Mb of hard disk space (not taking into consideration the files with the results of measurements).

4.1 Installing the software program

The software program is supplied on CD. Launching the Setup will result in starting the installation pmess. During the installation process the user has to select the directory for program and configuration files.

In order to ensure an effitient storage of the files with the results of measurements on the PC it is reasonable t~ ueate dedicated directories. It is reammended to mate separate sub-directories for periodically measured sections of the track, so to ensure that they will not confused with the data related to the other sebions, for example:

c:\Waviness\the results of\track-right-rail-1-km-133.5 In c:\Waviness\the results of\track-left-rail-1-ion-134.3 LD

LO It is also worth preparing subdirectories for the text files containing 1n filenames, the use of which drastically reduces time necessary for transferring o files from the recorder to the memory of the PC. Neglecting to produce a proper and correct architecture of the directories w~ll make difficult to use the program and to access the results of measurments stored in the memory of the PC. To create the directories it is indispensable to use the Windows Explorer.

i he attached software program consists of the following modules: * Programme files: RSG.exe the program to analyze results of measurements

Configuration files: 3EZD.par file with the configuration parameters program 3EZD.dpr file with the analysis parameters, Set of cdlibration files: WZORZEC-n-r.wzd file containing the profile of the master running

plane. ZEROWY-n-r.kad file containing the corrections profile for top plane. SPRAWDZIAN-n-r.kad file containing the profile of the running plane of a

test gauge. WZORZEC-n-r.wzb file containing the profile of the master lateral

plane

ZEROWY-n-r.kab file containing the corrections profile for lateral plane.

SPRAWDZIAN-n-r.kab file containing the profile of the side plane of a test gauge.

Where the li_r suffix in the calibration file name specifies the device for which it is intended n - device serial number, r - two last digits of the manufacturing year.

Adding the device serial number to the calibration file name makes possible to operate with several devices by means of one programme. The necessary condition is that the main program folder had a separate set of the calibration files for each device.

No&: me device &I number must be ansismt with tfie number indudad

in Ute wlibradIon file name suffix Ottrenvise, hncBons mnn& with optation wibs the spea'fic dene (measurement cbta downlwd, dene s y m ch&) mll not be p?h&. &libtation &ta or am~~late &ta I%&? o p n m r m% be announ&. .

4.2 Launching the program w I n After the programme is installed a shortcut is created in Start menu of !n

V) Windows system. In order to run program it is indispensable to: o

Run the menu Start by clicking the button Start or by means of a

shortcut Ctri+Ex,

From the pulldown menu, select the option Programs,

From the pull-down submenu, select option GRAW

Then, selection of the RSG.exe will result in launching the program

Once the program is started up, the main window appears that enables

starting the operation.

Fig. 24. Main window of RSG program.

4.3 Layout of the main window of the program

Immediately once the program is started up, a window appears on the screen with its line containing the main menu and the toolbar. After opening the file with data, all functions of the menu and toolbar buttons become active.

Fig. 25. The main menu and the toolbar.

In the upper part of the window, menu bar and the keys to navigate within the working sheet and to change the scale of the plot are located.

4.3.1 List of menu options

Options of the menu File:

Clcsr

mefence pld

List of fae5 -3- , 1 Stmqhb7euament - opening the file for the assessment of the

straightness. Waviness assessment opening the file for the assessment of the

waviness. am - closing the active window. D i ~ m c e p&t - creating the differential plot from two

measurements. Li3t of files - creating the list of measurement files . Seriatpo~t- selecting a serial port. Quit - terminating the program. Opbons of the menu Viw:

Zoom in - twice expansion of X-axis for the plot displayed in the active window.

zoom out - twice contraction of X-axis for the plot displayed in the active window.

Area selection of the range of the X axis for a plot. ~xtentts - returning for displaying of the whole plot. Sheet - establishing the size of the working field Print - printing a plot of active window. COPY - copying the plot to the clipboard.

Options of the menu Options : -

c h e & m che& lateral

0.Omrr L'mits Parametes

-0.5mrr 5etd6rr6tr Assessment hdb

CollbnuniwtMn manager - Haader - m t e r - Check running -

Check lateral -

set of limits-

transferring data from the recorder of the device editing the header. editing the footer. verification of metrological properties of the d e v i ~ for the top plane. verification of metrological properties of the device for the side plane. editing allowable deviations for assessment of the straightness. defining additional parameters identifying measurements. selection of a set of admissible deviations for the assessment of the straightness. defining the allowable deviations for assessment of the waviness.

Options of the menu Window:

We - arranging the windows with the plots not to overlap each other.

Oscade - arranging the windows with the plots overlap each other.

Arrange icons arranging the icons as thumbnails of the windows in the lower part of the main window.

Options of the menu Help: About tnepmgram. ..- displaying the information about versions of the

program.

