A

Report On
“Design and development of On-board panel of LHB AC
coach in Indian Railway”
(Industry Internship & Project)
At
Power Control Electro Systems Pvt. Ltd., Sangli

Submitted

For the award of degree of

Bachelor of Technology
In
Electrical Engineering
by
Mr. Vishwajeet Madhukar Gaikwad (1808014)

Under the Guidance of

Prof. Omkar Swami

Electrical Engineering Department

K. E. Society’s
Rajarambapu Institute of Technology, Rajaramnagar
(An autonomous Institute, Affiliated to Shivaji University)
2021-2022

I
 K. E. Society’s
Rajarambapu Institute of Technology, Rajaramnagar
(An autonomous Institute, Affiliated to Shivaji University)

Department of Electrical Engineering

CERTIFICATE
This is to certify that the internship under Industry Internship & Project (IIP) track completed at
“Power Control Electro Systems Pvt. Ltd., MIDC Kupwad, Sangli” is the bona fide work
submitted by the following student, to the Rajarambapu Institute of Technology, Rajaramnagar
during the academic year 2021-22, in partial fulfillment for the award of the degree of B. Tech in
Electrical Engineering under our supervision. The contents of this report, in full or in parts, have
not been submitted to any other Institution or University for the award of any degree.

Name of Students Roll Number

Vishwajeet Madhukar Gaikwad 1808014

Date:
Place: Rajaramnagar

Prof. Omkar Swami Mr. Chidhambar Pathak

Industry Internship & Project Industry Internship & Project
Mentor (College) Mentor (Industry)

Prof Amarjeet Pandey Dr. V. N. Kalkhambkar

Training &Placement Coordinator Head of Departmen

II
INTERNSHIP CERTIFICATE

III
 DECLARATION
I declare that this report reflects my thoughts about the subject in my own words. I have
sufficiently referenced the original sources, referred or considered in this work. I have not
plagiarized or submitted the same work for the award of any other degree. I also declare that I
have followed to all principles of academic honesty and integrity and have not misrepresented or
fabricated or falsified any idea/data/fact/source in my submission. I understand that any violation
of the above will be cause for disciplinary action by the Institute.
Sr. No. Student Name Roll No Signature

1. Vishwajeet Madhukar Gaikwad 1808014

Date:
Place: RIT, Rajaramnagar.

IV
 ACKNOWLEDGEMENT

I take this opportunity to thank all those who have contributed in the successful completion of a
Project Under Industry Internship & Project (IIP) track at ‘‘POWER CONTROL ELECTRO
SYSTEMS PVT.LTD’’. I sincerely wish to express my gratitude to Industry Internship & Project
(IIP) Mentor Prof.Omkar Swami for full support, expert guidance, and encouragement and kind
cooperation throughout the Internship work. I am greatly indebted to him for his help throughout
project work. I express my sincere gratitude towards Dr.Vaiju N. Kalkhambkar, Head of the
Department, Electrical Engineering, for providing necessary facilities, guidance, and support.
I respect and thank Mr./MS, Chidambar Pathak for providing me an opportunity to do an
internship in [POWER CONTROL ELECTRO SYSTEMS PVT.LTD] and giving us all support
and guidance, which made me complete the internship duly. I am extremely thankful to [her/him]
for providing such a nice support and guidance, although he had busy schedule managing the
corporate affairs.
I thank Prof. Amarjeet Pandey (Dept TPC) for providing Internship & Project Opportunity in an
Industry. I am thankful to and fortunate enough to get constant encouragement, support, and
guidance from all Teaching staffs of Electrical Engineering Department, which helped me in
successfully completing internship.
Nevertheless, I express my gratitude toward my family members for their kind co-operation and
encouragement which helped me in the completion of this internship.

