MALLABHUM INSTITUTE OF TECHNOLOGY

Approved by A.I.C.T.E || Affiliated to M.A.K.A.U.T

Session: 2021-2024

A Project synopsis on

“ RAILWAY TRACK CRACK DETECTION SYSTEM”

Submitted in partial fulfillment of the requirements for award of the degree

Bachelor of Technology in
Electronics & Communication Engineering from
MAULANA ABUL KALAM AZAD UNIVERSITY OF TECHNOLOGY

By,
CHANDAN SUTRADHAR (15800321036)

Under the guidance of

MS. DEBASHREE PATRA KARMAKAR

DEPARTMENT OF ELECTRONICS AND COMMUNICATION
ENGINEERING

MALLABHUM INSTITUTE OF TECHNOLOGY

BISHNUPUR, BANKURA-722122
WEST BENGAL, INDIA

1
 MAY, 2024

DECLARATION

I/We hereby declare that the project report entitled as “RAILWAY TRACK CRACK
DETECTION SYSTEM” is a bona fide record of the systematic work done by me/us under
the guidance of MS. DEBASHREE PATRA KARMAKAR, Department of Electronics and
Communication Engineering. Mallabhum Institute of Technology, Bishnupur, India and that
no part thereof has been presented for the award of any other degree.

Place: MIT, Bishnupur CHANDAN SUTRADHAR

Date:
2
 CERTIFICATE

This is to certify that the project proposal entitled “RAILWAY TRACK CRACK
DETECTION SYSTEM”, by CHANDAN SUTRADHAR (15800321036) submitted
to the Mallabhum Institute of Technology, Bishnupur affiliated to MAKAUT for the degree of
Bachelor of Technology, is a record of bonafide work, carried out by him/her in the department
of Electronics and Communication Engineering under my supervision and guidance. I/We
believe that the work fulfills part of the requirements for the award of degree of Bachelor of
Technology. To the best of my knowledge, the matter embodied in the project has not been
submitted to any other University/Institute for the award of any other degree.

---------------------------------------- ----------------------------------------
MS. DEBASHREE PATRA KARMAKAR DR. MOUSUMI KARMAKAR
Assistant Professor Head of the Dept.
Department of ECE Department of ECE

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 DEPARTMENT OF ELECTRONICS AND COMMUNICATION
ENGINEERING
MALLABHUM INSTITUTE OF TECHNOLOGY

BISHNUPUR,BANKURA-722122
WEST BENGAL

ACKNOWLEDGEMENT

I/We take this opportunity to express our sincere gratitude to my/our project guide, MS.
DEBASHREE PATRA KARMAKAR for his noble involvement and valuable guidance
during the project work. I/We are indebted to them for their kind help and timely
encouragement in making this project work professionally stimulating and professionally
satisfying.

I/We would also like to thank that the other faculty members of ECE Department and our
H.O.D DR. MOUSUMI KARMAKAR for his/her continuous support and encouragement
during the work.

NAME SIGNATURE

CHANDAN SUTRADHAR …………………………...

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 CONTENTS

Contents

Abstract

CHAPTER 1
1.1 Overview 8

1.2 Introduction 9

1.3 Proposed Methodology 10

1.4 Background work 11

1.5 Objective 12

1.6 Block Diagram 14

CHAPTER 2
2.1 SYSTEM COMPONENTS USED

2.1.1 ARDUINO UNO (ATmega328P) 15

2.1.2 GPS MODULE 19

2.1.3 GSM MODULE (SIM 900) 21

2.1.4 MAX 232 23

2.1.5 INFRARED SENSORS 26

2.1.6 BRUSHLESS DC MOTOR 28

2.1.7 LCD DISPLAY 30

2.2 CIRCUIT DIAGRAM 32

2.3 Final Image of Prototype 33
2.4 Coding 34

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 2.5 Working Principle 37

CHAPTER-3

ADVANTAGES , DISADVANTAGES AND FUTURE WORK :

3.1 Advantages 39

3.2 Disadvantages 41

3.3 Scope for Future Development 43

3.4 Application 44

CHAPTER-4

4.1 Marketing Strategies & Plan 45

4.2 Organization Plan 47

5. CONCLUSION 48
6. REFERENCE 49

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 ABSTRACT

Indian Railways, spanning over 115,000 kilometers, faces

challenges in maintaining track integrity, crucial for safety and
reliability. This project introduces an automated crack detection
system using infrared sensors and an Arduino microcontroller to
enhance track safety. The system detects cracks and obstacles,
leveraging GPS for location accuracy and GSM modules for
immediate SMS alerts to authorities. Designed for continuous
operation and
adaptable to various environmental conditions, this
system aims to improve detection accuracy, reduce maintenance
response times, and decrease the risk of rail-related accidents.
Keywords: Railway Safety, Automated Detection, Arduino,
GSM, GPS, IR Sensor.

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 CHAPTER 1

1. OVERVIEW
The project focuses on the development and implementation of a
prototype testing train designed to detect obstacles and cracks on railway
tracks, similar to a line-following testing train. Recognizing the critical
importance of rail transport in India's rapidly growing economy, the
project aims to address the challenges of reliability and safety within the
country's rail infrastructure.
At its core, the prototype testing train leverages advanced
technology to automate the detection process, significantly reducing
analysis time and enhancing the precision of fault
localization. By utilizing cost-effective solutions, the project seeks to
provide a viable alternative to existing methods, which often
suffer from inefficiency and high operational costs.
Key features of the prototype testing train include infrared sensors for
crack detection, GPS technology for precise location tracking, and GSM
modules for immediate communication of detected faults to maintenance
personnel. Through continuous monitoring and real-time reporting, the
system aims to expedite response times to track irregularities, thereby
minimizing the risk of accidents and improving overall operational
efficiency.

