1. BHEL – Electronics Division, Bangalore
IGBT BASED 3 PHASE PROPULSION TECHNOLOGY
FOR LOCO

2. 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

3. 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

4. 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)

5. 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

6. 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

7. 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

8. IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO

9. IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO

10. 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 %
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

11. IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
Challenges in retrofit
The control system offered is TCN, IEC 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

12. 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

13. 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

14. 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

15. IGBT BASED 3 PHASE PROPULSION TECHNOLOGY FOR LOCO
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