V
 ABSTRACT

The On board panel supplies power to the switchgears, Measuring/Indicating instruments, MMR &
IMR, protection devices, light, fan, sanitary/pump control, controller of the air conditioning unit,
switchgear for the pantry equipment, DC-DC converters, insulation monitoring devices, PIS/PA system,
Fire detection & suppression system etc. Depth wise, the panel contains contactors, relays, low voltage
fuses, insulation monitoring and terminal blocks for the incoming and outgoing 415 V ,230 V AC, 110V
AC circuits, cable trays and terminals for other layers. 4 mm thick transparent fire-retardant
polycarbonate sheet is provided to prevent accidental contact. The dimensions and layout are as per the
drawing given by railway department.
The panel gets supply from under sludge panel which is fixed under the railway coach which consists of
transformers, fuses, circuit breakers, etc. MCBs, MPCB, contactors in the on board panel are acting as
switchgear used for the appliances in the coach like lights, fans, AC, announcing speakers, fire detecting
systems etc. Wiring is done through PVC channels to avoid short circuit. Each wire connected to the
devices is given number to trace when the fault occurs and to make connection easy. After completion
of the panel various tests are carried out like electrical continuity, effectiveness of protective circuits,
temperature rise test, test for verification of insulation resistance etc. even the certificates and data sheets
of the components are checked.

VI
 INDEX

Chapter No. Description Page No

CHAPTER 1: About Project 1
1. Introduction 1
1
1.1 Problem statement 2
1.2 Objective 2
CHAPTER 2: Proposed Work 3
2.1 Onboard panel of ac coach in railway 3
2
2.2 Steps of wiring 4
2.3 Components used 6

CHAPTER 3: Process Sheet and Fabrication 21

3.1 Process Sheet 21

3
3.2 Fabrication 22
3.3 Expected Outcome 23
CHAPTER 5: Photo Gallery & Resources Required 24
4 4.1 Photo Gallery 24
4.2 Resources Required 25
5 CHAPTER 5: Conclusion 26

6 CHAPTER 6: References 27

VII
 LIST OF FIGURES

Figure No. Figure Name Page No.

1 On board front panel of LHB coach 1
2 On board panel of AC coach 3
3 Contactor 6
4 Miniature Circuit Breaker 7
5 Motor Protection Circuit Breaker 9
6 DC to DC Converter 11
7 Insulation Monitoring Relay 13
8 Diagnosis PCB 13
9 DC Voltmeter 14
10 AC Voltmeter 15
11 DC Ammeter 16
12 AC Ammeter 17
13 Indicator Lamp 17
14 Selector Switch 18
15 Rotary Switch 18
16 Push Button 19
17 Undervoltage & Overvoltage Relay 19
18 Fuse 20
19 Metal sheet cutting machine 22
20 Welding 23

VIII
 LIST OF TABLES

Table No. Table Name Page No.

1 DC to DC Converter Specifications 11
2 Process Sheet 21

IX
 CHAPTER 1: About Project

1. INTRODUCTION

Onboard panel is a control panel which is placed the inside the LHB Ac coach .It mainly used
to control and protect the electrical appliances inside the coach.it gets the 450v supply from
underslung panel and distribute the supply the AC coach. Onboard panel consist of front tray
right side door and left side door. we distribute the 415v supply by using contactor, fuse,
MPCB etc. We distribute the ac supply as well as dc supply through onboard panel.

Double
Pole MCB

Single
Pole
MCB

Three
Pole
MCB

MPCB

Three Pole
Contactor

Contactor
and MPCB

Fig 1. On board front panel of LHB coach

1
1.1 PROBLEM STATEMENT

Design and Development of onboard panel of LHB AC coach in railway. In a very efficient
manner and in accordance to the guidelines given by railway department of India.

1.2 OBJECTIVE

1. To design and develop Onboard panel.

2. To test the electric components like switchgear and wires before installation.
3. To check the wiring of panel once after installation
4. To test the panel after completion.

2
 CHAPTER 2: Proposed Work
2.1 ONBOARD PANEL OF AC COACH IN RAILWAY

Fig 2. On board panel of AC coach in Garibhrath railway

The On board panel consists of the switchgears, protection devices, light, fan, sanitary/pump control,
controller of the air conditioning unit, switchgear for the pantry equipment, DC-DC converters,
insulation monitoring devices, system, Fire detection & suppression system etc. This On-board panel
is used for controlling the appliances used in railway coach like fans, lights, AC, etc. The switchgear
devices used in the panel are MCB of different types like single, double, three pole and also AC or
DC. The switch gears are used according to the ratings and requirements of the appliance. This panel
is placed inside the coach and gets supply from under sludge panel which is placed under the railway
coach. The on-board panel is assembled according to the circuit diagram given by the railway
department. After completion of the panel testing is done in accordance to the sequence given by the
company. This on-board panel can be called as a control unit of the railway coach and every coach
needs a separate panel for controlling.

