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BHEL – Electronics Division, Bangalore. IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO. IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO. Current Status Locomotive with tap changer based DC drive Indian Railways migrated from conventional DC drive propulsion to AC 3 Phase

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bhel electronics division bangalore

BHEL – Electronics Division, Bangalore

IGBT BASED 3 PHASE PROPULSION TECHNOLOGY

FOR LOCO

igbt based 3 phase propulsion technology for loco
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
  • Current Status
  • Locomotive with tap changer based DC drive
  • Indian Railways migrated from conventional DC drive propulsion to

AC 3 Phase

    • High power traction converters manufactured with Oil Cooled GTOs
    • Microprocessor based controls
    • Bogie drive configuration and modularity concept adopted
igbt based 3 phase propulsion technology for loco1
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
  • Limitation with GTO based system
  • Requires large gate drivers and snubber circuits, hence higher losses
  • Obsolescence of power device GTO and electronic components
  • Proprietary ASIC’s and Hybrid circuits
  • Platform dependant control architecture, RTOS and software tools
  • Proprietary protocol, inability to configure third party hardware & software
igbt based 3 phase propulsion technology for loco2
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
  • Limitation with Proprietary H/W, S/W and
  • Component Obsolescence
  • Electronic hardware Components
      • Processors
      • Memory chips
      • ASICs
  • Computer H/W needed to interface with loco electronics
      • Proprietary interface card
  • Tools needed to develop and maintain software
      • Proprietary tools
  • Operating system of maintenance PCs & loco
      • RTOS on loco: Proprietary OS
      • DOS on PCs (Obsolete)
igbt based 3 phase propulsion technology for loco3
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
  • Emerging technology in converter
  • Introduction of high power IGBTs
    • • No snubber circuits
    • • Smaller gate circuits
    • • Higher switching frequency
    • • Lighter (20%) and smaller
    • • Higher reliability (30% longer MTBF)
    • • Lower noise
    • • Better slip/slide control (vector control)
  • Water Cooled System
  • Axle Control Configuration
igbt based 3 phase propulsion technology for loco4
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
  • Emerging technology in Control system
    • Open Standard Platform
      • Hardware on standard backplane bus – Vendor independent
      • Standard RTOS and third party Software tools
      • State – Of – Art Digital Communication as per TCN – IEC 61375
      • Reduction in number of electronic cards – Economical solution
      • Configuration and modification at ease using PC based tool
igbt based 3 phase propulsion technology for loco5
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
  • Salient features of IGBT based propulsion system
  • Traction Converter
    • Water cooled IGBT based power modules
    • State – Of – Art vector control
    • Axle Control Configuration
    • Modern Slip/Slide Control
  • Traction Control Unit (TCU)
    • Digital I/O cards and signal processor boards
    • Control cards based on TCN as per IEC 61375
    • Compatible to communicate with existing VCU
igbt based 3 phase propulsion technology for loco8
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
  • Challenges in retrofit
  • Accommodating the IGBT based system in the existing dimension

enhancing the performance and retaining interfaces both mechanically and

electrically

    • IGBT system occupies less space – ease in accommodating
    • Weight reduction - 43 %
    • Retain all electrical and optical connectors .
  • The equipment is designed for axle control over existing bogie control
    • Each Inverter feeds individual traction motor achieving axle control
    • Inverter power handled is less
    • More redundancy
    • More reliable operation of the locomotive
    • Additional software and separate electrical connections for
    • individual motors
igbt based 3 phase propulsion technology for loco9
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
  • Challenges in retrofit
  • The control system offered is TCN, IEC 61375 standard also

designed compatible with the existing Proprietary system

    • Control system designed with MVB for communicating with VCU(TCN)
    • Additional gateway provided to communicate with existing VCU
    • Rack enclosure and cooling arrangement retained
  • The control system designed with optimum hardware with vector control

along with modern slip/slide control for maximum adhesion under all rail

conditions

    • State of art fast Digital signal Processor Boards
    • Less control boards
    • No Proprietary ASICS and hybrid ICs
igbt based 3 phase propulsion technology for loco10
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
  • Challenges in retrofit
  • The equipment designed with normal water-cooling instead of oil cooled

system

    • Water cooling equipment is simpler more efficient and economical
    • Existing heat exchanger area retained modifying the oil cooling circuit to
    • water cooling.
  • The Converter equipment designed for existing Transformer and Motor as

used in GTO based system

    • IGBT based equipment injects high voltage and current stresses
    • Stress seen by transformer and motor.
    • Solutions offered for high stress as part of converter for designed
    • stress of motor and Transformer
igbt based 3 phase propulsion technology for loco11
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
  • Challenges in retrofit
  • TCN based Vehicle Control Electronics
    • Up gradation to TCN based open control platform
    • Vendor independent hardware due to standard back plane
    • A standard real time operating system
    • Software built using standard languages as per IEC 61131
    • Standard software tools on PC for programming.
    • Interfacing cabling in the loco retained the same.
    • Rack enclosure and cooling arrangement will be same
  • BHEL geared up to retrofit 4000 HP Diesel Loco IGBT based Electrics
igbt based 3 phase propulsion technology for loco12
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
  • BHEL Capability
  • Technically skilled manpower
  • Full fledged facilities for Assembly and manufacture
    • IGBT based Converter equipment
    • Surface Mount Technology for Controller card
    • Water and Oil Cooling system
  • Testing facility
    • Power module and cooling system
    • Automated test facility for controller card
    • Integrated testing of complete rack
    • Environmental test chambers in energized condition
  • Complete equipment testing at BHEL
  • Expert Technical support for trouble shooting
igbt based 3 phase propulsion technology for loco13
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO

Thank You

Thank You

Thank You

Thank You