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1.INTRODUCTION
Senlogic’s “DS 505 & DL 405” In-motion Weighing System overcomes many of the limitation
inherent of conventional static weighing systems by being able to weigh wagons on the move.
The state of art highly sophisticated yet simple in-motion weighing system has been designed and
developed indigenously. With conventional systems, each wagon has to be uncoupled from those
adjacent to it, and then carefully positioned and parked on the Weighbridge before its weight can
be recorded.
To overcome time factor in the weighing, Senlogic DS 505 & DL 405 In-motion Weighing
System can automatically identify the direction, type of wagon, engine and revoke the weight of
wagon axle by axle or bogie by bogie by bogie without any manual operation, thus ensuring
weighment accuracy.
DS 505 & DL 405 intelligent, innovative system is designed to detect the different type of
wagons to initiate the axle or bogie weighing. Also it automatically detects the different type of
engines and eliminates its weighment. The speed of wagon is directly related to the accuracy of
weighment.
The high speed A/D Micro Controller are having a remarkable compatibility to achieve accurate
weighment even upto a speed of 20KM/hr. The system is constructed to the highest international
standards, embodies the latest techniques and utilize the best components to ensure the highest
possible reliability and integrity, even when used in harsh environment.
The system can operate over wide temperature, power and hazard environmental condition
without affecting the accuracy and reliability which are being achieved by stringent design and
quality control.
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The multiprocessor technology of the system allows independent processing of weight, Track
logic and communication ensuring fast and accurate weighment essentially required for an
Inmotion Weighing System.
1. SYSTEM OVERVIEW
The load cell based In-motion Weighing System consisting of 4 load cells, weigh bridge with
prefabricated supporting structure and rail approaches. The load cells are strain gauge based
sensors which convert weight in to electrical signal with very high accuracy and stability. Wagon
movement on the weighbridge is identified by Track Switch, placed on either side of bridge, to
detect the direction, type of wagon, start and stop weighment.
The signals from the load cells and track switches are fed into DS 505 & DL 405. The system
automatically monitor the movement of wagon to initiate the weigh cycle & to record the weight
of the wagon when rolls on the bridge.
The robust steel structure, supporting beams and approach beams are constructed with tight
tolerance to with stand the abnormal impact.
The approach rails are rigidly tightened with approach beams to restrict the rail movement and
smooth load transfer to the weighbridge. The misalignment of approach rails, and weighrail may
induces error in accuracy.
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1.1. TRACK SWITCHES
Track sensors / switches are placed along the approach and weighrails in a manner that 4 axle, 2
axle and engine movement can generate a fixed pattern to initiate the weighing cycle.
Since the foot print of rail wheel is 30 mm, a set of proximity sensors are placed with a set of
stainless steel rod at a distance of 100mm (a distance between first and second arm of track
switch), so that the train movement can operate and will generate a forward track logic pattern of:
Track Pattern Logic Pattern
One arm hold
Two arm hold
Two one reach
0 0
1 0
1 1
0 1
0 0
In a similar way the wheel roll back is also identified.
Track switch pattern for two-axle wagon
sw1/2 sw3/4
Track switch pattern for four axle wagon
sw1/2 sw1/2 sw3/4 sw3/4
Track switch pattern for four axle wagon
sw1/2 sw1/2 sw3/4
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Track switch pattern for four axle coupled wagon
sw1/2 sw1/2 sw3/4 sw3/4
sw1/2 sw3/4 sw3/4
Track switch pattern for engine
sw1/2 sw1/2 sw3/4 sw1/2 sw3/4 sw3/4
sw1/2 sw1/2 sw3/4 sw1/2 sw3/4 sw3/4
1.2. TERMINATION BOX
JB boxes is provided to terminate all the loadcell, in a parallel connection. The parallel load cells
are connected through 6 or 4 wire and shield with weighing console.
In a similar fashion track switches are terminated in an another JB to connect with console. These
boxes are made by cast iron with tight rubber sealing to avoid entry of dust.
3. TECHNICAL SPECIFICATION
ANALOG
1. Dynamic Weighing Capacity : 1,00,000 Kg. (100 MT)
2. Static Weighing Capacity : 50 / Ds
For 4 M W/B : 50,000 Kg (50 T)
For 1.75 M W/B : 25,000 Kg (25 T)
3. Resolution Programmable for : 5,10,20,50,100 Kg
By Default : 20 Kg
4. Maximum Weighing Speed : 20 KM / Hr.
5. System Accuracy : ± 0.5% for Individual Wagon
± 0.2% for Unit Train
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A/D SECTION
A to D : 16 bit 100 K/S
Micro Computer : 80c31 / 80c320 20 Mhz
EPROM : 27C512 (64K x 8)
E2PROM : 24C16 (2K x 8)
RAM : 32K x 8
TRACK LOGIC
Micro Computer : 89C52 11.0592 MHz
CONTROL BOARD
Micro Computer : 80c320 20MHz
EPROM : 27c512
Non Volatile & RTC : DS 1644 / 1643 (Optional)
Non Volatile RAM : DS1230
SERIAL COMMUNICATION
Standard : Two RS 232 Channel
One is for communication with control
board & PC. Another is for a special and
future use.