3
2.2 Steps of wiring

Step 1 - Prepare the Drawing

The very first step in control panel is prepare the drawing. The control panel drawing will
help us to prepare the layout for panels. If you have good logic then go over the drawing and
if possible, take advice of specialist and make sure the logic works well on paper. If it works
on paper, then it will be easy to start with designing of control panels.

Step 2 - Determine the Number of Items

Recheck the control panel wiring drawing and determine the number of components or items
that we need to wire the panel. make a proper list and check for two to three times if it is
completed.

Step 3 - Prepare the Layout

Make a proper layout of all the components like fuse, timers, breakers, NO/NC, relay and
wire channels. We must need the din rail for IEC control. For simplicity of wiring and
installation, remove the backboard from the enclosure area.

Step 4 - Check the Order

Check for at least 2 times if everything is in order. Ensure that a terminal strip along the
bottom and that it have extra terminal blocks for each external and internal wire that is going
out of the panel.

Step 5 - Tap the Mounting Holes

Starting with threading, Drilling and tapping the mounting holes. After completing mount all
the components and wire channels. Use a set of center punches for our easy understanding.
While drilling and tapping there is chance of breaking the blade so tap with slow speed. Use
the drop of oil while tapping.

4
Step 6 - Install the Power Wires

In every panel the wiring is always started with installation of power wires. while wiring it is
very important to label all the wires. the proper labeling will help for the troubleshooting
when there is problem in future if arise. Begin with all the common wires or neutral wires
first by connecting them. Mark all the wires, especially when you are using other than white
or gray ones. Most people in industries prefer to use white wires to make the control panel
wiring look cleaner, what is important is to mark them properly.

Step 7 - Install the Wires

Always use the Panel drawing as your guide. starting from the installation of first wire to first
rung in the drawing. Mark and label using a number pads or labeler. after installing every
wire put mark on that wire. so that it can minimize mistakes or double installations of wires.

Step 8 - Test the Wires

Apply the voltage after you are completely done with installing the wires. Conduct all test on
the panel.

Step 9 - Install the Control Panel

If everything goes well, you may install the control panel and attach all incoming wires to the
terminal strip. Wrap it and install it on site.

5
 2.3 Components of Onboard Panel

2.3.1 Contactor

Fig No. 3

A contactor is an electrically-controlled switch used for switching an electrical power circuit.

Contactor is typically controlled by a circuit which has a much lower power level than the
switched circuit, such as a 24-volt coil electromagnet controlling a 415-volt motor switch.
Unlike general-purpose relays, contactors are designed to be directly connected to high-
current load devices. Relays tend to be of lower capacity and are usually designed for both
normally closed and normally open applications. Devices switching more than 15 amperes or
in circuits rated more than a few kilowatts are usually called contactors. Apart from optional
auxiliary low-current contacts, contactors are almost exclusively fitted with normally open
("form A") contacts. Unlike relays, contactors are designed with features to control and
suppress the arc produced when interrupting heavy motor currents.

KEY FEATURES:
 Wide Operating Band.
 Dc Ratings Available & Click Fit Type Construction
 Easy Inspection & Replacement of Coils & Contacts
 Alpha-Numeric Terminal Markings 4 Front On/Off Indication

6
 2.3.2 MCB

Fig 4. MCB

Types of MCB:

1. AC MCB
 Single Pole
 Double Pole
 Three Pole
 Four Pole

2. DC MCB
 Single pole
 Double pole

Safety is the first concern while choosing electrical appliances or devices. When the power
fluctuates or when excess current flows, it causes damage resulting in an overload or short
circuit. Hence, it is important to incorporate a device as a safety element to provide
overcurrent protection to the electrical devices/circuits. Fuse is one of the most common
devices used in the early days for the protection of the circuit. A fuse contains a metal wire or
strip that melts when overflow of current takes place, by stopping or interrupting the current.

MCB is an automatic switch that opens when excessive current flows through the circuit. It
can be reclosed without any manual replacement. In the case of a fuse, once a fuse has been
operated, it must be replaced or rewired, depending on the type of the MCB. Hence, fuse is
known as one of the sacrificial devices. This is the main reason why MCBs are used as an
alternative to the fuse in most of the circuits. Also, whenever there is a fault in the circuit, the
switches in the MCB automatically shut down and the fault of the device can be easily
detected.
Handling MCB is quite safe and it quickly restores the supply. MCB – Miniature Circuit
Breaker can be reset quickly and does not demand more maintenance costs. MCB works on a
bi-metal respective principle that protects against overload current and solenoid short circuit
current.

