BHEL – Electronics Division, Bangalore

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 - 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

11. 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

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 Thank You Thank You Thank You Thank You