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 2. INTRODUCTION
Transportation is a fundamental necessity for facilitating the
production and distribution of goods across various locations.
Throughout history, advancements in transportation have driven economic
expansion by facilitating increased trade. However,
while transportation infrastructure has been essential for
economic growth, it also has significant environmental and
energy consumption implications. In the modern era, with
transportation being a major energy consumer, its sustainability and safety
have become critical concerns.
In India, rail transport plays a pivotal role in meeting the demands of a
rapidly growing economy. Despite its importance, India's rail
infrastructure still faces challenges in meeting global standards,
particularly in terms of reliability and safety. The lack of efficient and
cost-effective technologies for detecting issues in rail tracks, coupled
with inadequate maintenance practices, contributes to
these challenges.
This project proposes a prototype of a testing train designed to detect
obstacles and cracks in rail tracks, similar to a
line-following testing train. The proposed system offers cost-
effective solutions with reduced analysis time. By
implementing this system, the precise location of faulty rail
tracks can be easily identified, potentially saving numerous lives.
Improving the operation and maintenance of transportation
infrastructure not only enhances safety but also has significant economic
implications. With efficient detection and maintenance systems in place,
disruptions to rail services can be minimized,
ensuring smooth operations and facilitating economic growth.

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 3. PROPOSED METHODOLOGY

The proposed Railway Track Crack Detection System has the following features: 1.
Checking the railway track for cracks or objects. 2. If a crack or object is detected,
collect the data from GPS. 3. Transmit the exact location of the crack or object via an
SMS with the help of the GSM module. When a crack is detected by the IR sensor the
vehicle stops at once, and the GPS receiver triangulates the position of the vehicle to
receive the Latitude and Longitude coordinates of the vehicle position, from satellites.
The Latitude and Longitude coordinates received by GPS are converted into a text
message which is done by microcontroller. The GSM module sends the text message to
the predefined number with the help of a SIM card that is inserted into the module. AT
NORMAL CONDITION: The IR transmitter sensor is transmitting the infrared rays.
These infrared rays are received by the IR receiver sensor. The Transistors are used as an
amplifier section. At normal condition Transistor is in OFF condition. At that time the
relay is OFF, so that the vehicle keeps running continuously. AT CRACK CONDITION:
When the track is without any cracks then output of IR LED and photodiode will be
high. As soon as the crack is detected by the system the sensor reflection will be equal to
zero and the robot will be stopped automatically. Another sensor is used to monitor the
pit on the way to the railway track. When this output is high then it is concluded that
there is no pit in the track. But if any pit is detected by the sensor the output of the
sensor given to the microcontroller will be zero and again the microcontroller will stop
the robot. When a crack is detected by the IR sensor the vehicle stops at once, and the
GPS receiver triangulates the position of the vehicle to receive the Latitude and
Longitude coordinates of the vehicle position, from satellites. The Latitude and
Longitude coordinates received by.GPS are converted into a text message which is done
by microcontroller. The GSM module sends the text message to the predefined number
with the help of a SIM card that is inserted into the module to send the SMS. Fig 1
shows a block diagram of "Railway track crack detection system", there are two sets of
IR sensor units fixed to the front side of the vehicle with the microcontroller to check the
railway track. When the vehicle is switched on, it moves forward along the track. The IR
sensors check the condition of the tracks. In normal condition the motor, LDR, Serial
transmission is in its initial stage. When the power is supplied to the microcontroller, it
starts the motor in forward direction and sends the messages to the microcontroller using
serial transmission. The Arduino controller is used to control the sensor outputs and
transmit the information through a GSM module, whose function is to send the signal
whenever it detects a crack or an obstacle to the base station through an SMS. The GPS
module is used to get the exact latitudinal and longitudinal position of the crack on the
track.

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 4. Background

Indian Railways, a cornerstone of the country’s infrastructure, supports

millions of passengers and massive freight loads daily. Despite its critical
role in India’s economic and social structure, the safety standards of the
railway system have room for improvement, particularly in terms of track
integrity. The traditional method of track inspection involves manual
checks, which are not only time-consuming but often inadequate due to the
vastness of the network and the limitations of human accuracy and
efficiency. A recent study revealed that over 25% of the track length might
be compromised due to undetected cracks, posing a significant risk of
accidents.

● Current challenges include:

1. Limited Reach and Frequency: Manual inspections cover only a
fraction of the track on any given day, leaving extensive
areas unchecked for prolonged periods.
2. Human Error: The effectiveness of manual inspections heavily
depends on the skill and alertness of the inspectors, which can be
inconsistent.
3. Response Time: Identifying the exact location of damage and
coordinating maintenance efforts can be slow, delaying crucial
repairs.

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 5. Objective

The primary goal of this project is to design, develop, and implement an

automated railway track crack detection system tailored to enhance the
safety and efficiency of Indian Railways. This system seeks to overcome
the limitations of current manual inspection methods by leveraging
advanced technology. The specific objectives of the project are outlined as
follows:

1. Automate the Detection Process: Develop a system that uses

infrared sensors and an Arduino microcontroller to
automatically detect cracks and obstacles on railway tracks. This will
reduce human error and increase the reliability of inspections.
2. Enhance Real-time Monitoring: Implement a continuous
monitoring mechanism that operates 24/7 under various
weather conditions and in different geographical terrains. This will
ensure that all parts of the track are regularly and consistently
checked for integrity.
3. Improve Response Times: Utilize GPS technology to pinpoint the
exact location of detected cracks or damages. Coupled with GSM
technology, the system will immediately alert
maintenance teams via SMS, enabling quick and precise responses to
potential hazards.
4. Increase Coverage and Frequency of Inspections: By
automating the process, the system aims to cover more track
kilometers per day than is feasible with manual inspections, thus
increasing the overall frequency of inspections across

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 the network.
5. Enhance Preventive Maintenance: Provide maintenance teams with
data-driven insights and predictive analytics about track wear and
tear, enabling proactive maintenance and repairs
before critical failures occur.
6. Contribute to Research in Railway Safety: Gather data and insights
from the implementation of this system to contribute to ongoing
research and development in railway safety technology, helping to
establish best practices and potentially informing future
improvements in global railway systems.
7. Ensure Scalability and Sustainability: Design the system to be
scalable across the vast Indian railway network and
sustainable with minimal environmental impact, ensuring long-
term operational viability.

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6. BLOCK DIAGRAM

Block diagram

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 CHAPTER 2

2.1 SYSTEM COMPONENTS USED:

2.1.1 ARDUINO UNO (ATmega328P)

Arduino is an open source programmable circuit board based on top of

easy to use hardware and software. The above Figure 7 depicts arduino
uno. It is tough in nature and can support the peripherals efficiently. It
is centered on ATmega328. It has 14 digital input/output pins, 6 analog
inputs, a USB connection, a power jack, an ICSP header, and a reset
button. The power essential to run the board can be supplied through
connecting it to the laptop using a USB cable or plugging an AC DC
power supply.