7
 Types of Miniature Circuit Breaker
MCB trip curve decides the type of MCB that has to be used for different types of appliances
or devices. There are 6 types of MCBs, they are:

A Type, B Type, C Type, D Type, K Type, Z Type

 A Type MCB trips off the circuit when the current exceeds 2-3 times the actual current
rating. A type MCB – Miniature Circuit Breaker is highly sensitive to the short circuit and
hence we can find its application in the manufacturing of semiconductors.
 B Type MCB trips off the circuit when the current exceeds 3-5 times the actual current flow
and finds its application in the cable protection.
 C Type MCB trips off the circuit when the current exceeds 5-10 times the actual current flow
and finds its application in the domestic as well as commercial appliances like transformers,
fluorescent lighting circuits, IT equipment like personal computers, servers, and printers.
 D Type MCB trips off the circuit when the current exceeds 10-20 times the actual current
flow and offers high resistance. It finds its application in motors.
 K Type MCB can withstand up to 8-12 times the actual current flow and finds its application
in the heavy-duty load devices like compressors, winding motors, and X-ray machines.

When the overflow of current takes place through MCB – Miniature Circuit Breaker, the
bimetallic strip gets heated and it deflects by bending. The deflection of the bi-metallic strip
releases a latch. The latch causes the MCB to turn off by stopping the flow of the current in
the circuit. This process helps to safeguard the appliances or devices from the hazards
happening due to overload or overcurrent. To restart the flow of current, MCB must be turned
ON manually.
In the case of short circuit conditions, the current rises suddenly in an unpredictable way,
leading to the electromechanical displacement of the plunger associated with a solenoid. The
plunger hits the trip lever, it causes the automatic release of the latch mechanism by opening
the circuit breaker contacts.
An MCB is a simple, easily operable device and is maintenance-free too. MCB can be easily
replaced. The trip unit is the key part of the MCB – Miniature Circuit Breaker on which the
unit operates. The bi-metal present in the MCB circuit protects against overload current and
the electromagnet in the circuit protects against short-circuit current.

8
2.3.3 Motor Protection Circuit Breaker

Fig 5. MPCB

Motor protection circuit breakers are a specialized type of electrical protection device that is
designed specifically for electric motors, like their name implies. Electric motors have plenty
of applications and are used to drive mechanical devices of all types, so it is very important to
protect them adequately with MPCBs.

A motor protection circuit breaker, or MPCB, is a specialized electromechanical device that

can be used with motor circuits of both 60 Hz and 50 Hz. It has several functions that allow it
to provide a safe electrical supply for motors:

Protection against electrical faults such as short circuits, line-to-ground faults and line-to-line
faults. The MPCB can interrupt any electrical fault that is below its breaking capacity. Motor
overload protection, when a motor draws electric current above its nameplate value for an
extended period of time. Overload protection is normally adjustable in MPCBs. Protection
against phase unbalances and phase loss. Both conditions can severely damage a three-phase
motor, so the MPCB will disconnect the motor in either case as soon as the fault is detected.

Thermal delay to prevent the motor from being turned back on immediately after an overload,
giving the motor time to cool down. An overheated motor can be permanently damaged if it
is turned back on.

Motor Circuit Switching – MPCBs are normally equipped with buttons or dials for this
purpose.
Fault Signaling – Most models of motor protection circuit breakers have a LED display that
is turned on whenever the MPCB has tripped. This is a visual indication for nearby personnel
that a fault has occurred and the electric motor must not be connected again until the fault is
addressed.
Automatic Reconnection – Some MPCB models allow a cool down time to be input in case
there is an overload, after which the motor will restart automatically.
Electric motors are expensive equipment, so the role of the motor protection circuit breaker is
very important. If a motor is not protected correctly, it may be necessary to carry out costly
repair works or even replace the equipment completely. An electric motor that is adequately
protected with an MPCB will have a much longer service life.

