Keystone Technology

                          This railroad combines technologies from several hardware and software sources. More than a controller, power supply and throttles, these technologies include Occupancy Sensing, remote control of Turnouts and Signals, and Transponders (that identify specific trains at specific places). Hardware vendors include Digitrax, Team Digital, RRCirkits, Circuitron, Kato, and others.  The principle software driving our layout is a combination of JMRI and our own MRRM code base. Of course, there is embedded software in most the circuit boards also.

    Beginning in 2009, the Keystone Division layout evolved from a construction and basic trackwork project into an electronically and software controlled system. Many of the sub-projects are summarized in the paragraphs below. By the first quarter of 2010, the Keystone Division has implemented most of these automation subprojects except for train automation and Erie yard. We recently completed a project to install frog powering to the many Peco turnouts installed. Another ongoing subproject is to significantly detail the scenery (an early example).

One recently completed project was to find a suitable signal head housing for the many Digitrax SMBK signal posts that are now operational.

We are currently working on our Robot Trains scripting generator.  In the future we will complete these sub-projects and add some more.

 

The primary technologies that we use are:

JMRI software

MRRM software

Digital Command Control hardware and embedded software from Digitrax, Team Digital, RR CirKits,

Block Occupancy

Turnout Automation

Signal Automation

Transponder Automation

Automated Train Control

Other Electronic and electromechanical products

 

JMRI

Configuration - not current as of 2015

The Reading and Chesapeake Keystone Divisions comprises three rooms:

We run a minimum of two JMRI computers for operations:

1. Loconet Server, the Track Status display for crews in the main Train Room and another status display for the Yardmasters in the West and East staging yards room

2. Dispatcher System Client for the Dispatcher and Real Time Status display for crews waiting in the Crew Lounge room

The Dispatcher System is virtually connected to the Loconet via WiFi LAN through the Loconet Server which is directly connected to the Loconet. The Loconet Server use the LoconetOverTcpLbServer feature in JMRI. This client/server feature is extensible to other clients via the WiFi wireless LAN and may eventually support remote clients via the Internet. Crew members may bring their laptops with JMRI installed to observe the real time status if desired.

We currently use Digitrax and Powerline control interfaces to JMRI as indicated in the JMRI PanelPro Server screen below:

For this snapshot we show the Loconet Locobuffer II Interface.  For X10 Powerline we use a CM11, Insteon 2412S, or CP290 interface device.

For the Dispatcher Client we use the JMRI Panel Pro configuration shown below.

Upon start-up, we run several scripts to properly set the state of all devices and logical objects used by JMRI. First we declare and initialize the state of each physical and virtual (Internal) sensor used. We also set up a number of control buttons described later. Next we load our Configuration File. This file declares the many logical objects used by our layout under JMRI:

Lastly, the configuration file contains three Layout Panel specifications for the two Dispatcher screens and the Real-Time Status Display. These specifications are automatically created in the process of making a Layout Editor panel within the JMRI PanelPro program.

The control buttons we create are summarized here

Networking

We are gradually adding networking to our configuration. The first major networking added LoconetOverTcp between the TrainRoom Server and the Dispatcher client. We have also tested this Server/Client method between the TrainRoom Server and a Client that provides a RealTime status display in the Crew Lounge. The key is syncing sensor, turnout and signal status in each JMRI copy running concurrently.

In our first layout, we installed sensor, turnout, signal and reporter listeners in some custom JMRI java additions plus some web servlet interface technology. These listeners queued layout changes and timestamps within my JMRI code additions. My servlets were invoked every 250 milliseconds by my MRRM software to pull these layout changes from the queue in JMRI into my relational datbase. This database then refreshed my custom panels and supported commanding the layout turnout and signal changes from these clients.

We now are using multiple copies of JMRI, each with its own XML store, as opposed to a centralized relational database. Loconet busses are relatively slow so there is concern how far we can push this change in architecture. Hence minimizing Loconet traffic when syncing up another client bears scrutiny.

We have also tested the WiThrottle Server and the WiThrottle-Lite app in my iPhone - works fine!  We have not stress tested it with other concurrent clients yet..

Real-time Status Display

Dynamically displays the current status of all track occupancy, turnout state, signal head aspect and transponder output.

Dispatcher Displays 

To allow the dispatcher to follow all trains, the current status is displayed on a 'flat' point-to-point track diagram. Controls are installed to allow the Dispatcher to manage all turnout states and signal aspects thereby specifying permitted traffic flows for the entire layout.

 

MRRM Configuration

We use our MRRM software to manage the large inventory of components comprising the railroad and to support operations on the Keystone Division.

Inventory Management

Railroad work is created by the MRRM clock-based simulator of the industries using the railroad. The specification for the simulator are created and stored in a database.

