A WIRELESS THROTTLE

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THROTTLE Introduction Overview Handheld Transmitter Receiver Remaining Circuits Power Supply Personality Module Momentum Capacitor Wave Shaping Power Amplifier Reversing	RELATED TOPICS Test Motor Part Lists for Throttle Linx RF Parts Wave Forms Part Info, Pinouts, Specs etc.	MORE TOPICS Meters etc. Prototyping Circuits Bench Top Power Supplies Batteries Charger Monitor Transformers

A local switcher starts the day at Bobston	An engineer picks up a throttle and begins his run. He can select an origin, then select a turntable stall and bring his engine out of the roundhouse. His train passes a signal and it turns from green to red. He stops at a major turnout and can throw it for the main or diverging route. At the end of his run, he releases his train to the yard crew to take over. The throttle described here contains all of the above functionality from well over 300 feet. Yes, a computer and train detection units are involved, but the wireless throttle controls all.
The wireless throttle on the North River Railway is a rather unique blending of the old-time transistor throttles of the fifties combined with modern integrated circuit technology then merged with a computerized block control system. The main function of the throttle is to control the speed and direction of a train however; it also sends signals to a computer interface to operate auxiliary devices including turntables, switch machines, and signals.
I do not pretend this throttle to be the next generation of control after and/or instead of DCC. It is simply a product of tinkering over many years as an approach to watching the train, not the control panel. Block systems require the engineer’s constant attention as the train travels along and can become quite complex on large railroads. DCC systems may work extremely well to prevent this but also have certain limitations. Locomotive space for receivers often means a slight reduction of weight for pulling power, the programming for the acceleration curve is complex, and getting started with DCC can be expensive. The main problems are that things do go wrong, standards are poor, and devices burn out much the way they did back in the fifties. It is also very harsh on motors.		Computer for controlled block system
This Throttle, when combined with a computer control, provides a rock-solid wireless control of trains with many features not available on a typical DCC system including: § Range of 300’ indoors using internal antennas - 1000’ with external. § Over 750 control channels possible § Personality modules to customize characteristics for engineers or types of engine(s) with simple plug-in § No decoders or other modifications required to engines. Will run both unmodified and DCC/DC modified engines § Will not harm brushless or permanent magnet DC motors § Simplified computer compatible interface for Accessory control § Anti-reverse lockout protection at running speeds to prevent jamming of gears. § Other features too numerous to enumerate here. Back to Table of Contents

Building this throttle (if you have already cheated and looked at the schematics below) may seem like a daunting task. Let me assure you there is nothing critical in its construction and most of the features have appeared in other articles. Just in case though, please SEND AN EMAIL to let me know if you find any errors.

Throttles have about the same general configuration as shown in the diagram below. You will find each of these elements in many designs so a good understanding of each element is a good place to begin

The power supply converts dangerous house current to a safe level to work with. It also converts alternating current to direct current and should have a fuse to protect equipment from severe overheating due to derailments and shorts. The output of the power supply made available to each element of the throttle circuits.

The controls found on a regular power pack usually consist of a simple rheostat and a reversing switch. The control and distribution elements separate these in a transistor throttle. A rheostat is essentially acts as current limiting device by varying a resistance from 0 to about 50 ohms. The potentiometer is a voltage divider. Its resistance in the circuit is constant but its output voltage varies from 0 to some amount, often in the magnitude of just five volts. Push buttons and resistors may replace potentiometer in circuits containing a momentum capacitor, especially where a transmitter/receiver interface is involved.

The interface of an old time power packs is simply part of its internal wiring. For an early transistor throttle, a long tethered cable allowed the operator a certain degree of freedom to walk with the train. Modern throttles seem to have some type of transmitter/receiver arrangement of some type, infrared and radio frequencies being the most common. No matter what type of interface is used, it is simply a way to deliver a signal to the momentum section that is in proportion to the setting of the controls to the momentum section.