9
10
 Motor Protection Circuit Breaker Working Principle:

 The motor protection circuit breaker can be considered a subtype of a thermal magnetic
circuit breaker, but with additional functions that are specially designed to protect electric
motors. The basic working principle is similar to all other circuit breakers.
 Thermal protection is used to guard the electric motor against overload. It is based on an
expanding and contracting contact that disconnects the motor if excessive current is detected.
It is very important to know that thermal protection has a delayed response, to allow the high
inrush currents when a motor starts. However, if the motor is unable to start for some reason,
thermal protection will trip in response to the extended inrush current.
 Magnetic protection is used when there is a short circuit, line fault, or other high current
electric fault. Unlike thermal protection, magnetic protection is instantaneous; to immediately
disconnect the dangerous fault currents.
 The main difference between the MPCB and other circuit breakers is that the MPCB can
provide protection against phase unbalance and phase loss. Three-phase circuit motors
require three live conductors with balanced voltages in order to operate effectively. An
unbalance of more than 2% will be detrimental to the motor’s service life. If one of the phase
voltages is suddenly lost, the effect is even more damaging because the motor will keep on
running with only two phases. The motor protection circuit breaker is capable of detecting
these conditions by measuring the differences among phase voltages, and disconnects the
motor immediately when they occur. It is important to note that phase current unbalance is
normal in three-phase systems that power separate single-phase loads, but is unacceptable
when the three-phase circuit powers an electric motor.

MPCBs are also equipped with a manual interruption mechanism, allowing disconnection of
electric motors for replacement or maintenance.

Motor protection circuit breakers are available in a wide variety of current ratings, and one of
their best features is that many models allow the current rating to be adjusted. This means
that the same MCPB can be configured to protect motors of different capacities.

Features:
• MPCB for Overload & Short Circuit Protection
• Compact Size
• Short circuit protective co-ordination
• Reduction in wiring work
• Padlocking feature available even without extended rotary handle
• Stand alone motor protection
• Common accessories

11
2.3.4 DC TO DC CONVERTER

Fig 6. DC to DC Converter

The DC to DC Converter are Mainly used to increase or decrease the DC voltage. Here we
use Buck Converter of rating, Input 110volt DC, Output 24volt 1.7-amp DC. These
converters are for higher frequency conversion circuits and they use components like
inductors, transformers and capacitors to give out smooth DC signal at the output. In this the
closed loops which are for feedback maintain a constant output voltage even when the DC
input voltages vary at a particular range .The above DC to DC converter consists of CMOS
and a feedback diode across it .A transformer which is an stepdown transformer is used to
reduce the voltage. Finally filters are used like capacitor and inductor to reduce the noise at
the output. The output of the filters are connected to other DC links.

Specifications

Battery Operation Output Voltage 24 VDC

Nominal Voltage 100 VAC - 240 VAC

Power Supply Voltage Output 24 VDC

Power Supply Type Switching

Power Supply Mounting Din Rail Mount

Power Supply Number of Outputs Single Output

Power Supply Voltage Phases Single Phase

12
 Power Supply Hazardous Class Class 1 Div 2

Power Supply Housing Enclosed

Non-matching Non-matching

Power Supply Voltage Input 85 VAC - 264 VAC

Power Supply Low Temperature -25 °C

Power Supply High Temperature 70 °C

Power Supply Connection Type Screw Connections

Component Power Supply

Power Supply Amperage Range 0-5 Amp

Power Supply Amperage Output 1.75 Amp

Power Supply Watts (Nominal Power) 42 Watt

Manufacturer Phoenix Contact

Line STEP

Table no. 1: Specifications

13
2.3.5 INSULATION MONITORING RELAY

Fig 7. Insulation Monitoring Relay

Insulation monitoring device for AC and DC ungrounded systems. Used on control circuits
and main circuits. The new ISOMETER® iso415R is a simple and intelligent ground-fault
monitor for electrical safety in control circuits and other applications. It is for ungrounded
systems for compliance with IEC 60364-4, and meets IEC 61557-8 requirements. It combines
easy operation, multiple interfaces, flexible application options and a compact design. It is the
first device of Bender's new Smart Detect series and offers maximum safety in ungrounded
AC, AC/DC, and DC systems. Fast, simple operation was a central goal in the development
of the new iso415R. That is why the parameters of the ISOMETER® can be set either with
two rotary potentiometers, with the Bender Connect app, or with Modbus RTU
communications. With the app, the iso415R can be set up before installation. In addition, a
setting made once can be transferred to any number of devices. All technical information
including the manual can be conveniently accessed at any time via the QR code. The
measured value is displayed by LEDs. The device, which is only 18 mm (0.7”) wide, is
installed by simply pushing it into place on a DIN rail.