Optional : RS 485 Installed in Channel
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COMMUNICATION PROTOCAL
Band Rate : 4800
Data : 8 bit per character
Start bit : 1
Parity : No
Stop bit : 1
SYSTEM POWER SUPPLY
Power Supply Voltage : 230 V ± 10%
Power Supply Frequency : 50 Hz ± 2 Hz
ENVIRONMENTAL & MECHANICAL
Operating Temperature : 00 C to + 550 C
Storage Temperature : 00 C to + 700 C
Humidity : 20% to 95% RH
Weighbridge or Rail sensor : 4 Meter
Console : 19 Inches Rack
System Weight : 75 Kg.
Track Switch Weight : 5 Kg.
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4. BLOCK DIAGRAMS
The block diagram of DS 505 & DL 405 is subdivided into three parts
1. Main Section (Central Processing Board)
2. Track Logic Section
3. Analog and Digital Section
MAIN SECTION
TRACK LOGIC SECTION
ANALOG & DIGITAL SECTION
ACK
START / STOP / END WEIGH
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MAIN SECTION
ANALOG AND DIGITAL SECTION
TRACK LOGIC SECTION
PERSONAL COMPUTER
HIGH SPEED MAIN
CONTROLLER
PRINTER
KEY BOARD
LCD & 7 SEGMENT
DISPLAY
NON VOLATILE
MEMORY FOR DATA STORAGE
LOAD CELL
INSTRUMENTATION
AMPLIFIER
ANALOG TO DIGITAL
CONTROLLER
ANALOG TO DIGITAL CONVERTER
WHEEL SENSOR
OPTO ISOLATOR & BOUNCE FREE ELLIMINATOR
TRACK LOGIC CONTROLLER
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4.1. DESCRIPTION OF BLOCK DIAGRAMS
Basically, the Central Processor interfaced with the control board does the combined function of
track logic controller and the atod processor. The track logic controller and the main controller
are interfaced through serial communication with ACK signals. The track logic controller sends
the speed, wagon forward, wagon reverse, unknown vehicle and other track side status to the
main controller.
The main controller, keyboard and all other are combined with the central processor. Once a valid
track pattern is detected by the track controller, it issues a START WEIGH and STOP WEIGH.
For this command the A/D initialize its weigh cycle, consisting of WAIT cycle and WEIGH
cycle. End of the wagon is detected by the track logic, which sends the control signals to A/D, so
that it can send the add weight of a current wagon under weighment.
The main CPU receives the speed and weight for display through serial communication and sends
to printer for printing.
4.1.1. ANALOG TO DIGITAL CONTROL
The load cell produces the mV/ V output to the weight applied with specified accuracy and with
zero, span stability, to be converted into digital form for processing and printing & display.
The weigh transducer (load cell) produces low level signal for its applied load, which are to be
amplified and converted into a digital form for the processing. The A/D board is having the high
speed A/D and very fast instrumentation amplifier with built in reference to achieve good gain
and stability.
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4.1.2. DISPLAY AND DIAGNOSTIC BOARD
Diagnostic Board:
This board contains six sections with gold coated switches for simulating the wagon pattern to
diagnose the system operation, when required. Also remote and reset switches are produced for
the wieghbridge operation.
A high efficient RED six digit seven segment LED display is provided with 2 x 16 character
backlite LCD display for the weight and message.
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5. MENU OPERATION – FLOW DIAGRAM
The following shows the menu flow diagram
MENU
SETUP STATIC MODE CLOCK CALIBRATION DIAGNOSTICS
UNIT
BRIDGE LENTH
DATE
TIME
CAPACITY
HEADER 1
BRIDGE TYPE
ENTER AUTO ZERO
HEADER 2
HEADER 3
DRIFT COUNT
LOAD DEFAULT VALUE
RESOLUTION
CALIB WEIGHT
FULL SCALE CAL
RAW COUNT
ZERO SCALE CAL
ENTER CAL COUNT
ENTER TAR COUNT
SHUNT VAL Y/N
RAM 1 TEST
RAM 2 TEST
PC COMM. TEST
PRINTER TEST
DISPLAY TEST
AD RAM TEST
AD EEPROM TEST
AD COMM. TEST
KEY BOARD TESTTRAC COMM. TEST
TRAC SWI TEST
LAMP POST TEST
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5.1. SETUP FLOWCHART
MENU
SETUP
STATIC MODE
CLOCK
CALIBRATION
DIAGNOSTICS
UNIT
BRIDGE LENTH
BRIDGE TYPE
EXIT AUTO ZERO
HEADER 1
HEADER 2
HEADER 3
DRIFT COUNT
LOAD DEFAULT VAL
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5.2. CLOCK FLOWCHART
MENU
SETUP
STATIC MODE
CLOCK
CALIBRATION
DIAGNOSTICS
DATE
TIME
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5.3. CALIBRATIION FLOWCHART
MENU
SETUP
STATIC MODE
CLOCK
CALIBRATION
DIAGNOSTICS
CAPACITY
RESOLUTION
CALIB WEIGHT
ZERO SCALE CAL
FULL SCALE CAL
ENTER CAL COUNT
ENTER TAR COUNT
SHUNT VAL Y/N
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5.4. DIAGNOSTICS FLOWCHART
MENU
SETUP
STATIC MODE
CLOCK
CALIBRATION
DIAGNOSTICS
DISPLAY TEST
AD RAM TEST
AD EEPROM TEST
AD COMM TEST
KEY BOARD TEST
TRAC COMM TEST
TRAC SWI TEST
LAMP POST TEST
RAW COUNT
RAM 1 TEST
RAM 2 TEST
PC COMM TEST
PRINTER TEST
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6. MENU OPERATION – DETAILS
The software menu provides options like SETUP, STATIC MODE, CLOCK, CALIBRATION
and DIAGNOSTICS.