The momentum section is essentially a capacitor where the charge on the capacitor controls the speed of a train. There are many ways to change this charge, all of which involve resisters and diodes.

We now come to the conditioning section. This is the black box where a throttle works its magic and blends the pure DC from the momentum section with any of a number of waveforms. Sign, triangle and square waves (as either AM or FM waveforms) can also be added to improve the performance of an engine. The amplifier uses this modified waveform to power the train. A DCC system decoder performs all these functions using mostly programming instructions instead of hard wiring to manage its internal circuitry.

The Amplifier is essentially one or more power transistor that amplifies the low-power waveform from the conditioning circuits to enough power to drive a train. Protection circuits guard against shorts, the high voltage spikes generated by the locomotive’s electric motor, and whatever other hazards that may exist.

The distribution element is usually straightforward. A reversing switch or relay changes the direction of an engine and block switches allow for multiple train operation. This throttle is a bit unusual in two ways. First, two relays are used to change the direction of an engine such that it runs at equal speed in either direction. There is also a circuit to prevent the jamming of a forward running engine into reverse while running above a preset speed.

Look for these elements in the detailed description that follows

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			TRANSMITTER / CONTROL The hand-held throttle or more properly the throttle control uses five push buttons for the control of a train. The Black buttons control the forward and reverse, The blue button I for acceleration, the yellow is the service break, and the red button is for emergencies. The red button also signals the computer that a cab is in use. The three grey buttons are used for auxiliary functions The slide switch on the end is the on/off power switch and the three pins barely visible on the side if for charging the battery without having to open the box
This view inside the box shows the battery located to the right. This gives the box a nice balance when held by this end. The PC board on the left contains the Transmitter module and antenna. Note that the antenna is as far from the user as possible. The center board contains most of the circuitry required to send a signal at every key press.
		This close-up shows the groves cut to separate the pads required for the transmitter module. Groves are cut first with a knife then widened with a triangular file. The orange area on the bottom of this view is the copper cladding laminated to the backside of the circuit board that acts as a ground plane. The pins jumper connections between both sides of the board.
	ß The header strip between the two rows of diodes connects to the pushbuttons on the box cover. The jumpers at the bottom assign a unique code embedded in the transmitter’s signal. Two capacitors flanking a voltage regulator are to the right. One of two push-button clusters are à mounted on their own prototyping board and screwed to the underside of the top cover.
Circuit description This throttle uses a transmitter, receiver, and other parts from LINX Systems. These hybrid circuits are almost completely self-contained needing only an antennae and power to transmit and receive a signal. Also, Be aware that there are several chips similar to the encoder chip used here. Visit Reynolds Electronics for several RF projects and parts. Almost all of these parts are also available at DigiKey. The encoder chip (IC-1) combines the status of the eight switches (SW1 through SW8) and (D1 through D8) to a single signal that leads to the transmitter. Diodes (D9-D16) provide connect the rest of the circuit to the battery power. Resister network (R3) holds the inputs each input low unless pulled high by the press of any button. This saves power when no button is pressed. The remaining eight diodes pull a corresponding input of IC-1 low. A 9-volt battery supplies about 7 volts under normal loads. IC-2 further drops this to the 5 volts required by the decoder while capacitor C1 prevents any transient changes. This voltage passes through each switch as it is pressed, then passes through a diode (D9-D16) to a resister (R2) whose value is selected such that about 3 volts to power the transmitter module (TX1). Capacitor C2 again removes any transient changes of voltage.				TRANSMITTER / CONTROL CIRCUIT See specifications for part pinouts. The four jumpers (J1 through J4) provide a unique four-bit device address. Eight jumpers would expand this to an eight-bit address for a possible 256 throttle devices. There are also three different frequencies available to provide control for over 750 trains simultaneously. See PARTS LIST for transmitter for parts and additional information. Back to Table of Contents