Arduino Uno Working Principle:

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Overview

● Microcontroller: The core of the Arduino Uno is the ATmega328P

microcontroller.
● Programming: Users write code (called sketches) using the Arduino IDE
and upload it to the board via a USB connection.
● Execution: Once uploaded, the microcontroller executes the program
autonomously.

Key Components

1. Power Supply:
● USB Power: Provides 5V through the USB connection from a
computer.
● External Power: Can be supplied via the power jack (7-12V
recommended).
● Voltage Regulator: Converts external power to 5V and 3.3V for the
board.
2. Digital I/O Pins:
● 14 digital pins that can be configured as either input or output.
● Can be used for interfacing with sensors, actuators, and other digital
devices.
3. Analog Input Pins:
● 6 analog pins (A0 to A5) that read analog signals and convert them
to digital values using the ADC (Analog-to-Digital Converter).
● Used for reading sensors that output analog signals, like
temperature sensors.
4. PWM Outputs:
● 6 of the digital I/O pins can be used for PWM (Pulse Width
Modulation) output, useful for controlling motors, LEDs, and
other devices that require analog control.
5. Serial Communication:
● USB connection provides a serial interface for programming and
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 communication with a PC.
● Supports additional communication protocols like I2C and SPI for
interfacing with other devices and modules.

ATmega328P Microcontroller

Features

● Architecture: 8-bit AVR RISC-based microcontroller.

● Clock Speed: 16 MHz.
● Flash Memory: 32 KB (of which 0.5 KB is used by the bootloader).
● SRAM: 2 KB.
● EEPROM: 1 KB.
● Operating Voltage: 1.8V to 5.5V.
● I/O Pins: 23 programmable I/O lines.
● Timers: 3 timers (2 8-bit and 1 16-bit) for timing operations.
● ADC: 10-bit ADC with 6 multiplexed channels.

Working Principle

1. Reset:
● When powered on or reset, the ATmega328P starts executing the
program stored in its flash memory from the reset vector.
2. Initialization:
● Setup routines (defined in the setup() function in Arduino
sketches) are executed once. This is typically where pin modes
(input/output) are configured and initial conditions are set.
3. Main Loop:
● The loop() function in Arduino sketches runs continuously. This is
where the main logic of the program resides, handling inputs,
processing data, and controlling outputs.
4. Peripheral Interaction:
● Digital Read/Write: Using functions like digitalRead() and
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 digitalWrite(), the microcontroller can read the state of input
pins and set the state of output pins.
● Analog Read: Using analogRead(), it reads the voltage level
from analog pins and converts it to a digital value (0-1023).
● PWM Output: Using analogWrite(), it generates PWM signals to
control devices like LEDs and motors.
5. Communication:
● Serial: The Serial library facilitates communication with a PC or
other serial devices.
● I2C/SPI: The Wire library (for I2C) and SPI library enable
communication with sensors, displays, and other modules.

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 2.1.2 GPS MODULE:
A satellite navigation system used to position the ground place of an object.
The above figure 8 shows a GPS modem. A GPS receiver calculates the
position by timing the signals sent by the GPS satellites high above the
earth. The position is then displayed through a moving map display or
latitude and longitude.

Components

1. Antenna: Receives signals from GPS satellites.

2. RF Front End: Filters and amplifies the received signals.
3. Signal Processor: Converts the analog signals into digital form and
processes them to extract location data.
4. Microcontroller: Manages communication with the host device (e.g.,
Arduino) and performs calculations.
5. Power Supply: Powers the module and its components.

Working Principle

1. Satellite Signal Reception:

● The GPS module's antenna receives signals from multiple GPS satellites.
Each satellite transmits a signal that includes its location and the precise
time the signal was sent.
2. Signal Timing:
● The GPS module calculates the time it takes for the signal to travel from
the satellite to the receiver. This is done by comparing the
satellite's transmission time with the module's reception time.
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 3. Distance Calculation:
● The time delay is multiplied by the speed of light to calculate the
distance between the satellite and the GPS module.
4. Trilateration:
● To determine its position, the GPS module must receive signals from at least
four satellites.
● Using trilateration, the module calculates its position by finding the point
where the spheres intersect. Each sphere's radius is the
distance calculated from one satellite.
5. Data Output:
● The processed data includes geographic coordinates (latitude,
longitude), altitude, and precise time.
● This data is typically sent to a host device (e.g., Arduino) via a
communication protocol such as UART (serial communication).

CIRCUIT CONNECTION:

1. Power Connections:
● VCC: Connects to a 3.3V or 5V power supply (depending on the GPS
module specifications).
● GND: Connects to the ground.
2. Serial Communication:
● TX (Transmit): Sends data to the Arduino's RX (Receive) pin.
● RX (Receive): Receives data from the Arduino's TX (Transmit) pin
(optional, usually not n

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2.1.3 GSM MODULE (SIM 900):
SIM 900 is a Quad-band GSM/GPRS engine, it works on a wide range of
frequencies, such as 850 MHz, 900 MHz, 1800 MHz and 1900 MHz. It is
very compact in size and easy to use as a plug in GSM Modem. The
Modem is designed with RS232 Level converter circuitry, which allows
you to directly interface the PC Serial port. The baud rate can be
configured from 9600-115200 through AT command. The modem needs
only 3 wires. (Tx,Rx, GND) except Power supply to interface with
microcontroller/Host PC. The built in Low Dropout Linear voltage
regulator allows you to connect a wide range of unregulated power supply
(4.2V-13V). Using this modem, you will be able to send and read SMS
and connect to the internet via GPRS through simple AT commands.

Working Principle

1. Initialization and Network Connection

● Power Up: The module is powered on and begins the initialization process.
● SIM Card Reading: It reads the SIM card and retrieves information
necessary for network registration.
● Network Search: The module searches for available GSM networks.
● Network Registration: Once a network is found, the module registers itself with
the network using the subscriber information from the SIM card.

