Traction Systems For Locomotives And High- Speed Applications

Transcription

—Traction systems forlocomotives and highspeed applications

—Partnering with ABBMajor benefits—High flexibility and innovation to realize yourproject vision—Large global corporation and technologyleader with a long-term strategiccommitment to the rail industry—ABB as a pure traction chain and electricalpartner for train builders and operators—Competent local service and supportwherever your project is

3—Table of contents004 ABB – your partner of choiceUnrivaled flexibility005Complete product portfolioABB traction solutions006Proven traction componentsTransformers, motors, generators007Proven traction componentsBORDLINE CC – Compact Converters008 Proven traction componentsBORDLINE M – Auxiliary converters009Powerful converter modulesFull flexibility for customized solutions0 10Cutting-edge control technologyHigh-performance control software0 1 1 Cutting-edge control technologyExcellence in software development0 1 2 Retrofit and modernizationsCooperation with operators0 13Service and supportNew era of industry partnership014 – 023Selected referencesLocomotives and high-speed trains

4T R A C T I O N S Y S T E M S F O R L O C O M O T I V E S A N D H I G H - S P E E D A P P L I C AT I O N S—ABB – your partner of choiceUnrivaled flexibilityLarge series of trains and locomotives fitted with ABB traction equipmentare in reliable and economic operation every day and in every climate.ABB is the expert for traction converters, motors, transformers,and complete traction chain solutions. In deep and trustfulpartnerships with vehicle builders, refurbishers, and railoperators, we supply state-of-the-art traction systems.Among traction specialists, ABB excels with the broadesttraction portfolio and engineering capabilities for tailormade solutions.We combine decades of rail experience and a world-leadingposition in areas such as traction transformers with a wealthof cross-industry know-how in power electronics, motioncontrol and project management. ABB is not only the leaderin industrial drives, but also the most innovative supplierof power semiconductors.The following pages offer many ideas of how ABB couldcontribute to your next locomotive and high-speed project.We hope to inspire you as to what is possible today in theareas of power management and energy efficiency, hybridand multi-system technology, compactness and energydensity, reliability and robustness, control and adaptability.One of the greatest strengths of ABB is our flexibility tocreate real value-adding innovations. Given a sound businessopportunity, ABB is ready to quickly embark with you on apartnership for game-changing new solutions.—“We care for every detail, because weknow the impact on the lifetime of thetraction system.”

5—Complete product portfolioABB traction solutionsBORDLINE traction converters and ABB traction solutions stand forcomprehensive, flexible solutions with high performance and rewardingcost and energy savings over the life cycle.Traction chain partnerAs a major supplier of traction systems, ABB works with mostof the leading rolling stock manufacturers. We also supporttransport operators throughout the whole life cycle of thetraction chain, i.e. in the areas of service, maintenance,upgrades, and retrofit projects.Benefits of comprehensive traction chain responsibility Single partner for the entire traction chain Optimization of component dimensions and interfaces Fast commissioning and homologation TCMS integration and system optimization Higher total energy efficiency and reduced life cycle costABB traction solutions for all rail applicationsComplete portfolio of traction chain solutions from a few100 kW to more than 7 MW and for all types of locomotives(e.g. passenger, freight, shunting), power heads, and distributed propulsion systems.Global presenceABB is present in more than 100 countries and can providestrong local support to your project. With a truly globalorganization, we are committed to local competence andlocal /DCDE/MS—Overview of ABB’s traction offerings!—01 Traction transformer02 Traction converter03 Traction control04 Train Control and Monitoring System05 Traction motor06 Diesel engine generator07 Auxiliary converter08 Battery charger09 Energy storage#% "