Select SETUP option to configure the system. The system features like auto zero, bridge length,
bridge type, units, header etc., are configured by selecting this option.
Select STATIC MODE option to display the weight.
Select CLOCK to set DATE and TIME.
Select CALIBRATION option to calibrate the system.
Select DIAGNOSTICS to check for correct functioning of the system.
The options detailed above are sequential in order of their occurrence in the MENU. The MENU
is invoked by the KEY F1. When the indicator is switched ON a Display Test is performed where
in all the digits of weight display will glow from ‘9’ to ‘0’ and now the system is ready to take
weighment with auto calibration.
Press key F1 to invoke MENU. The following message is displayed in message display
Use left to right arrow to move to STATIC MODE, CLOCK, CALIBRATION &
DIAGNOSTICS options.
To select setup option move to SETUP and press the key Enter. The following are the options of
the SETUP menu.
MENU <SETUP>
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6.1. SETUP MENU OPTIONS
6.1.1. Units
In this option we can select either kilogram or tons by using left arrow key or right arrow key and
then by pressing enter key.
6.1.2. Bridge Length (CM)
Using this option enter the weight bridge length between second arm of track switch One and
Second arm of track switch Two for accurate speed calculation.
6.1.3. Bridge Type
Using this option select bridge type either 1.75 meter or 4 meter by using left arrow key or right
arrow key and then press enter key.
6.1.4. Auto Zero
This option requires 0/1/2/3 of resolution, which enables automatic zeroing of weight below the
selected resolution. This is useful to arrest any change in tare weight of scale over a period of
time, due to accumulation of debris etc. select the required value and press Enter. Selecting the
value 0 will disable this operation. The default value is 0.
6.1.5. Auto Latch
Using this option select auto latch either YES or NO by using left arrow key or right arrow key
and then press enter key. When you select `YES` the weight in the weight display will change
only when the next change of weight is less or more than 2-resolution. The default is ‘NO’ than is
disable condition.
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6.1.6. Header
Using this option we can change the printer header string. The Maximum string size is 30
charters. The default string is SENLOGIC AUTOMATION (P) LTD.,
6.1.7. Default Values
Using this option we can change all setup and calibration parameters. The default parameters are:
UNITS - Kilograms
BRIDGE LENGTH - 120 cm
BRIDGE TYPE OR SENSOR - 1.75 meter
AUTO ZERO - 0 (Disable)
HEADER - SENLOGIC AUTOMATION (P) LTD.,
CAPACITY - 30,000 Kg
RESOLUTION - 20 Kg
CALIBERATION WEIGHT - 1,100 Kg
CALIBRATION COUNT - 1633
TARE COUNT - 4558
SHUNT VALUE - No (Disable)
6.2. STATIC MODE MENU OPTIONS
This option involves loading the weigh bridge, with calibrated block weights and checking that
the indicated weight is within the prescribed error allowances. To invoke this option use right or
left arrow key and enter key. The test procedure is as follows:-
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1. Enter the static mode menu & ensure zero display
2. Load the weigh bridge, with calibrated weights note down the indicated reading as each
weight is placed on the weigh bridge. Check that any deviation between the actual and
indicated weights are within the prescribed error allowance.
3. Remove the weights note down the indicate reading as each one is removed. Check
that the indicate weight is within the prescribed error allowance if the indicate weights
are outside the prescribed limits, recalibrate the system (Ref.6.4 Calibration Menu of
this manual )
6.2. CLOCK MENU OPTIONS
Real Time Clock is provided for storing the date and time of the weighment taken on the
system. This is 24 hours mode clock with programmable DATE and TIME Battery backup
is provided for the RTC.
To view DATE & TIME use arrow keys & move to CLOCK and press Enter. The
message display will show
Use right or left arrow keys to show TIME & DATE display.
To set DATE view the DATE in message display and press Enter, the message display will
show
DATE 15/09/2002
DATE _
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Enter the correct date and press Enter. For example : 8 MAY 98 will be entered as
08/05/98.
To Set TIME view the display and press enter, the message display will show
Enter the correct time and press Enter. The time should be enter in 24 hours mode only. (Eg.
18:45:00 for 6.45 PM)
6.3. CALIBRATION MENU OPTIONS
This is to be done by authorized persons only. Using arrow Keys move to CALIBRATION and
press Enter. The message display will show
Enter the correct password and press enter. Then the message display will show
6.4.1. Capacity
Using this option enter the scale CAPACITY in Kgs as required and press Enter. The
defaults value of capacity is 30000 Kgs.
