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BHEL – Electronics Division, Bangalore

IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO

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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

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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

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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)

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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

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IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO

Emerging technology in Control systemOpen 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

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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

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IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO

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IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO

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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

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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

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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

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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

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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

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IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO

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