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 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 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 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 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 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 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 LOCO

IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO

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 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 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 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 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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