TIME _
ENTER PASSWORD _
<CALIBRATION> <ENTER CAPACITY>
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6.4.2. Resolution
Using this option enter the scale RESOLUTION in Kgs as required and press Enter. The default
value of resolution is 20 Kgs.
6.4.3. Calibration Weight
Using this option enter the scale CALIBRATION WEIGHT in Kgs as required and press Enter.
The default value is 1100 Kgs.
6.4.4. Zero Scale Calibration
Using this option makes the zero scale calibration. When you select this option and press Enter,
the message display will show
Clear the scale and ensure platform is empty, press Enter. The system makes the current A/D
value as zero and shows the value 0 in weight display.
6.4.5. Full Scale Calibration
Using this option makes the full scale calibration. When you select this option and press Enter,
the message display will show
MINIMUM MAXIMUM min_val max_val
KEEP SCALE CALER
22
Place the entered calibration weight on scale. The reading displayed on weight display will be
within the proportional range of full scale raw count corresponding to the scale capacity. The
calculation for minimum expected raw count reading and maximum expected raw count reading
for the given calibration weight is as follows:-
30,000 CALIBRATION
Minimum Expected Value = -------------------------------- X WEIGHT ON
SCALE CAPACITY SCALE
50,000 CALIBRATION
Maximum Expected Value = -------------------------------- X WEIGHT ON
SCALE CAPACITY SCALE
Adjust the GAIN potentio meter in AD board such that the reading on weight display is brought
to within or close to the calibration range and press Enter. Now the system is calibrated and the
calibration weight is displayed on the weight display.
6.4.6. Shunt Value Y/N
Using this option we can do the initial calibration. The procedure is as follows:-
� Make zero scale calibration
� Switch on the shunt value
� Measure load cell output in mV.
� Calculate the weight according to the weight
� Enter the calculated weight
� Make full scale calibration
� Switch off the shunt value
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6.5. DIAGNOSTICS MENU OPTIONS
This option provides for self diagnosis of DS 505 & DL 405 IMS. Move to this option and press
Enter. The menu chart for this option is as follows:
6.5.1. Raw Count
Invoking this option you can view the internal raw A/D count corresponding to the current weight
displayed in the weight display. This is mainly useful during calibration
6.5.2. RAM Test
This is to check whether the memory chips are okay or not. Move to this option and press Enter.
The system will show the message either RAM OK, if the memory is accessible or RAM NOT
OK if the memory not accessible.
6.5.3. PC Communication Test
This option is used to check the serial communications are okay or nor. Using arrow keys
move to this option and press Enter. The system sends the string ‘SENLOGIC AUTOMATION ’
to personal computer.
6.5.4. Printer Test
This options is used to check whether the printer connected to the system is okay or not. Using
arrow keys move to this option and press Enter. The system checks the printer communication
and if any error, displays the message PRINTER OFF or PRINTER ERROR. If the printer is
okay the system will print the titles 1 to 3 entered in the HEADER option.
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6.5.5. Display Test
This option is used to check all the segments in the weight display are okay or not. Using arrow
keys move to this option and press Enter .the system will glow 9to 0 in the weight display.
6.5.6. AD RAM Test
This is to check whether the memory chips are okay or not Move to this option and press Enter.
The system will show the message either AD RAM OK if the memory is accessible or AD RAM
NOT OK if the memory is not accessible.
6.5.7. AD EE- PROM Test
This is to check whether the non-volatile memory chips which is used to store calibration
constants are okay or not. Move to option and Enter. The display will show the message PLEASE
WAIT and display either EE-PROM OK if the memory is accessible or AD RAM NOT OK if the
memory not accessible.
6.5.8. AD Communication Test
This is to check, Analog to Digital converter board is either working or not working. Move to this
option and press Enter. The system will show the message ‘AD COM OK’ if AD board is
working else ‘AD COM NOK’ if AD board is not working.
25
6.5.9. Track Communication Test
This is to check track logic board is either working or not working. Move to this option and press
enter. The system will show the message ‘TRACK COM OK’ if Track logic board is working
else ‘TRACK COM NOK ‘ if Track logic board is not working.
6.6. F4 – REPORTS OPTIONS
This option is used to take current reports and rakewise reports. The following options are used
in reports.
6.6.1 Current Report
Use arrow keys to select this option and press Enter. The system prints current rake information.
6.6.2 Rake wise Report
Use arrow keys to select this option and press Enter. The system prints entered Rake
information.
REPORTS CURRENT REPORT
REPORTS RAKE WISE REPORT
26
7. WIRING DIAGRAMS Line 230 V A/C Neutral
Line Filter
Yellow
Yellow
Blue
Blue
Brown
Brown
Fuse 250 mA
Line
Neutral
8 V/2V
8 V/0.2V
14V/0.5V
1
2
3
Gray
White
Gray
Violet
Violet
14/0/14V 0.5A
14V/0.5A
1
2
J10 TRFORM 1
27
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7. MOTHER BOARD CONNECTION DETAILS
U5 – 7805 (To 3 Pakage)
1 - I / P
2 - GND
3 - O / P
U5 – 7805 (To 3 Pakage)
1 - I / P
2 - GND
3 - O / P
J6
1 - Excitation (+)
2 - Excitation (-)
3 - Signal (+)
4 - Signal (-)
5 - Shield
6 - Sense (+)
7 - Sense (-)
7805
GND
I/P O/P
2N3055
Collector
Base Emitter
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JP8
26 - Pin flat cable to diagnostic board
J7
34 - Pin flat cable to display board
JP1 to JP4
32 x 2 Female Euro Connector.