The following selected Inventory data sets have been declared at this time for the R&C Keystone Division:

Inventory related objects derived from the Inventory declarations

Traffic Generation

 

Maintenance Management

 

Interface to JMRI

 

Digital Command Control (DCC)

   We use a Digitrax DCS100 Command System as our DCC master device. A Digitrax PM4 divides our layout into four power districts and reduces disruptions in one area of the layout from incapacitating other areas of the layout. We expect to add a 5th district for our Erie Yard (West Staging) and Pottsville Yard (East Staging) area later this year. We will use a Digitrax DB150 or DB100 device to power this section.
     We use Digitrax radio throttles. Most are DT400 devices. We recently added duplex radio capability to the layout and currently have three DT402 throttles.
     A Fast Clock has been installed. We have not begun to have 'real' operating sessions yet so we have some new experiences coming.  Most of our large locomotive collection has had decoders installed in them. Almost half of these locos have a Digitrax transponder enabled decoder option installed.

Slave station that commands locomotive decoders via the Track Buss in the two staging yards and a limited part of the layout room

Four Power Districts from the Commend Station's Booster: Left, Center, Wye, Right sections of layout. A separate Booster is planned for Eire yard

Five Circuit Boards; capacities  40 occupancy sensors, 40 turnouts, 40 SPST switches; 160 signal post and 320 signal heads  

Three Circuit Boards; capacities 48 occupancy sensors, 24 transponder readers   

WYE Reversing Trackage

Philadelphia Reverse Loop Trackage

West Staging Reverse Loop Trackage

Turntable support - tbd

Controls several Peco/Tortoise and Kato Turnouts

Controls 8 Tortoise Turnouts per circuit board; two boards

Controls 8 Kato Turnouts per circuit board;  two boards

Links Radio Throttles to Command Station

Container Siding doubles as the programming track via DPDT switch.

Operations Scheduling

 

 

 

Block Occupancy Detection

About 80 Block Occupancy Sensors (BODs) have been installed. Each BOD creates a track-turnout segment that will become active when a train is present in that segment. Currently we can detect the presence of a locomotive and certain cars - typically illuminated passenger cars or cars with resisters on metal wheel axles.

We expect to install insulated metal axles to many of our cars. A 10K Ohm surface mount resister will be cemented to each axle and a conductive pen will complete the circuit across the metal axle. With these modified axles our occupancy detectors will detect the presence of such cars.

In 2015 we installed metal wheels and axles on all  'in-service' cars and have added resisters to one axle of each caboose used. We used axles from Fox Valley.

 All active/inactive state changes of each BOD are reported to JMRI listener software. The BOD change events are used by the signal logic to trigger aspect changes. These change events also modify the track-turnout segment 'color' on the Dispatcher and Real-Time Status displays. An occupied or 'active' segment is Red; an unoccupied  or 'inactive' segment is Blue. Additionally, MRRM sensor listeners that we install into JMRI will queue these occupancy events to the MRRM server. MRRM will poll this queue about every 250 milliseconds to update our monitoring system.

 Each Se8c supports 8 BODs via two remote Digitrax BD4 circuit boards. We installed remote RR-CirKit boards to Se8C ports to provide BODs in special cases such Reverse Loop/Wye track segments. The five Se8c circuit boards support a total of 40 BODs. We also have 3 Digitrax BDL168 circuit boards installed. Each of these circuit boards support 16 BODs or a total of 48 BODs.

To see some photos of the block occupancy wiring construction click here.

Turnout Automation

We now have over one hundred turnouts on the layout and we have installed computer control for more than 60 turnouts. Most of these are Peco turnouts using a Tortoise slow motion machine driven by a one of 8 ports on one of our 5 Digitrax Se8c circuit boards or 12 dual port Digitrax DS52 circuit boards. Another eight of our Tortoises are driven by a Team Digital SRC8 circuit board. We also have six Kato turnouts with built-in switching machines driven by Digitrax DS51K1 circuits. We also have one Kato double crossover driven by a Digitrax DS52 circuit board. All turnouts are controllable from the JMRI software or from Digitrax throttles. Our JMRI Dispatcher panels can command these turnouts. There are no fascii panel switches at this time. However, the needed supporting control electronics are preinstalled for 40 such future fascia switches (from 5 Se8C circuit boards).

Erie Yard uses Kato track and turnouts. Automation is under construction.

Pottsville yard is mostly Peco turnouts with some tortoises now installed. Awaiting new DCC controlled turntable product. Automation is under construction.

MRRM can also command these turnouts using our Web Services interface to JMRI. Additionally, MRRM turnout listeners that we install into JMRI will queue turnout change events to the MRRM server. MRRM will poll this queue about every 250 milliseconds to update our system.