4.3.2 The program toolbar buttons

These buttons enable a quick access to the most frequently used functions of the program. Additionally, pointing the cursor on any button will produce a prompting box to help the user. The content of the toolbar is functionally divided in four groups.

4.3.3 Buttons of basic plot operations

@ @ B Q To these buttons, the following functions are assigned (looking from the left):

Opening the file for the assessment of the straightness Opening the file for the assessment of the waviness Printing a plot of an active window Copying the plot of active window to the dipboard

4.3.4 The buttons that change the displayed plot

rd 4r 62 They perform the following functions, looking from the left: twice expansion of the plot X-axis twice antraction of the plot X-axis Selecting the range of the plot X-axis

' 4.3.5 The buttons for scrolling a plot along the X axis

These buttons are used to displace the plot to the left or to the right in respect to the window. The following functions are assigned to them (looking from the left):

displaying the initial portion of the plot displacing the working range to the left, 0 displacing the working range to the right co displaying the final portion of the plot V )

V ) - U

4.3.6 The buttons for changing the range Y of the working field of a plot * They perform the following functions, looking from the left: Reducing the upper range of the axis Y by 0.1 mm Increasing the upper range of the axis Y by 0.1 mm

Reducing the lower range of the axis Y by 0.1 mm Increasing the lower range of the axis Y by 0.1 mm

4.3.7 Arranging the results of presentation of measurements

This program is an application that can operate simultaneously with many views. This means that results of various measurements can be displayed simultaneously. For each measurement a window is created, containing the profile that has been measured and optionally additional windows can be created containing the plots based on equations calculated with reference to the results of measurements data (plot of the trend, plot of the waviness for the waves from a preset range etc).

Fig. 26. mew of the windw program with displayed results of measurement

An active window has a highlighted title Wbar . All options of the menu and the functions of toolbar buttons are carried out on the contents of this window. r-(

CD Each window is divided into a plot field, having ~ h i i background and a L, frame with a gray background. A plot is drawn in the plot field, whilst the frame is, contains the description of the X-Y axis. The cursor in the working field is drawn a is in the form of a cross. The coordinates of the point pointed by the cursor appear in the left field of the status bar of the main wir4ow. The inscription: rail in the field the plot enables to position the plot in respect to the true orientation. I n case of running plane the material is always under the plot, whereas for side

plane - over the plot. I f a portion of the profile is displayed, in the lower part of the window appears a scroll bar with the slider. Two modes of drawing the plot : are used resulting from the chosen type of assessment:

Straightness assessment mode - this mode is valid for all windows for which the measurement files have been read using the option File->Stm~gllmess assessmentor open key !d was used from tool bar. It is characterized by the following properties:

length of the plot should be equal to 120cm,

the zero point of the horizontal axis is at the half of the length of a plot,

if there isdisplayed a plot or its pottion, it accurately reproduces the

profile saved in the measurement file.

on the plot, there are placed two sets of allowable deviations of the

straightness,

the pop-up menu contains the option of the generation of a report on the

assessment of the straightness,

There are always created three separate windows containing:

o basic profile,

o trend of the basic profile

o a plot of the waviness waviness assessment mode. It is valid for the windows produced as a result of the use of the options of the menu File->WaM'ness assessment or Fie- >DifferenG?plotor option key ld was used. It is characterized by the following properties:

the length of the displayed plot is not limited,

the zero point of the horizontal axis is in the left end of a plot,

if a portion of the plot is displayed, this is so converted that the Y of the

extreme X points of the presented portion of the profile have the value

Y=O.

The pop-up menu contains the options of assessment of the waviness, N

I Co a single window containing the profile that has been measured is created Lo V, 4.3.8. Options of the local menu 0

Clicking the right mouse button when the cursor indicates the field of the plot will result in displaying the pop-up menu. It contains the options common for both modes of assessment and specific options, which permit to modify the

- . . . . . . . ... . . .

parameters of assessment or to produce a report. Options of the local menu relates only to the active window.

4.3.8.1 Options common for all windows

Fig. 27. Local menu - common options

Z m in - two fold expansion of the plot in the X-axis. Z m out- two fold contraction of the plot in the X-axis. Area - selecting the range of the X axis of a plot. W n b - displaying the whole profile.

re lab'^ - change of the origin of coordinate system to the local one pointed by the cursor on the working field

Ab,/u& - change of the origin of mrdinate system to the absolute system.