2. Communication Protocols

● AT Commands: The SIM900 module uses AT commands, a standard

protocol for controlling modems. These commands are used to perform various
functions such as sending SMS, making calls, and setting up GPRS connections.
● Voice Communication: For voice calls, the module establishes a
circuit-switched connection to another phone via the GSM network.
● SMS: Text messages are sent and received via SMS protocols. The module formats
and transmits SMS messages over the network to the recipient.
● GPRS Data Connection: For data services, the SIM900 establishes a

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 packet-switched connection using GPRS. This connection is used to transmit and
receive data packets from the internet.

3. Serial Communication with Microcontroller

● Baud Rate Setup: The SIM900 usually communicates with a

microcontroller like Arduino through a serial interface. The baud rate and other
serial settings are configured to match both devices.
● Data Exchange: Data (e.g., AT commands and responses) is exchanged
between the SIM900 and the microcontroller over this serial connection.

4. Application Integration

● Microcontroller Programming: The microcontroller is programmed to send

specific AT commands to the SIM900 module to initiate actions like
making a call or sending an SMS.
● Handling Responses: The microcontroller also handles responses and
unsolicited results (like incoming SMS notifications) from the SIM900.

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2.1.4 MAX 232:
The MAX232 is a popular interface integrated circuit (IC) used to convert signals
from a standard RS-232 serial port to signals suitable for use in TTL (Transistor-
Transistor Logic) compatible digital logic circuits. It is commonly employed in
microcontroller-based projects that require communication with a computer via a
serial COM port.

Basic Functionality

The core functionality of the MAX232 is to convert the RS-232 signal voltages, which
typically range from ±12V, to TTL signal voltages, which are 0V and 5V. This
conversion is essential because the higher voltage levels used in RS-232 communication
can damage TTL circuits, which are designed to operate at much lower voltages.

Components of MAX232

The MAX232 IC typically contains the following components:

● Driver Circuits (Transmitters): Convert TTL signal levels (0V and 5V) to RS-
232 signal levels (±12V).
● Receiver Circuits (Receivers): Convert RS-232 signal levels back to TTL signal
levels.
● Charge Pump: A voltage converter that uses capacitors to generate higher voltage
levels (±10V or ±12V) from a single 5V supply, eliminating the need for a dual
power supply.

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Working Principle

1. Voltage Conversion (Charge Pump)

The MAX232 includes a charge pump circuit that converts a +5V input voltage into the
±10V or ±12V necessary for RS-232 signal levels. The charge pump functions in several
steps:

● Double (or more) the +5V input voltage: Using capacitors and internal
switching circuits, the charge pump creates a higher voltage (about +10V).
● Invert the +10V to -10V: The charge pump also generates a negative
voltage from the positive voltage.

2. Signal Transmission (Drivers)

● When transmitting data from TTL to RS-232, the TTL signal (0V or 5V) is
received by the driver circuit within the MAX232.
● If the input TTL signal is 0V (logic low), the driver outputs a positive RS-232
voltage (about +10V or +12V).
● If the input TTL signal is 5V (logic high), the driver outputs a negative RS-
232 voltage (about -10V or -12V).

3. Signal Reception (Receivers)

● Conversely, when receiving RS-232 signals to be read by TTL circuits, the

incoming RS-232 signal levels are reduced and inverted by the receiver
circuits.
● A positive RS-232 voltage (indicating logic low) is converted to 0V (TTL logic
low).
● A negative RS-232 voltage (indicating logic high) is converted to 5V (TTL logic
high).

Circuit Connection

Typically, a MAX232 IC will have two drivers and two receivers, allowing for full-
duplex communication. Here’s how you might connect the MAX232 in a typical
application:

● RS-232 side: Connect the RS-232 input and output to the respective DB9
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 connector pins.
● TTL side: Connect the TTL input and output to a microcontroller or another TTL-
compatible device.
● Power and Ground: Connect VCC to +5V and GND to the system ground.
● Capacitors: Connect external capacitors to the charge pump pins as specified
in the datasheet. These capacitors are critical for the proper operation of the
voltage conversion process.

Applications

The MAX232 is extensively used in applications where microcontrollers need to

communicate with computers or other devices that use RS-232 level serial ports, such as:

● Programming and debugging microcontrollers.

● Serial communication in embedded systems, like point-of-sale systems or
telemetry devices.
● Bridging between computer serial ports and microcontroller-driven
equipment.

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 2.1.5 INFRARED SENSORS:
Infrared sensors are effective tools for detecting cracks in railway tracks due
to their ability to sense temperature variations and detect infrared radiation emitted
from objects. Here's a detailed explanation of how they work and their circuit
connections for a railway track crack detection system.

Working Principle

1. Infrared Radiation and Temperature Detection:

● Infrared Sensors detect infrared radiation, which is a type of
electromagnetic radiation with wavelengths longer than visible light. All
objects emit some level of infrared radiation as a function of their
temperature.
● In a railway track crack detection system, the infrared sensor is used to
monitor the temperature profile of the railway tracks. Cracks or
defects in the track can lead to temperature anomalies due to
differences in thermal conductivity and heat dissipation.
2. Detection Process:
● Temperature Gradient Analysis: The infrared sensor scans the
surface of the railway track. When it encounters a crack, the
temperature reading changes because the crack disrupts the uniformity of the
track's thermal profile. Cracks typically show up as cooler or warmer spots
compared to the surrounding material.
● Signal Processing: The sensor's output, which is a voltage
proportional to the detected infrared radiation, is processed by a
microcontroller or a signal processing unit. This unit analyzes the
data to identify any significant deviations indicating potential cracks.

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Circuit Connection

The circuit for a railway track crack detection system using infrared sensors typically
includes the following components:

1. Infrared Sensor:
● Type: Commonly used sensors include thermopile infrared sensors or
pyroelectric sensors. These sensors generate a voltage signal based on the
infrared radiation they detect.
● Power Supply: Ensure the sensor is powered correctly, usually
requiring a regulated DC supply (e.g., 5V or 3.3V depending on the sensor
specifications).
2. Microcontroller or Processor:
● Microcontroller: Microcontrollers like Arduino, ESP32, or Raspberry Pi are
often used to process the sensor data.
● Analog-to-Digital Converter (ADC): If the sensor output is analog, it
needs to be converted to a digital signal using an ADC. Many
microcontrollers have built-in ADCs.
3. Signal Conditioning Circuit:
● Amplification: Operational amplifiers (op-amps) may be used to
amplify the weak sensor signals.
● Filtering: Filters can be used to remove noise from the sensor output,
ensuring accurate readings.
4. Communication Interface:
● Display/Alert System: LCDs, LEDs, or buzzer systems can be
integrated to alert when a crack is detected.
● Data Transmission: For remote monitoring, communication modules like Wi-
Fi, GSM, or LoRa can be used to transmit the data to a central monitoring
system.