To improve electrical continuity on mainline turnouts, we have powered the frogs on Peco turnouts using the SPST switches built into the tortoises. Note: The Peco turnout springs DO have to be removed from the Peco turnouts to avoid shorts due to turnout movement becoming out of sync, however briefly, with Tortoise movement and SPST switch closure. The time and motion associated with the turnout and tortoise is very important to avoiding shorts.

For the remaining tortoise driven turnouts, we still rely soley on the pressure that the tortoise exerts on the points. Eventually all frogs will likely need to be powered for reliable operations. The Kato turnouts rely on Kato's design for reliable electrical continuity.

To see some photos of the turnout wiring construction click here.

 

Signal Automation

  We currentlky have installed 138 three light signal heads on the layout (404 LEDs). At this time, all signals are based on Digitrax SMBK head over head posts which are a good size for our N scale railroad. Signal Post with 2 Heads

We are still looking for a good dress-up kit for these Digitrax signal posts. We are looking into a RepRap machine to design a dress-up kit. Any ideas from readers would be welcomed.   

To dress up the Digitrax signal heads, we created our first 3D printing project in 2014. Dual Head Signal Shroud

We settled on two styles for the masts: two groups of three hooded single lamps and two groups of one surrounded triple lamps. They are shown here:

 

Red over Green tripple hoods    Green ver Red Signal     

   2 triple heads     Red over Green Signal

 

The number placard on the mast identifies the DCC address of the first of four sequential addresses that control the aspects.


     All signals are driven by Digitrax Se8C circuit boards. Each board drives 4 heads via each of eight ribbon cable or 32 heads per circuit board. We have five Se8c circuit boards installed supporting our signals at this time. All signal heads are driven by JMRI software. Each signal is programmed using 'simple signalling rules' and Logix installed into JMRI..  Each signal head is controlled by a pair of 'turnout' addresses. One must plan the turnout number address space carefully in conjunction with the constraints imposed by the various circuit boards.Here are my accessory address range standards and sensor addess standards for my Digitrrax controlled layout.

MRRM can also command these signals using our Web Services interface. Additionally, MRRM signal listeners that we install into JMRI will queue signal change events to the MRRM server. MRRM will poll this queue about every 250 milliseconds to update our system.

To see some photos of the signal wiring construction click here.

See the next video for a cascading signal test of the operating signaling system with the shrouds and placards installed on the signal masts.

Transponder Automation

    A Transponder is a device implemented as a Digitrax proprietary extension to the NMRA DCC specification. Locomotives with certain Digitrax decoders have the capability to transmit their 'Address' to a Digitrax 'Reader' or tranponder installed on a given track-turnout block segment. These addresses are forwarded to JMRI listener software. The address is shown on the JMRI based Dispatcher and Real-Time Status displays we have built with JMRI PanelPro. When, say, loco #3424 enters a transponder section, the message displayed is "3424 enter" .When that loco leaves the segment, it displays "3424 exit".

      MRRM tranponder listeners that we install into JMRI will queue decoder address enter and exit events to the MRRM server. MRRM will poll this queue about every 250 milliseconds to update our system. The decoder's address and state values are forwarded to the MRRM software to link the locomotive to an active manifest and set of waybills. Thus we know where the train is going to next and what cars are currently on the train  - among other things.

    Each BDL168 can support a pair of quad segment transponders. These four port circuits are known as Digitrax RX4 devices. Each of the eight RX devices supports one track-turnout segment whose BOD is also supported by the BDL168 circuit board. The RX sends a signal on the track segment during the quiescient period between DCC packets. If a transponder equipped loco decoder senses the RX signal it 'transponds' its address back to the RX and thus to the BDL168 and thus to the JMRI listener on the Loconet bus.

We currently support 20 transponders and 8 to 12 more are under development. Most are assigned to key mainline or bypass track-turnout segments.

To see some photos of the transponder wiring construction click here.

Automated Train Control

Under construction!

We have experimented with the two tools built into JMRI for automated control as well as the JMRI Robothrottle scripts with mixed results. We are currently building a script generator into MRRM to create automated train scripts. This script builder will replace the one we built into the pre-2005 version of MRRM. We expect to control these scripts via a custom layout panel that is under development.

We have created an automated train scripting tool based on the sensors, signals, turnouts, speed limits etceteras. Since they obey "the rules", we can have human engineers and robot engineers on the railroad at the same time. Check the Robot Trains page for examples.

 

Other Electronic and electromechanical products

We have installed 10 Miller Electronics electroluminescent billboards. We also installed 8 ITCC sound generating devices throughout the layout. Two operating oil pumps are installed. A flashing sequence lighted radio tower is installed. A Windmill is installed - we saw many of these during a recent trip on the Appalachian Mountains. A Faller Mine was built but operation is balky. Many more lights and animated devices are planned.