JP9 & JP10
32 x 2 Female Euro Connector
J14 – RS232 Secondary Port for communication with PC for weighment.
1- N.C
2- RXD
3- TXD
4- N.C
5- GND
J5 – RS232 Primary Port for communication with PC for diagnostic purpose.
1- N.C
2- RXD
3- TXD
4- N.C
5- GND
30
J1- The key board connection details are:
1- SCLK
2- SDATA
3- N.C
4- GND
5- Vcc (+5V)
Load Cell Wiring
7 Pin DIN Connector male for loadcell connection from J6 in Mother Board.
1
2
6
5
7
43
Sense ( - )
Sense ( + )
Signal ( - ) Signal ( + )
Excitation ( + )
Excitation ( - )
Shield
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Connector Signal J6 in Mother Board
1
2
3
4
5
6
7
Excitation ( + )
Excitation ( - )
Signal ( + )
Signal ( - )
Sense ( + )
Sense ( - )
Shield
1
2
3
4
6
7
5
Keyboard Wiring
5 pin male connector from keyboard to connector in J1 in mother board.
1
4
3
5
2
N.C
Vcc ( +5V )
DATA
SCLK
GND
32
RS 232 Wiring
2 - TXD
3 - RXD
5 - GND
RS 232- WRITING TO PC
2 TXD RXD 2
3 RXD TXD 3
5 GND GND 5
DTR 4
9 pin ‘D’ type male connector in DSR 6
DN 505 & DN 405 RTS 7
CTS 8
RS 232 – 9 pin ‘D’ type male connector in PC
33
2 RXD TXD 2
3 TXD RXD 3
5 GND GND 7
RTS 4
RS 232 – 9 pin ‘D’ type male CTS 5
Connector in DS 505 & DN 405 DSR 6
DTR 20
RS 232 – 25-pin ‘D’ type male connector in PC
Printer connection
25 pin ‘D’ type female connector JP5 in mother board for centronics parallel interface to printer.
1 - STROBE 11 - BUSY
2 - DATA 12 - PE
3 - DATA 1 13 - N.C
4 - DATA 2 14 - AUTO
5 - DATA 3 15 - ERROR
6 - DATA 4 16 - INIT
7 - DATA 5 17 - N.C
8 - DATA 6 18 to 25 - GND
9 - DATA7
10 - PRNACK
34
Track switch connection
25 pin ‘D’ type male connector in back panel to track switch. The connection details are:-
1 - TXI 11 - TX6 22 - T- GND
2 - RED LAMP 12 - VCC 24 - 12 V
3 - TX2 13 - TX7
4 - YELLOW LAMP 14 - N.C
5 - TX3 15 - TX8
6 - GREEN LAMP 16 - N.C
7 - TX4 17 - TXA
8 - SIREN 19 - TXB
9 - TX5 20 - T-GND
10 - GND 21 - TXC
35
8. TRUBLE SHOOTING
In the trouble shooting is aimed at isolating the fault to be either with the weighing console or
with connected accessories. The following are the testing procedures.
Step Action Result
1.
Supply power to the system &
switch ‘ON’ the system. The
power ‘ON’ switch should glow.
Y - Goto setup 2
N - May be fault fuse.
Replace fuse.
2.
A display test will be performed
where in all digits of weight
display will glow from ‘9’ to ‘0’,
the message display will okay.
Y - The system is ready for
normal operation
N - Possible problem in
power supply main / Display
Board.
36
9.1. WEIGHT NOT DISPLAYED OR DISPLAYED IS INCORRECTLY
Step Action Result
1. Select RAW COUNT in diagnostics option
place known Weight on scale and remove the
same. The raw Count reading should
increase and decrease linearly.
Y - Recalibrate the system
N - Go to step 2
2. a. If the raw count reading is not changing
b. If the raw count is changing linearly
Y – Go to step 3
N – Go to step 2b
Y – Problem with loadcell or A/D
Section
3.
Are all load cell are okay
Y – Go to step 4
N – Replace load cells
4.
All load cell connection & platform okay
Y – Go to step 5
N – Rectify connection
5.
Check excitation voltage, if it is okay
Y – Problem in A/D borad
N- Problem in power supply
37
9.2. PROBLEM IN PARALLEL PRINTER COMMUNICATION
Step Action Result
1.
Switch ON power to system. Switch ON
printer, make sure Paper is loaded
Select printer in Diagnostics and press enter
key. The heading will be printed on printer.
Y-printer communication okay.
N- Go to step2
2.
If the printer switch ON and the ONLINE
Indication in printer will show
Y - Check interface cable
N - Switch On printer and press
ONLINE.
38
10. SOFTWARE OPERATION ( DOS VERSION )
This is the completely automated software with few user interactions Data acquisition, data
storing and all other operations are through the computer running on DOS based Menu Driven
Software . Through the software you can communicate with the In- motion Weighing System.