2.3.6 DIAGNOSIS PCB

Fig 8. Diagnosis PCB

Diagnosis PCB is mainly used to provide protection to the indicators. It is connected in series
with supply and indicator. It consists of unidirectional diodes. It is used to 24-volt dc supply.
The problems are identified using the Vi mounted on the PCB. The alternating voltage is used
to test the unidentified pin count. This test involves using fixed probes laid out in a way that
matches the design of the PCB. The probes check the integrity of the solder connection. The
bed of nails tester simply pushes the board down on Without testing your PCBs, there may be
errors and problems that have been overlooked during the production stage the bed of probes
to start the test.

14
 2.3.7 VOLTMETER

Fig 9. DC Voltmeter

Parameter displayed: DC Voltage

Features:
 Microcontroller based meters with low VA burden.
 4-digit seven segment display
 Auto scaling of parameter values
 Touch proof voltage & current terminals.
 Compact size and light weight.
 ABS dust-proof rugged casing.
 Auxiliary Supply: Universal Auxiliary (90-300V AC) Supply (Other supply voltages on
demand)
 Accuracy: Class 1.0 or Class 0.5
 Standard: IEC62053-21/22
 Inputs: 0-200V and 0-500V DC
 Dimension: 96x96x57 mm
 Panel Cutout: 92mm x 92mm
 Standards for enclosure: IP-20(Back), IP-65(Front)

15
 AC VOLTMETER

Fig 10. AC Voltmeter

 Parameter displayed: Line to Line Voltage (RY, YB & BR), Line to Neutral Voltage Phase
wise, Line to Neutral Voltage Average and System Frequency.
 Features:
 Microcontroller based meters with low VA burden.
 4-digit seven segment display.
 PT primary range 50V to 500kV AC programmable.
 PT Secondary 50V to 500V AC programmable.
 Password protected.
 True RMS measurement of parameters.
 Auto scaling of parameter values.
 Auto/Manual scrolling of parameters.
 Two switches for easy onsite programming.
 Touch proof voltage & current terminals.
 Compact size and light weight.
 ABS dust-proof rugged casing.
 Voltage displayed with Kilo indication.

 Auxiliary Supply: Universal Auxiliary (90-300V AC) Supply (Other supply voltages on
demand).
 Accuracy: Class 1.0 or Class 0.5.
 Standard: IEC62053-21/22.
 Inputs: Voltage (up to 500V).
 Dimension: 96x96x57 mm.
 Panel Cutout: 92mm x 92mm.
 Standards for enclosure: IP-20(Back), IP-65(Front).

16
 2.3.8 AMMETER

Fig 11. DC Ammeter

 Parameter displayed: DC Current

 Features:
- Microcontroller based meters with low VA burden.
- 4-Digit seven segment display.
- Shunt selectable with primary range 1A to 50kA DC programmable.
- Shunt Secondary range 0-75mV.
- Password protected.
- Auto scaling of parameter values.
- Two switches for easy onsite programming.
- Touch proof voltage & current terminals.
- Compact size and light weight.
- ABS dust-proof rugged casing.
- Current displayed with Kilo indication.

 Auxiliary Supply: Universal Auxiliary (90-300V AC) Supply (Other supply voltages on
demand).
 Accuracy: Class 1.0 or Class 0.5.
 Standard: IEC62053-21/22.
 Inputs: 0-75mV DC.
 Dimension: 96x96x57 mm.
 Panel Cutout: 92mm x 92mm.
 Standards for enclosure: IP-IP-20(Back), IP-65(Front).

17
 AC AMMETER

Fig 12. AC Ammeter

 Parameter displayed: Phase wise AC Current and Average AC Current.

 Features:
- Microcontroller based meters with low VA burden.
- digit seven segment display.
- CT primary range 1A to 50kA AC programmable.
- CT Secondary range 0.5A to 5A – AC programmable.
- Password protected.
- True RMS measurement of parameters.
- Auto scaling of parameter values.
- Auto/Manual scrolling of parameters.
- Two switches for easy onsite programming.
- Touch proof voltage & current terminals.
- Compact size and light weight.
- ABS dust-proof rugged casing.
- Current displayed with Kilo indication.