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2.1.6 BRUSHLESS DC MOTOR:
Brushless DC motors are a relatively new class of motors whose
applications have been increasing at a rapid rate each year, due to both
declining costs as well as increasing functionality. A brushless DC motor
is similar to a brush DC motor in that it has an internal shaft position
feedback which tells which windings to switch on at which moment. This
internal feedback gives both the brush DC motor and brushless DC motor
their unique characteristics. Linear speed-torque curves which are well
suited for speed and position control and high starting torque. The
internal feedback is accomplished in a brush type DC motor with the
mechanical commutator (a series of copper bar which are insulated from
each other) and the mechanical brushes through which the current is fed
into the commutator bars and switched sequentially into the appropriate
winding in the armature.

Working Principle

1. Basic Structure:
● Stator: The stationary part of the motor, which contains windings. The
stator is typically made up of laminated steel to reduce eddy current
losses.
● Rotor: The rotating part, which contains permanent magnets.
2. Operation:
● Electronic Commutation: Unlike traditional DC motors that use brushes
and a mechanical commutator, BLDC motors use electronic commutation to
control the motor. This means that the switching of current through the
motor windings is managed by an electronic
controller.
● Hall Effect Sensors: BLDC motors often use Hall effect sensors to
determine the position of the rotor. These sensors provide feedback to the
controller about the rotor's position, allowing the controller to switch the
current in the windings at the correct time.
● Magnetic Field Interaction: The controller energizes the stator windings
in a sequence that creates a rotating magnetic field. The permanent
magnets on the rotor are attracted to the rotating magnetic field, causing
the rotor to turn.
3. Phases:BLDC motors typically come in three-phase configurations. Each

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 phase corresponds to a set of windings in the stator. The phases are
energized in a specific sequence to produce the rotating magnetic field.

Circuit Connection

To operate a BLDC motor, you'll need the following components:

1. BLDC Motor: The motor itself with three windings.

2. Electronic Speed Controller (ESC): A device that handles the electronic
commutation of the motor.
3. Power Supply: A DC power source suitable for the motor and ESC.
4. Microcontroller: For controlling the ESC (optional, if not using a pre-built ESC
with its own control mechanism).

Basic Connection Steps

1. Power Supply to ESC:

● Connect the positive terminal of the power supply to the positive input
of the ESC.
● Connect the negative terminal of the power supply to the negative input
of the ESC.
2. ESC to BLDC Motor:
● The ESC has three output wires (often color-coded). Connect these to the three
input wires of the BLDC motor. The order can be adjusted to change the
direction of rotation if needed.
3. ESC Control Input:
● The ESC typically has a signal input for speed control. This is usually a
PWM (Pulse Width Modulation) input that can be connected to a
microcontroller (such as an Arduino) or a dedicated remote control
receiver.
● Connect the signal input of the ESC to the PWM output pin of the
microcontroller.
● Connect the ground (GND) of the microcontroller to the ground of the ESC
to ensure a common reference.

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2.1.7 LCD DISPLAY:
LCD (Liquid Crystal Display) screen is an electronic display module and has
a wide range of applications. A 16x2 LCD display is used in our project. A
16x2 LCD display is a very basic module and is very commonly used in various
devices and circuits. These modules are preferred over seven segments and
other multi segment LEDs. The reasons being: LCDs are economical; easily
programmable; have no limitation of displaying special & even custom
characters (unlike in seven segments), animations and so on. A 16x2 LCD
means it can display 16 characters per line and there are 2 such lines. In this
LCD each character is displayed in a 5x7 pixel matrix. This LCD has two
registers, namely, Command and Data. 16 Characters x 2 Lines Built-in
HD44780 Equivalent LCD Controller Works directly with ATMEGA,
ARDUINO, PIC and many other microcontroller kits.

Working Principle

1. Structure:
● LCD (Liquid Crystal Display): Consists of liquid crystals that align to
block or pass light when an electric field is applied.
● Backlight: Provides illumination, usually LED-based, so the display is
visible in various lighting conditions.
● Controller: Manages the display and handles communication with the
microcontroller.
2. Operation:
● Initialization: The LCD must be initialized to set it up for
communication and to configure the display settings.
30
 ● Data Display: Characters or graphics are displayed by sending
appropriate commands and data from the microcontroller to the LCD.
For alphanumeric displays, ASCII codes are used to represent characters.
● Updating Display: The microcontroller updates the display content by
sending commands to clear, write, or position the cursor.

Circuit Connection

To integrate an LCD display into a railway track crack detection system, you typically use
an LCD module such as a 16x2 character display, which is common and easy to interface
with microcontrollers like Arduino.

Components Needed

1. LCD Display Module (e.g., 16x2 LCD with HD44780 controller)

2. Microcontroller (e.g., Arduino)
3. Resistors (for contrast adjustment and pull-up/pull-down)
4. Potentiometer (for contrast adjustment)
5. Connecting Wires
6. Power Supply (for the microcontroller and LCD

31
2.2 BLOCK DIAGRAM:

● CIRCUIT DIAGRAM:

32
2.3 Final Image of Prototype:

33
2.4 CODDING:
#include <AFMotor.h>
#include <LiquidCrystal.h>

// Define the LCD module's pins.

const int rs = 12, en = 11, d4 = 7, d5 = 8, d6 = 9, d7 = 10;
LiquidCrystal lcd(rs, en, d4, d5, d6, d7);