There are few things user should know before going to operate the system,
When you switch on the computer it normally shows the Main Menu as follows:
26.10.2002 SENLOGIC AUTOMATION (P) LTD. 12:11:36
In motion weighing system
SNO WT SPEED KM COMMENTS SW COUNT DS505&DL405
VER1.0
KEEP SYS ON & PRESS A KEY WHEN SYS IS READY
HELP F1 EXIT F10
39
When you press any key the system will show the following Popup Menu WEIGH, PRINT,
SETUP and EXIT.
26.10.2002 SENLOGIC AUTOMATION (P) LTD. 12:11:36
In motion weighing system
SNO WT SPEED KM COMMENTS SW COUNT DS 505 & DN 405
VER1.0
HELP F1 EXIT F10
WEIGH
SETUP
EXIT
40
Use the bottom arrow key to select WEIGH, PRINT, SETUP and EXIT options.
WEIGH OPTION
To select weigh option move to WEIGH and press Enter key, it will show
SYSTEM READY TO WEIGH
After pressing any key the system will wait for the wagon weights. If the Train enters the weigh
bridge each and every wagon will be displayed serially in the Main menu. After the train passed
the user should given the command ‘Ctrl T’ to totaling the wagon information.
- To totaling the wagon information
PRINT OPTION
Using the aroww key to move PRINT option and press Enter. The system will produce printout
of the current weighment information.
SETUP OPTION
Using the arrow key to move SETUP option and press Enter key, it will show the following
popup menu.
CTRL T
41
TEST STATIC
TEST TRACK SW
PRODUCT INFO
EXIT
� The TEST STATIC option will show the Current Weight of the In-motion weighing System.
� The TEST TRACK SWITCH option is used to testing the track switches are working
properly or not.
� The PRODUCT INFO option shows the product details of the system.
� The EXIT option return to the main popup menu
EXIT OPTION
Using the arrow key to move EXIT option and press Enter key. The EXIT option come out from
the main screen and enter into the Data Entry Screen.
42
DATA ENTRY SCREEN
Before going to the Data Entry Screen the gross weight will be restored automatically and it
will show the current rake number and the previous rake number.
26/062002 SENLOGIC AUTOMATION (P) LTD. 12:22:02
DATA ENTRY VIEW REPORTS M.I.S. REPORT INITIALIZATION QUIT MODIFICATION
43
DATA ENTRY OPTION
Using the arrow key to move into DATA ENTRY option and press Enter key. In the Data
Entry Option will show the following screen.
Every time it will show the current rake information of Date In, Date Out, Time In, Time Out and
Gross Weight. At the time of data entry the user want to edit the previous rake information
through entering the rake number.
After entering the rake information Press <Esc> to save the current rake information.
REPORTS OPTION
Using the arrow key to move into REPORTS opption and press Enter key. In the Reports Option
will show the following screen.
RAKE NUMBER : PROD . NAME : ENTER DATA IN : TIME IN : ENTER DATA OUT : TIME OUT : FROM : TO :
PRINTING REPORTS ENTER RAKE NO : Esc to Quit
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When user select the REPORTS option it will ask the rake number. After entering the rake
number it will produce the printout of the given rake number.
INITIALIZATION OPTION
Using the arrow key to move into INTIALIZATION OPPTION AND PRESS Enter key. In this
option will show the following screen.
This option is used to erasing the rake information. When user select the INITIALIZATION
option it will ask the password. After entering the password it will ask from which rack number
to which rake number the user want to delete.
Enter password: Erase data(Y/N) :
From Rake No : To Rake No: Are you sure (Y/N):
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MODIFICATION OPTION
Using the arrow key to move into MODIFICATION option and press Enter key. It will show the
following screen.
This option is used to modifying the existing rake information except the gross weight. This
screen format will be same as the Data Entry Screen.
VIEW OPPTION
Using the arrow key to move into View Option and press enter key. In the View Option the
system will ask the following command.
DO YOU WANT TO VIEW ( Y / N ) : _
The user will press ‘Y’ it will show all the existing rake number information. The user select the
particular rake number and view the same.
RAKENUMBER : PROD. NAME : ENTER DATE IN : TIME IN : ENTER DATE OUT: TIME OUT : FROM : TO :
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M.I.S. OPTION
Using the arrow key to move not M.I.S option and press enter key. When the user select the
M.I.S option it will show the popup menu as follows:
PRODUCT WISE REPORT
RAKEWISE REPORT
SOURCEWISE REPORT
QUIT
PRODUCTWISE REPORT
This is the periodical Product wise report. When user select this option, (using arrow key )it will
ask the FROM DATE and TO DATE. It will generate all the product wise information, which
are loaded with in that period.
RAKEWISSE REPORT
The Rakewise Report is not related with any periodical information. After completion of
weighment the system will automatically generate the rake number comparing with the previous
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one. The user want to generate the report of rakewise information they should give the FROM
RAKE NO and TO RAKE NO.
SOURCEWISE REPORT
This is the periodical Source wise report. When user select this option, it will ask the FROM
DATE and TO DATE. It will generate all the source wise information, which are loaded with in
that period.
