Polish authorities, aiming to modernize the country's transport infrastructure, have overhauled the electronics of the railways with a novel control system based on state-of-the-art embedded computer technology. The new system, called ILTOR-2, is already installed on most routes and has contributed to improvements in speed, quality, reliability, and safety in rail passenger and freight transport.
Modular design to increase flexibilityILTOR-2 is divided into two levels of track control: a management level for visualization, control and diagnostics and a field level control/automation system that is responsible for carrying out the fundamental technical control functions and obtaining information regarding the status and location of rolling stock.
A modular system design based on standard components is used at every level. This not only simplifies and accelerates future system expansions, but also gives the ILTOR-2 enormous versatility: different modules can be implemented or omitted depending on the requirements, allowing for quick and cost-effective adaptation for use on main or secondary lines and urban transport systems (tram and metro).
VME bus for field control
The modular design establishes the use of different embedded hardware platforms to implement the individual modules. For field-level control, Kontron developed several embedded computer racks containing multiple 3U VME CPU and I/O cards. These racks are located in remote (unmanned) control centers with up to ten control points (level crossings, signals, or other points), along with a designated section of railway track. These racks collect and process information on train position and speed, as well as the status of lights, signals, and other points.
The VME systems also act as interfaces between the control points and the Siemens interlocking system, which connect via Profibus. This system has been specifically designed for railway control and is an extremely important safety element, as it ensures that no signals are sent to the train except when the track is ready for its passage. It also ensures the correct interaction of thousands of I/O points and complies with SIL-4 (Safety Integrity Level 4), the industry's leading safety standard.
Like Profibus interfaces, the VME system also offers Gigabit Ethernet ports for cross-protocol communication and full network integration, enabling the transmission of field parameters to control centers. This transmission is carried out via fiber optic cables for optimal protection against electromagnetic interference (EMI). Twisted-pair cables provide the redundancy and backup transmission required by rail transport systems. CompactPCI® platforms for management level
While remote control centers direct trains to the corresponding platform at each station, distribution centers are responsible for "taking" the trains safely to their final destination, from Warsaw to Krakow for example.
For these distribution centers, multiple units of the 3U CompactPCI® CP-Pocket platforms and 4U KISS Silent Industrial Servers were supplied. The Kontron CP-Pockets are used for monitoring tasks, allowing operators to graphically track the movement of rolling stock and input commands to adjust control points. Kontron equipped the versatile CompactPCI® platforms with the appropriate combination of graphics and Fast Ethernet cards and controllers from its own catalog to meet the specific requirements for visualization, processing, and communication functions.
Advanced diagnostics
For system diagnostics, Kontron developed multiple KISS 4U industrial servers on a Kontron PICMG® 1.3-slot CPU card. With their shock- and vibration-protected drive bays and non-stop replaceable fans that contribute to an MTBF of over 50,000 hours, the Kontron KISS servers were the ideal complement to ruggedized VME and CompactPCI® cards and systems.
Connected to the system via Ethernet and capable of supporting multiple monitors, KISS servers are continuously online and allow technicians to graphically monitor all system parameters.
Unlike most diagnostic systems that only offer online functionality, KISS-based solutions can store and recall historical parameters to quickly troubleshoot problems, minimize downtime, and, most importantly, increase safety.
All from a single source
In large projects like ILTOR-2, which require a wide variety of embedded boards and platforms, OEMs are constantly looking for the simplest management approach. For this reason, Siemens Sp. z o.o. wanted to work with a partner capable of developing all the embedded boards and platforms from a single source. This not only simplifies project management but also ensures faster delivery of the ILTOR-2 hardware platforms. Furthermore, Kontron had already designed and deployed a VME- and CompactPCI®-based system for the Warsaw Metro and therefore possessed the expertise needed to create a system that met the specific requirements of the Polish rail network.
System check
In addition to supplying the embedded hardware platforms, Kontron also collaborated closely with Siemens in the three phases of system testing.
Following the development of each new hardware platform, engineers from both companies conducted functional tests using simulated input data to ensure proper operation. These tests took place at Siemens' test center in Poland, which was built specifically for this project.
The second phase is the functional test in the presence of members of the Polish Railway Safety Agency in order to obtain local certification. After passing this Factory Acceptance Test (FAT), the system was ready for the final phase: field testing.
ILTOR-2 also passed the field testing phase and is operating on selected sections. Thanks to its modular design based on proven standard components from a single supplier, Poland now has a cost-effective, state-of-the-art embedded control system that far exceeds current and future railway infrastructure requirements.
Author:
Ingrid Einsiedler, Marketing Manager at Kontron, and Slawomir Jasinsky,
CEO of Kontron for Eastern Europe