2.3.9 INDICATOR

Fig 13. Indicator Lamp

Indicator Lamp or Indicator Light is a widely used in the ship, machine tools, machine
equipment, switch cabinet, power distribution cabinet. Indicator lamp, also name pilot lamp,
who to indicate whether power is on or a equipment device is for showing the operating
condition of some system.

18
2.3.10 SELECTOR SWITCH

Fig 14. Selector Switch

A selector switch is a mechanical switch that can be turned right, center or left to open or to
close the electrical contacts. It is mostly used to start/stop devices or to switch between
two/three electric circuits. It is a link between man and machine.
Selector switch provides flexible control options in a minimal amount of space. It performs
multiple functions and only inhabits the space of a typical pushbutton.

Selector switches are used to select one of several circuit possibilities such as manual or
automatic operation, low or high speed, up or down, right or left, and stop or run.

The switch function can be maintained or momentary. In a maintained the actuator stays in
thrown position (on-off). In a momentary, the switch must be held in position; it reverts to the
normal position when an actuating force is removed.

2.3.11 ROTARY SWITCH

Fig 15. Rotary Switch

A rotary switch is a switch operated by rotation. These are often chosen when more than 2
positions are needed, such as a three-speed fan or a CB radio with multiple frequencies of
reception or "channels".
A rotary switch consists of a spindle or "rotor" that has a contact arm or "spoke" which
projects from its surface like a cam. It has an array of terminals, arranged in a circle around
the rotor, each of which serves as a contact for the "spoke" through which any one of a
number of different electrical circuits can be connected to the rotor. The switch is layered to
allow the use of multiple poles; each layer is equivalent to one pole. Alternatively, the
rotation can be limited to a fraction (half; third etc.) of a circle and then each layer can have

19
multiple (two; three etc.) poles. Usually, such a switch has a detent mechanism so it "clicks"
from one active position to another rather than stalls in an intermediate position. Thus, a
rotary switch provides greater pole and throw capabilities than simpler switches do.

2.3.12 PUSH BUTTON

Fig 16. Push Button

A push switch (button) is a momentary or non-latching switch which causes a temporary

change in the state of an electrical circuit only while the switch is physically actuated. An
automatic mechanism (i.e., a spring) returns the switch to its default position immediately
afterwards, restoring the initial circuit condition.
A 'push to make' switch allows electricity to flow between its two contacts when held in.
When the button is released, the circuit is broken. This type of switch is also known as a
Normally Open (NO) Switch. (Examples: doorbell, computer case power switch, calculator
buttons, individual keys on a keyboard)
A 'push to break' switch does the opposite, i.e., when the button is not pressed, electricity can
flow, but when it is pressed the circuit is broken. This type of switch is also known as a
Normally Closed (NC) Switch. (Examples: Fridge Light Switch, Alarm Switches in Fail-Safe
circuits)

2.3.13 UNDERVOLTAGE AND OVERVOLTAGE RELAY

Fig 17. Undervoltage & Overvoltage Relay

The over- and undervoltage relay is a secondary relay which is connected to the voltage
transformers of the object to be protected. The unit continuously measure the fundamental
wave of the phase-to-phase voltages of the object. On detection of fault, the relay will
activate and trip the circuit breaker, provide alarms, record fault data, etc., in accordance with
the application and the configured relay functions.

The overvoltage unit includes low-set stage U> and high-set stage U>> and the undervoltage
unit low-set stage U< and high-set stage U<<. The high-set undervoltage stage can
alternatively be set to evaluate the positive-phase-sequence voltage. In addition, the high-set
undervoltage stage can be configured to evaluate only one instead of three phase-to-phase
voltages.

The protection functions are independent of each other and have their own setting groups and

20
data recordings. The over and undervoltage functions use conventional voltage transformer
measurement.
An output contact matrix allows start or trip signals from the protection stages to be routed to
the desired output contact.

2.3.14 FUSE

Fig 18. Fuse

Fuse is an electrical safety device that operates to provide overcurrent protection of an

electrical circuit. Its essential component is a metal wire or strip that melts when too much
current flows through it, thereby stopping or interrupting the current. It is a sacrificial device;
once a fuse has operated it is an open circuit, and must be replaced or rewired, depending on
its type.