QUIT
This will exit the current popup menu and focus into Date Entry Screen.
QUIT OPTION
This will exit the Date Entry Screen and focus into the Main Screen.
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Rail In Motion Software: (Window Based)
This is completely automated software with few user interactions. Data acquisition, Data storing and all other operations are through the computer running on window based software. Through the software, you can communicate with the In-Motion Weighing System.
When you switch on the computer it normally shows the main menu as follows:
The Main Menu contains:
Weigh Option
In Motion
Tare Entry
Report
Edit
Setup
Wagon Entry
Merge Tare
Exit
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When you press WEIGHING Command it show following weighing mode menu.
Now, Communication status it shows Communication Error!!!. These messages appear RS 232 (Serial Communication) not communicate properly to computer. Then you check the communication cable, again go to main menu then press WEIGHING command button.
Now, Communication status it shows
When this message appears you have select
GROSS or TARE ratio button.
Then you have select type of wagon that is
Communication OK.
BOXN or BOBR
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After selecting type of wagon, now, system is READY TO WEIGH. When the rake is enters the weighbridge, the system automatically detect the type engine and eliminate the engine weight. The system detects each wagon, and weight will be displayed serially in the weighing menu. After the train passed the weighbridge operator press or click the END OF WEIGHMENT then press PRINT Command button. Now, the system will produce printout of the current rake information. The rake serial no is automatically incremented.
Gross printout like,
Then the rake serial no automatically incremented, after taking printout you press Back
Button on the weighing menu screen. System shows main menu screen.
Now, You press Command button in the main screen.
Tare Entry
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Rake Information Screen;
Now, select the Gross rake in rake information mode. Then give the input of
� Rake No - � R.R.No -
� Invoice No -
� Indent No -
� From -
� Product -
� To (Destination) -
� PCC + -
The above field is enterable; PCC limit is 1 to 9.
Enter your PCC limit (0 to 9), then the wagon no, tare entry screen open automatically,
The tare entry screen as bellow.
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Tare Entry Screen.
Tare Entry: Here first you select wagon type, then enter wagon no, wagon field limit is 20 characters. Then enter wagon tare weight, automatically calculated C.C.weight.
The input field is:
Wagon No : 20 Characters (Alpha Numeric Value)
Tare Weight : 05 Characters (Numeric Values, 00.00)
C.C.Weight : 05 Characters (Numeric Values, 00.00)
The caring capacity is correct then enters next tare weight otherwise, you correct caring capacity. Once again you check all tare weight, Wagon no & C.C. Then press or click SAVE command button. All data storing in your database, here automatically calculate Net weight, Permissible C.C, Under Load, Over Load, Penal Load, Chargeable Weight. Then you want print out of complete rake information, you press PRINT command button, the print out automatically generated.
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The net print out format likes;
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REPORT Our system generated the following MIS report,
� Rake wise Report � Daily Report � Monthly Report � Customer Report � Gross Report
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Rake Wise Report The rake wise report is not related with any periodical information. After completion of weighment, the system will automatically generate the rake number comparing with previous one. The user wants to generate the report of rake wise information they should select the RAKE NO only. Daily Report These reports create on particular date rake summary information. Monthly Report When user select this option, it will ask the FROM DATE and TO DATE. It Will generate all the rake summary information which are loaded with in that period. Customer Report When user select this option, it will ask the FROM DATE, TO DATE and CUSTOMER NAME. It will generate all particular customer rake summary information which is loaded with in that period. The rake report it shows Slno, Wagonno, CC, PCC, Gross, Tare, Net, Under Load, Over Load, Speed. The under load & over load calculation generated automatically. The date wise Report Like:
Edit: When user select this option, it will ask the RAKE NO. You edit the wagon no, tare weight, caring capacity
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Database Security The proposed software will have multilevel of password and to prevent the data being handled by unauthorized person. The password is to be designed with hirarchive pattern, So that at every level we can control the usage of the system data. The multilevel not only provided the security it gives very high encrypted data production in case of any wrong access of the data. Exit This will exit the main menu screen it will focus to computer normal screen. SHUT DOWN This will shut down your computer.
In-Motion Software Installation
Step 1: First insert in CD in your CD drive. Step 2: Go to Setup Folder in your CD drive Step 3: Double Click SETUP icon.
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Software Setup first Window Fig.1.0.1
Step 4: Click Next Button.
Software Setup Second Window. Fig.1.0.2
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Here you must change the software path like; D:/Inmotion Once again you conform your path is correct, then click Next Button.
Software Setup Third Window Fig.1.0.3
Now, Click Next Button
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Software Setup Third Window Fig.1.0.4
Here Click Create a desktop icon The software icon automatically created in your computer desktop.
Software Setup Third Window Fig.1.0.5
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The software is Ready to Install in your computer system Now, you click Install Command.
The Software is automatically installed in your computer system, & Click Finish Button. You go & see your program group of your system. Note:
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The important file is D:/Inmotion Senlogic.Exe Main.Mdb
Computer Specification
• Intel Pentium 4 Processor @ 2.0 GHZ • 256 KB CACHE • Intel 845 GE Chipset • 400 Mhz Front Side Bus • 1 Parallel Port • 2 Serial Port • 2 USB Port • TVS Key Board & Scroll Mouse • 15 “ Colour Moniter • Windows XP OS • 132 Column Printer Reputed Make.