OVERVIEW OF RECEIVER AND THROTTLE CIRCUIT BOARD
	The board above is the other half of the wireless throttle. The schematic below shows the receiver portion of this circuit. It receives the signal and splits it into individual channels to control the train speed, direction, and auxiliary functions. The receiver, like its transmitter à counterpart, consists of the receiver module (RX1) and an antenna (ANT). Note the ground plane visible on the far side of the PC board.
See specifications for part pinouts.
Circuit description The antenna (ANT) provides a signal to the receiver module (RX1) which in turn presents a data signal to the decoder (IC-3). The decoder separates the data into eight channels each of which connects to the input of one of the eight Operational Amplifiers (IC1 and IC2). Note that several similar decoders are available and operate in a slightly different manner. One type (A) presents a signal that appears as a train of square pulses when a high signal is present at that channel. The other type (B) changes with the level of the signal. Both will work by a simple change of resister values in the personality module but here it the problem. If you are running a train using the type (B) decoder, and for any reason the signal is lost as in a weak battery, the throttle may be left in the acceleration mode with the train speeding up to full speed. Opto-isolator (IC-4) has four channels and completely separates outputs meant for computer interface from any circuitry of the throttle. Resister networks (R8 and R9) limit the power and protect all the inputs and outputs of the isolator from excessive current. Two amplifiers lead to the throttles reversing circuits. Three more lead directly to opto-isolator (IC4) used to isolate the auxiliary computer signals. Two more amplifiers lead to the personality module that controls the speed of a train. Notice that the acceleration amplifier is the one that uses the (+) input to (IC3). All other amplifiers use the (-) lead. Also, note the direction of the diodes leading to the personality module.		The last amplifier leads both to the personality module and to the fourth input of opto-isolator through the resister (R7) and transistor (T1). IC-5 further drops the 18 volts from the power supply to the 5 volts required by the decoder. Capacitors C2 and C3 suppress any transient changes. Resistors (R2) and (R3) form a voltage divider that supplies 2.5 volts to one side of each amplifier. The output of each amplifier as the decoder’s signal passes this value. The value of resister (R1) is such that it will drop the five volts from (IC05) to about 3 volts. C1 prevents any transients of this voltage. The four jumpers (J1 through J4) provide 16 unique device addresses but as with the transmitter, using eight jumpers will allow the control of 256 devices. Three frequencies available expand this to a total of control over 750 trains simultaneously. See PARTS LIST for transmitter for parts and additional information. Back to Table of Contents

The personality module is a “surf board” or Single-row In-line module (SIM) card. Several cards, each with slightly different resisters, are easily unplugged and interchanged allowing the rapid change of the how the throttle performs. It is, of course, possible to have one card for each engine or for each operator. Practical experience has show that is not necessary. A more reasonable approach is to have one for very light engines, another for medium engines, and a third for double heading. A forth may be kept to virtually eliminate any momentum effects.

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Remaining throttle circuits

	The transformer portion of this throttle is elsewhere in a special fire-resistant cage along with the other transformers that power the railroad. The basic requirement is simply a transformer that will supply about 16 to 20 volts AC at an amp and a quarter. I use one that provides 20 volt/amps (watts) of power. See more on POWER SUPPLIES.
Looking near the right, middle of the schematic above we see that power from the transformer connects to the main rectifier shown here in the top center. The large capacitor to the right raises and filters the DC to a more constant 22 volts with no load and about 18 volts while running a train. There is no further regulation for the throttle power. Mounting rectifier with the throttle circuitry insures that crossed wires from the transformer will not cause any damage.

The 470-µfd capacitor, above the rectifier in the schematic, provides the momentum simulation of a train. The personality module increases or decreases the charge (voltage) on this capacitor and in turn, this charge is reference by the remaining parts of the throttle to determine the final speed of the train. Push-button throttles require a capacitor but the size can be smaller. 470 µfd is large enough to keep the train moving for half an hour before it coasts to a stop. Back to Table of Contents