//defining pins and variables

#define left A0 // Ir sensor
#define right A1 // Ir sensor

//defining motors
AF_DCMotor motor1(1, MOTOR12_1KHZ);
AF_DCMotor motor2(2, MOTOR12_1KHZ);
AF_DCMotor motor3(3, MOTOR34_1KHZ);
AF_DCMotor motor4(4, MOTOR34_1KHZ);

void setup() {
//declaring pin types
pinMode(left,INPUT);
pinMode(right,INPUT);
//begin serial communication
Serial.begin(9600);
lcd.begin(16, 2);
lcd.setCursor(1, 0); // Set the cursor to the second line of lcd
lcd.print("RAILWAY CRACK ");
lcd.setCursor(0, 1); // Set the cursor to the second line of lcd
lcd.print(" DETECTOR ");
delay(3000);
lcd.clear();
lcd.print("CRACK DETECTOR ");

}
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void loop(){

//printing values of the sensors to the serial monitor

Serial.println(digitalRead(left));

Serial.println(digitalRead(right));

//line detected by both

if(digitalRead(left)==0 && digitalRead(right)==0){
//Forward
motor1.run(FORWARD);
motor1.setSpeed(130);
motor2.run(FORWARD);
motor2.setSpeed(130);
motor3.run(FORWARD);
motor3.setSpeed(130);
motor4.run(FORWARD);
motor4.setSpeed(130);

lcd.setCursor(0, 1);
lcd.print(" Track is OK "); // Clear the line of lcd

else if(!digitalRead(left)==0 && !digitalRead(right)==1){

//stop
motor1.run(RELEASE);
motor1.setSpeed(0);
motor2.run(RELEASE);
motor2.setSpeed(0);
motor3.run(RELEASE);
motor3.setSpeed(0);
motor4.run(RELEASE);
motor4.setSpeed(0);

lcd.setCursor(0, 1); // Set the cursor to the second line of lcd

35
 lcd.print("Crack Detected");
}
else if(!digitalRead(left)==1 && !digitalRead(right)==0){
//stop
motor1.run(RELEASE);
motor1.setSpeed(0);
motor2.run(RELEASE);
motor2.setSpeed(0);
motor3.run(RELEASE);
motor3.setSpeed(0);
motor4.run(RELEASE);
motor4.setSpeed(0);

lcd.setCursor(0, 1); // Set the cursor to the second line of lcd

lcd.print("Crack Detected");

36
2.5 WORKING PRINCIPLE:

The railway track crack detection system described by your code operates on the
principle of using infrared (IR) sensors to detect cracks or gaps in the railway tracks.
The system includes a set of motors to propel the detection vehicle along the tracks
and an LCD display to provide status updates. Here's an overview of the working
principle based on the code provided:

Components:

1. IR Sensors:
● Left Sensor (connected to A0)
● Right Sensor (connected to A1)
2. These sensors detect the presence of the railway track. When both sensors detect
the track, it means the track is intact. If either sensor does not detect the track, it
indicates a potential crack or gap.
3. Motors:
● Four DC motors are used to move the detection vehicle forward or stop
it.
4. LCD Display:
● A Liquid Crystal Display (LCD) is used to provide visual feedback on the
status of the track.

Working Principle:

1. Initialization:
● The system initializes the sensors, motors, and LCD display. During setup,
a welcome message is displayed on the LCD.
2. Continuous Monitoring:
● The system continuously reads the values from the IR sensors to monitor
the status of the railway track.
3. Track Status Detection:
● Normal Track Condition:
● When both the left and right IR sensors detect the track (i.e., both
sensors return 0), it indicates that the track is intact. In this case, the
motors are set to move the vehicle forward, and the
37
 LCD displays "Track is OK".
● Crack Detection:
● If either the left or right IR sensor does not detect the track (i.e., one or
both sensors return 1), it indicates a potential crack or
gap in the track. The motors are stopped to prevent the vehicle from
moving forward, and the LCD displays "Crack Detected".
4. Motor Control:
● The motors are controlled based on the sensor readings. If a crack is
detected, the motors stop the vehicle to prevent it from moving over the
damaged section of the track. If the track is intact, the motors move the
vehicle forward.
5. Serial Communication:
● The system also prints the sensor values to the serial monitor for
debugging and monitoring purposes.

38
 CHAPTER 3

3.1 ADVANTAGES:
Using Arduino for railway crack detection can offer several advantages in terms
of cost-effectiveness, real-time monitoring, and efficient maintenance. Here are
some potential advantages:

1. Cost-Effective Solution:
Arduino-based systems are often more cost-effective compared to proprietary
solutions. The availability of open-source hardware and software can
significantly reduce the overall cost of implementing a crack detection system.

2. Rapid Prototyping and Development:

Arduino platforms are known for their ease of use and rapid prototyping
capabilities. This can accelerate the development and testing phases of a crack
detection system, allowing for quicker deployment.

3. Modularity and Expandability:

Arduino systems are modular, allowing you to easily add or upgrade
components as needed. This flexibility makes it straightforward to expand the
crack detection system or integrate additional features in the future.

4. Real-Time Monitoring:
Arduino-based systems can provide real-time monitoring of the railway tracks.
This capability enables railway operators to detect cracks or faults promptly,
reducing the risk of accidents and allowing for timely maintenance.

5. Data Logging and Analysis:

Arduino can be programmed to log data related to track conditions. This data
can be analyzed to identify patterns, predict maintenance needs, and optimize
maintenance schedules for better efficiency.

6. Remote Monitoring and Control:

Arduino systems can be designed to allow remote monitoring and control. This
is particularly beneficial for large rail networks, where centralized monitoring
39
 can enhance the efficiency of maintenance operations.

7. Low Power Consumption:

Arduino platforms are designed to be power-efficient. This can be
advantageous for remote or off-grid locations where power supply may be
limited. Low power consumption ensures continuous operation without
frequent battery replacements.

8. Community Support and Resources:

The Arduino community is large and active. This means that there is a wealth
of resources, tutorials, and support available online. Developers can leverage
this community support to troubleshoot issues, seek advice, and share
knowledge. It's important to note that while Arduino-based systems offer
advantages, the design and implementation of a railway crack detection system
must comply with safety standards and regulations. The reliability and accuracy
of the system should be thoroughly tested to ensure the safety of railway
operations. Additionally, collaboration with relevant authorities and experts in
railway maintenance and safety is crucial.