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TRACK SWITCH SPECIFICATION: In - Direction
4 Mtr Rail Sensor SW1 1 2 3 4 SW2 SW4 4 3 2 1 SW3 Out - Direction Distance: Sensor Weigh Rail : 4 Mtr (Each) Sensor Bar : SW1 (1) to SW2 (4) : SW1 (2) to SW2 (3) : SW3 (1) to SW4 (4) : SW3 (2) to SW4 (4) :
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SENSOR TECHNICAL SPECIFICATION: System : In motion Weighing system. Capacity of the Rail Sensor : Adequate Capacity to measure 100 Mt. Rated Excitation Maximum Excitation Bridge Resistance Temperature Effects.
15V AC /DC 25V AC/DC 700 Ohms (Nominal >1000 Meg Ohm @50 VDC
Span / degree C (of load)
+/- 0.006%
Span / degree C (of load)
+/- 0.006%
Zero/degree C (FSO)
+/- 0.008%
Combined Error (FSO)
<+/- 0.085%
Safe Overload (FSO)
150%
Ultimate Overload (FSO)
300%
Protection Class IP 67 Bridge Configuration : Quad strain guage Encapulated .8 Surge Protection: a) Transient voltage suppressers. b) Semi Conductor fuse. Advantages:
1) Improved mv/v output 2) Better sealing. 3) Better isolation so no need of isolate the approach Rails 4) Best Quality strain gauges.
Long term stability, span & Zero effect.
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LOAD CELL
Load cells are utilized in nearly every electronic weighing system. In understanding load cells, you’ll be better able to comprehend the systems in which they are used.
The following is a brief summary of the inner workings of a load cell. While this explanation does not answer every question, it can provide the basic framework for understanding load cells.
System Components: In contemporary control applications, weighing systems are used in both static and dynamic applications. Some systems are technologically advanced, interfacing with computers for database integration and using micro-processor based techniques to proportion material inputs and feed rates. To send the weight information to computers, signal conditioners are utilized to permit direct communication from the load cell via conversion of the load cell’s analog signal to a digital signal.
An entire system can be constructed, one piece at a time, from basic modules.
Parts of a system can include:
• Load cells
• Cable
• Junction Box (summing up the load cell signals up to one output),
• Instrumentation (indicators, signal conditioners, etc),
• Peripheral Equipment (printers, scoreboards
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Shear beam
Single Ended Shear Beam 3 mV/V, .03% nonlinearity, 350 ohms, 20 ft cable, stainless steel with threaded hole. Environmentally protected.
Bridge Resistance Input Ohms
Output Ohms
343-357 349-355
Applications include Hostile Environments,
Tank weighing, Bin and Hopper scales
Capacity A1 A2 B C D E F G H Thread 1,000 Lbs
shear beam 1.22 1.22 5.1
2 .62 1.00 3.00 2.2
5 .53 1/2 -20 UNF-2B, 0.53 x .61DP. C'Bore
2,500 Lbs shear beam
1.22 1.22 5.1
2 .62 1.00 3.00 2.2
5 .53 1/2 -20 UNF-2B, 0.53 x .61DP. C'Bore
4,000 Lbs shear beam
1.22 1.22 5.1
2 .62 1.00 3.00 2.2
5 .53 1/2 -20 UNF-2B, 0.53 x .61DP. C'Bore
5,000 Lbs shear beam
1.50 1.50 6.7
5 .75 1.50 3.75 3.0
0 .78 3/4-16 UNF-2B, 0.78 x .75DP. C'Bore
10,000 Lbs 1.5 1.50 6.7 .75 1.5 3.75 3.0 .78 3/4-16 UNF-2B, 0.78 x .75DP. C'Bore
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shear beam 0 5 0 0
TECHNICAL SUPPORT
If this product fails to operate satisfactorily upon arrival, contact your Senlogic dealer of Senlogic to arrange for an exchange.
Tel: 044- 2486 8937 FAX: 044-2486 5640
Upon contacting Order Entry, you will be given a Return Material Authorization (RMA) number. The RMA number is your authorization number. Please write this number on your purchase order and shipping label.
Send all authorized returns to: Senlogic Automation (P) Ltd.
New No.6, 4th Street, Suresh Nagar, Valasaravakkam, Chennai – 600 087.
For technical assistance, contact Senlogic’s Measurement and Control Division (MCD) Applications Engineering: To arrange for service, contact the Customer Service Office: Tel: 044 – 2486 8397 You must provide the Customer Service Office with the following information:
•Model number •Serial number •Purchase order number •Quantity being returned •Detailed description of the malfunction •Your “Bill To” and “Ship To” addresses Our Customer Service Coordinator will provide you with the following:
� Customer service order number (CSO) � Warranty status of the units being returned � Repair charge, if any
Send all authorized return to: Senlogic Automation (P) Ltd.
New No.6, 4th Street, Suresh Nagar, Valasaravakkam, Chennai – 600 087.
Or mail at: [email protected]