Fuses have been used as essential safety devices from the early days of electrical engineering.
Today there are thousands of different fuse designs which have specific current and voltage
ratings, breaking capacity, and response times, depending on the application. The time and
current operating characteristics of fuses are chosen to provide adequate protection without
needless interruption. Wiring regulations usually define a maximum fuse current rating for
particular circuits. Short circuits, overloading, mismatched loads, or device failure are the
prime or some of the reasons for fuse operation. When a damaged live wire makes contact
with a metal case that is connected to ground, a short circuit will form and the fuse will melt.

21
 CHAPTER 3: Process Sheet and Fabrication

3.1 Process Sheet

START Fabrication

Drilling on Plates Powder Coating

Instrument Mounting Plate Mounting

STOP Wiring

Table no. 2 Process Sheet

22
 3.2 Fabrication – Outline structure of the Control Panel

Five steps or sub processes in fabrication:

1. Bending
2. Cutting
3. Welding
4. Grinding
5. Powder Coating

3.2.1 Bending:

The process of bending is required the hydraulic pressure-based machines. It is manually

operated by hand. bending machines are of two types, one is used for busbar or conductor
bending and another is used for metal sheet bending. The bus bars and metal sheet are bended
as per our requirement of panel.

3.2.2 Cutting:

For cutting stainless steel metal sheet we use laser cutting machine, which operate
automatically. This cutting is done according to the dimensions given by the railway
department. The cutting of the panel is done by professionals. After the panels are cut into
pieces the inspection is done by the testing department which rechecks the dimensions of the
panel and mark as tested ok or rejected. For accuracy in cutting we use laser cutting machine.
The laser cutting cuts the metal pieces by vaporizing the materials resulting in cut edge.

Fig 19. Metal sheet cutting machine.

23
 3.2.3 Welding:

Fig 20. Welding

Welding is a fabrication or fixing metal process that joins materials, generally metallic
element, or thermoplastics, by using high temperature to melt the parts together and allowing
them to cool causing fusion. Lower temperature metal-joining techniques in the welding’s
such as soldering, and brazing which do not melt the base metal.

3.2.4 Grinding:
To show high surface quality for the workpieces the grinding technique is used (e.g., low
surface roughness) where finish work is with high accuracy of shape and dimension. In most
applications it tends to be a finishing operation and removes somewhat little metal called as
bur. However, there are some roughing applications in which grinding removes high volumes
of metal quite rapidly

3.2.5 Powder coating:

In power coating process that uses finely ground particles of coloring and resin that are
electrostatically charged and sprayed onto electrically grounded parts. It is dry finishing
Process where the powder particles stick to part for the time until melted and merged into a
uniform coting in curing oven. Theoretically, 100 percent of the powder over-spray can be
recovered and reused. Even with some loss in the collection filtering systems and on part
hangers, powder utilization can be very high. Powder coating requires no air-drying or flash-
off time.

3.3 Expected outcomes

 Reliable, have longer service life
 It should have less maintenance
 Easy for maintenance
 Operate in any weather conditions
 There is no chance of fire hazard
 Withstand for vibrations
 They are compact in size

24
 CHAPTER 4: Photo Gallery and Resource Requirements

4.1 Photo Gallery:

25
CHAPTER 5: CONCLUSION
The Onboard panel was designed and developed in the research and development department
at Power Control Electro Systems. This panel does a work of controlling the electrical
components inside the railway coach such as switchgears, contactors, converters , etc . The
supply to each and every appliance in the railway coach goes through the on board panel.The
switch gears are used according to the ratings and requirements of the appliance. This panel is placed
inside the coach and gets supply from under sludge panel which is placed under the railway coach.
The on-board panel is assembled according to the circuit diagram given by the railway department.
After completion of the panel testing is done in accordance to the sequence given by the company.
This on-board panel can be called as a control unit of the railway coach and every coach needs a
separate panel for controlling.

26
 CHAPTER 6: REFERENCES
 https://www.cisak.pl/Home?gclid=CjwKCAjw77WVBhBuEiwAJ-
YoJHYVUx17xUZSkTTCWVSQR7AIq0MEq7VbCdkCHvb8Xg4q-
9tdeMr5oRoCXA8QAvD_BwE
 https://www.electricalindia.in/load-break-switch-evaluation-of-breaking-making-capabilities/
 https://www.indiamart.com/proddetail/sf6-load-break-switch-19643983948.html
 https://www.pcesystems.in/
 Wikipedia.com
 Power Control Electro System Pvt. ltd. railway division files

27