40
3.2 DISADVANTAGES:
1. Limited Detection Accuracy

● Sensor Limitation: The IR sensors might not detect very small cracks or subtle gaps in
the track. They primarily detect the presence or absence of the track and may not provide
information on the size or severity of the crack.
● False Positives/Negatives: Environmental factors such as dirt, debris, or reflective
surfaces might cause false readings, leading to incorrect detection of cracks or failure to
detect actual cracks.

2. Environmental Sensitivity

● Weather Conditions: IR sensors can be affected by weather conditions such as rain, fog,
or extreme temperatures. These conditions can interfere with the sensor's ability to
accurately detect the track.
● Lighting Conditions: Changes in ambient light, such as direct sunlight or
shadows, can impact the performance of IR sensors, potentially leading to
inaccurate readings.

3. Limited Range and Coverage

● Coverage Area: The system uses only two IR sensors (left and right), which might not
be sufficient to cover the entire width of the track comprehensively. There could be
undetected cracks if they fall outside the sensor's coverage area.
● Detection Distance: IR sensors have a limited detection range. If the detection vehicle
moves too quickly, the sensors might not have enough time to accurately detect and
respond to cracks.

4. Mechanical Reliability

● Motor Wear and Tear: Continuous operation of motors can lead to wear and tear,
affecting the reliability and maintenance needs of the detection vehicle.
● Sensor Calibration: Over time, IR sensors may require recalibration to maintain
accuracy. This adds to the maintenance requirements of the system.

5. Power Consumption

● Battery Life: The system relies on multiple components, including motors,

41
 sensors, and the LCD display, which can consume significant power. This could limit the
operational time of the detection vehicle if it is battery-powered, necessitating frequent
recharging or battery replacement.

6. Limited Data Logging and Analysis

● Real-time Monitoring Only: The provided code only prints sensor values to the serial
monitor and updates the LCD display. It does not log data for historical analysis or
trend detection, which could be valuable for preventive maintenance and long-term
monitoring.
● Lack of GPS Integration: The system does not include GPS or any form of location
tracking, making it difficult to pinpoint the exact location of detected cracks for
maintenance crews.

7. Scalability and Integration

● Scalability Issues: The current system is designed for a small-scale application. Scaling
up to cover long distances of railway tracks would require multiple detection vehicles
and coordination between them.
● Integration with Existing Systems: Integrating this detection system with existing
railway infrastructure and maintenance protocols might require additional
development and customization.

8. Response Time

● Immediate Stopping: The system stops the vehicle immediately upon detecting a crack,
which is a reactive approach. It does not provide a way to continue operation while
ensuring the safety of the track, potentially causing delays in railway operations.

42
3.3 Scope for Future Development:
1. Enhanced Sensor Technology

● Use advanced sensors (e.g., laser, ultrasonic, high-resolution cameras).

● Implement multi-sensor fusion for better accuracy.

2. Environmental Robustness

● Develop weather-resistant sensors.

● Implement adaptive algorithms to handle varying environmental
conditions.

3. Expanded Coverage and Precision

● Increase the number of sensors for wider track coverage.

● Improve sensor resolution for detecting smaller defects.

4. Improved Data Logging and Analysis

● Add data logging for historical analysis.

● Utilize machine learning for predictive maintenance.

5. Integration with GPS and Mapping

● Integrate GPS to log and map defect locations.

● Develop mapping software to visualize track conditions.

6. Automated Reporting and Alerts

● Implement real-time alerts for detected cracks.

● Generate automated maintenance reports.

7. Scalability and Networked Systems

● Deploy a fleet of detection vehicles for extensive coverage.

● Create a centralized monitoring system for aggregated data analysis.

43
3.4 APPLICATION:
This system is useful in finding cracks or objects on a railway track with
the help of sensors, without the need of human intervention and less
analysis time. This system is also capable of finding hairline cracks that
are invisible to the naked eye, ensuring safety and avoiding derailment
of trains, saving many human lives. VI. CONCLUSION In this paper we
have designed a cost effective, low-power embedded system, which
facilitates better safety standards for rail tracks for preventing railway
accidents due to cracks and obstacles on railway tracks. The Prototype
testing vehicle can efficiently detect cracks and obstacles on railway
tracks. The result shows that this new innovative technology will
increase the reliability of safety systems in railway transport. By
implementing these features in real time applications, we can avoid
accidents up to approximately 70%.

44
 CHAPTER 4

4.1 Marketing Strategies & Plan:

To market the railway track crack detection system effectively, start by identifying your
target market, which includes railway operators, government transportation departments,
and railway infrastructure maintenance companies. Private companies involved in railway
construction and maintenance are secondary targets.

Differentiate your product by highlighting advanced features like sensor technology, real-
time monitoring, GPS integration, and predictive maintenance. Emphasize benefits such as
improved safety, reduced maintenance costs, and increased operational efficiency.

Strategic partnerships are key. Collaborate with industry leaders and engage with
government and regulatory bodies for endorsements and potential mandates. These
partnerships validate and endorse your product, making it more appealing to
potential customers.

Content marketing should be a major focus. Create educational content such as

whitepapers, case studies, and technical articles on railway safety and maintenance. Host
webinars and workshops to educate potential customers about your crack detection
system's benefits.

Digital marketing is crucial for reaching your audience. Optimize your website for
search engines (SEO) and use targeted ads (SEM) to reach decision-makers in the
railway industry. Leverage social media platforms like LinkedIn and Twitter to share
updates, customer testimonials, and industry news.

Participate in trade shows and conferences. Exhibiting at industry events allows you to
demonstrate your system and network with potential customers. Secure speaking
engagements to discuss railway maintenance and how your product addresses common
challenges.

Collect customer testimonials and develop case studies from early adopters to build
credibility. Use video testimonials for a more engaging narrative.

Implement direct sales strategies by building a dedicated sales team to reach out to
potential customers. Establish a network of distributors and resellers with strong industry
connections.

Begin with thorough market research to understand your target customers'

45
needs and pain points. Set clear short-term goals like increasing brand awareness and
generating leads, and long-term goals such as achieving market leadership and expanding
internationally.

Allocate your budget across digital marketing, trade shows, content creation, and
partnerships. Ensure flexibility to adjust strategies based on performance and feedback.

Develop a content calendar for blogs, whitepapers, case studies, videos, and social
media posts. Ensure high-quality, relevant content that addresses your audience's key
concerns.