4.3.8.2 Options of the local menu for the mode of assessment of straightness

These options appear only in the local menu called (right mouse button) from the window open in the mode of assesanent of straightness and containing the basic pmfile (highlighted title toolbar - Running: nam o f ti/e...Or Lateral : CD Name of file.. .). LO

1.0 0

02mm - .--

-02mm

-0 4mm -

S d d W .n Rmm 1

Fig. 28. Local menu of straightness assessment window

Limits - editing the values of the allowable deviations for assessment of the rollina or side surface ~ ~

PrintaSSeSwnt - printing the-report on assessment of the straightness, Paramem - editing the parameters describing the analyzed

measurement Set of limits - selection of a single set of allowable deviations for

straightness. 4.3.8.3 Options of the local menu for the mode of assessment of waviness

These options appear only in the local menu called from the window open in the mode of assessment of waviness and containing the basic profile. Option menu File-, Wanness asesmmt or Fik->Dh%?mce plot or option key \@El '

-2 1mm --aremen*

Fig. 29. Local menu of waviness assessment window

Lirni& - editing the parameters of allowable deviations for * assessment of the waviness,

Palarneh?~~ - editing the pa~rneters describing the analyzed measurement,

Analyze measurement -execution and displaying the results of assessment of the waviness,

Printasserrent - printing the report on assessment of the waviness

4.3.9 Change of the view displayed in the working field

In order to match the view of the plot displayed in the field of the window plot there is provided a series of functions that permit to modify the range of each axis and to xroll the plot along the X-axis.

4.3.9.1. Change of the plot range of the X-axis

4.3.9.1.1. Two fold expansion of a plot in the X-axis

In order to display in the field of the window plot a half of the currently displayed profile, select one of the following possibilities:

the option Hew->Zoom in from the main menu the button of the toolbar

. the option Zmm in of the lml menu It will cause two fold expansion of the middle part of ctirrently displayed

profile and a reproduction of the plot field.

4.3.9.1.2 Two fold contraction of a plot in the X-axis

In order to display in the plot field a portion of the profile 2 times greater than that currently displayed, select one of the following possibilities:

the option Uew->Zoom outfrom the main menu the button !-!d of the toolbar the option Zmm outof the local menu It will cause displaying a portion of the profile 2 times greater than that current& displayed.

4.3.9.1.3 Selecting the range of X-axis

In order to have a free choice of a portion currently displayed in the working plot field, select one of the following possibilities: Ln

the option Hew->Area from the main menu, a the button of the toolbar, the option Area of the local menu After selecting the option, a cursor shaped as a view-finder will appear. It

is indispensable to move it at the beginning of the range to be selected. Then, press the left mouse button hold it and select the mnge of X-axis defined by a

. frame shaped as a rectangular. Releasing the button will result in displaying the chosen portion in the plot field.

4.3.9.1.4 Displaying the whole profile

In order to display the whole profiie, select one of the following possibilities:

the option Hew->&entrfrom the main menu, the option Extents of the local menu

4.3.9.2 Change of the plot range of the Y-axis

4.3.9.2.1 Increasing the upper range of the Y-axis

With the key kd you can increase the value of the upper range of the Y- axis. Each pressing this button causes that the value of the upper limit of the Y- axis is increased by 0.1 mrn.

4.3.9.2.2 Decreasing the upper range of the Y-axis

With the key 3 you can decrease the value of the upper range of the Y- axis. Each pressing this button causes that the value of the upper limit of the Y- axis is deaeased by 0.1 mm.

4.3.9.2.3 Increasing the lower range of the Y-axis

With the key you can increase the value of the lower range of the Y- axis. Each pressing this button causes that the value of the lower limit of the Y- axis is increased by 0.1 mm.

4.3.9.2.4 Decreasing the lower range of the Y-axis

With the key you can decrease the value of the lower range of the Y- axis. Each pressing this button causes that the value of the lower limit of the axis is decreased by 0.1 mm.

co 4.3.10 A free selection of a portion of the displayed plot

V, a In order to activate an option that permits making a free selection of the I r j 0

range of X-axis and Y-axis, select either possibility: the option View->Sheet from the main menu, click the right mouse button when the cursor indicates the gray background of an active window with a plot

In such a case, a dialogue window will appear that permits direct entering (from the keyboard) the values of the range of both axes.

40

W d n g s p s e bordsr.

Top: 1 rmn R* 1 T m m

I Left mm

Botta ( m

Fig. 30. Defining the working space borders

The following items are to be verified and adjusted:

the value entered in the field Letshould be lower than the values entered into the field Right

the value of the field Letcannot be lower than the coordinate of the left end of the profile to be edited,

the value of the field Right cannot be greater than the mrdinate of the right end of the profiie to be edited, the value entered in the field Bortom should be lower than the values entered into the field Top,

The key Save is designed to accept the entered changes whilst the key Cancel makes them invalid.

4.3.11 The buttons for scrolling a plot along the X axis

They are used to displace the plot to the left or to the right in respect to the window; thereby it is possible to change the displayed portion of the plot without changing the scale. The following functions are assigned to them:

pressing the button will result in displaying the left initial portion of the profile , rek kina the button I will result in dis~lacement of the olot field by 1 measurkg step to the left that cor