Launch digital marketing campaigns focusing on SEO and SEM with targeted keywords.
Use social media ads to reach industry professionals. Capture leads with gated content and
nurture them through email marketing.

Participate in key industry events with prepared demonstration kits and marketing
collateral. Track marketing campaign performance using analytics tools, monitoring
metrics like website traffic, lead generation, and ROI.

Collect feedback from customers and pilot projects to continuously improve the product
and marketing strategies. Refine and enhance marketing messages using customer
testimonials and case studies.

A suggested timeline: Months 1-2, conduct market research, set goals, and create content.
Months 3-4, launch website, SEO, and SEM campaigns; initiate social media activity.
Months 5-6, participate in the first trade show; start email marketing. Months 7-8, host
webinars and publish case studies. Months 9-10, expand digital marketing; start direct
sales outreach. Months 11-12, review performance, adjust strategies, and plan for the next
year.

By following this comprehensive approach, you can effectively market your railway
track crack detection system, build brand awareness, generate leads, and drive sales
growth.

46
4.2 ORGANIZATION PLAN:

The organization plan for a railway track crack detection system involves establishing a
structured team and clear roles to manage operations, development, and market outreach
efficiently. The setup starts with a strong leadership core including a CEO, COO, CTO,
and CMO who oversee the strategic direction and daily operations. Product development
is spearheaded by a team of engineers and product managers focused on delivering a
high-quality and innovative system. Operations and manufacturing require coordination to
ensure products are built to standards and delivered on time, managed by an operations
manager and supported by a manufacturing and quality assurance team.

Marketing and sales strategies are crucial, led by a CMO and executed by a dedicated
team that works on brand positioning, engaging potential customers, and driving sales
through direct and digital channels. Customer support and services are vital for
maintaining customer satisfaction and are managed by support engineers and customer
service teams who handle installations, troubleshooting, and ongoing support.

The financial health of the organization is monitored by the CFO and a finance team
responsible for budgeting, payroll, and financial planning. Human resources and
administrative staff ensure the company runs smoothly, addressing recruitment, employee
relations, and day-to-day administrative tasks. Legal and compliance officers ensure all
operations adhere to industry regulations and standards.

This organization plan aims to establish a framework that supports the growth and scaling
of the business, focusing on efficient processes and customer satisfaction as key drivers
of success.

47
 CONCLUSION

Byutilizing this autonomous vehicle will help in preventing train accidents. The areas where
manual examination in thick forest aerial lifestyle is done utilizing this vehicle. This will help
in maintaining and observing the state of railroad tracks with no mistakes and thereby keeping
up the tracks in good condition. The solar panel is an additional preferred Standpoint, which
helps rationing the power asset the cost of the proposed system is very less. It also checks
surface and the pace of the cracking position. Transmitting signals are immediately transferred
and accidents are reduced. It can work in any terrain 24 ^ * 7 and detects cracks accurately.
The system is robust and rugged to environmental changes. As more relevant data is acquired
it is expected that the present system may assist loco pilots in averting accidents effectively.
Since the robot is made up of a sensor unit it may get damaged anywhere while detecting and
power consumption is more. The project is developed and designed to improve rail track
management. The main aim of the project is to reduce manpower. By using this project we can
detect cracks in railway tracks and obstacles on the track. In the proposed method IR sensor is
used to detect the crack and UV sensor is used to detect objects on the track. The robotic
section continuously checks the crack and obstacle. Location of crack and obstacle is detected
by GPS and then sent to authority by GSM. The system can be operated in a tunnel without
any interruptions. By utilizing this autonomous vehicle will help in preventing train accidents.
The areas where manual examination in thick forest areas can be effortlessly done utilizing this
vehicle. This will help in maintaining and observing the state of railroad tracks with no
mistakes and thereby keeping up the tracks in good condition. The solar panel is an additional
preferred standpoint, which helps rationing the power asset. The cost of the proposed system is
very less. It also checks the surface and near surface of the cracking position. Transmitting
signals are immediately transferred and accidents are reduced. It can work in any terrain 24*7
and detects cracks accurately. The system is robust and rugged to environmental changes. As
more relevant data is acquired it is expected that the present system may assist loco pilots in
averting accidents effectively. Since the robot is made up of a sensor unit it may get damaged
anywhere while detecting and power consumption is more. The project is developed and
designed to improve rail track management. The main aim of the project is to reduce man
power. By using this project we can detect cracks in railway tracks and obstacles on the track.
In the proposed method IR sensor is used to detect the crack and UV sensor is used to detect
objects on the track. The robotic section continuously checks the crack and obstacle. Location
of crack and obstacle is detected by GPS and then sent to authority by GSM. The system can
be operated in tunnel without any interruptions.

48
 REFERENCES

[1] Somalraju S. Murali V. Saha G. Dr. Vaidehi V. (2012) "Robust Railway Crack Detection
Scheme (RRCDS) Using LED LDR Assembly," IEEE Int. Conf. on Networking, Sensing and
Control, vol. 6, iss. 3, pp. 453-460.
[2] Qiao Jian-hua; Li Lin-sheng; Zhang Jing-gang, (2008) "Design of Rail Surface
Crack-detecting System Based on Linear CCD Sensor," IEEE Int. Conf. on Networking,
Sensing and Control, vol. 14, no. 4, pp. 961-970.

[3] K. Vijayakumar, S.R. Wylie, J. D. Cullen, C.C. Wright, A.I. Shammaa, (2009)
"Non-invasive rail track detection system using Microwave sensor," Journal iss. 11, pp.
1743-1749. of App. Phy., vol. 9,

[4] Reenu George, Divya Jose, Gokul T. G, Keerthana Sunil, Varun A. G, (2015) "Automatic
Broken Track Detection Using IR Transmitter and Receiver", International Journal of
Advanced Research in Electrical, Electronics and Instrumentation Engineering (IJAREEIE),
vol. 4, iss. 4.

[5] Prof. P. Navaraja, (2015) "Crack detection system for railway track by using ultrasonic and
PIR Sensor", International Journal of Advanced Information and Communication Technology
(IJAICT), vol. 1, iss. 1. [6] Anand S. Muley, Siddhant B. Patil, A.H.Shelar, (2017) "Railway
Track Crack Detection based on GSM

49