6T R A C T I O N S Y S T E M S F O R L O C O M O T I V E S A N D H I G H - S P E E D A P P L I C AT I O N S—Proven traction componentsTransformers, motors, generatorsABB traction transformers World market leader with unrivaled experience Minimum line harmonics and optimum total efficiencyof the traction system State-of-the-art production technology as well as designand simulation software Tailor-made configurations for under-floor or machineroom installation Highly flexible design for compactness and optimizedwinding topology, being critical for multi-system (MS)vehicles to respect vehicle weight/axle restrictionsABB traction generators Synchronous brushless generators designed forhigh-powered diesel-electric locomotives Single bearing design for two couplings to be combinedwith the diesel engine crankshaft decreasing the sizeand weight of the gensets ABB UNITROL 1020 automatic voltage regulator generator,designed for reliable excitation control in tractionapplications Complete family of induction (asynchronous) generatorssuitable for medium power range applications Main advantages: simple, compact and reliable designABB traction motors Frameless induction traction motors designed to ensurereliable operation and high torque output Fully customizable motor concept to meet a broad rangeof requirements regarding e.g. output power, mountingarrangements and air duct position Broad design skills and experience to achieve a carefullycalculated optimum solution for each application, whethertailor-made or based on a standard designExamples of ABB traction componentsTraction transformer LOT 11001.5 MW for 16 2/3 Hz high-speed double-deck trainsTraction transformer LOT 6500/67004.5 MW for 50 Hz AC locomotivesTraction transformer4.8 MW for 16 2/3 Hz and 5.2 MW for50 Hz high-speed trainsTraction motor1.2 MW for cargo locomotivesTraction motor600 kW for high power applicationsTraction generator2.65 MW for high power applications

7—Proven traction componentsBORDLINE CC – Compact ConvertersABB traction converters BORDLINE CC Compact Converters: the heart andthe brain of the traction system Two-level and three-level topologies for optimal energyefficiency, economic retrofit, and fast homologation Integrated auxiliary converters, battery chargers, andhead-end power (HEP) converters fed from the DC link Large portfolio of optimized durable housing solutions:from lightweight all-aluminum machine room cabinetsto stainless steel underframe constructions Most compact and economic multi-system converters Tailor-made configurations for under-floor or machineroom installation Environmentally friendly and highly efficient water cooling Easy handling of low weight replacable power electronicmodulesExamples of ABB traction componentsCompact Converter2.3 MW for electric locomotivesCompact Converter3 MW for electric locomotivesCompact Converter1.6 MW for electric multi-system high-speed trainsCompact Converter1.8 MW for diesel-electric locomotives

8T R A C T I O N S Y S T E M S F O R L O C O M O T I V E S A N D H I G H - S P E E D A P P L I C AT I O N S—Proven traction componentsBORDLINE M – Auxiliary convertersAuxiliary converters and battery chargers Complete portfolio of auxiliary converters, convertingpower from 2 kW up to 1.2 MW, ranging from converters forindividual loads or batteries, to full onboard power supplyfor a train BORDLINE M: all stand-alone auxiliary converter types,battery chargers and head end power (HEP) converters BORDLINE CC: Compact Converters for the traction chainwith integrated auxiliary converters (and battery chargers)connected to the DC linkAuxiliary converter210 kVABattery charger10 kWAuxiliary converter130/260 kVAHead end power converter1200 kW

9—Powerful converter modulesFull flexibility for customized solutionsHigh-performance control module Key advantage of ABB traction solutions: the AC 800PECcontrol platform, probably the most powerful modularcontroller for high-speed performance on the market AC 800PEC control platform also used in ABB windconverters, high-power industrial drives, plant automation,high-power rectifiers and many other applications High volume and wide application diversityhigh reliabilityExcellent range of control and communication functionalityin cycle times extending from the sub-microsecond tothe millisecond level Fast reaction times crucial to protect the traction system Complemented by a variety of input/output modules aswell as engineering and service tools Tested under the most stringent environmental conditions Admired for the workmanship of the control wiringThree-level power moduleRobust, reliable, service-friendly power modules All BORDLINE converters, offered in a multitude of configurations and designs, are built on a platform of a fewoptimized PEBBs (Power Electronic Building Blocks) with1.7 kV, 3.3 kV, 4.5 kV, and 6.5 kV IGBTs (Insulated GateBipolar Transistor) High production quantity of standardized PEBBs:-- Excellent reliability and field experience-- Technical optimization (lifetime, switching behavior,power density)-- Multiple sources for all PEBB components-- High spare part availability at reasonable cost PEBBs also optimized for service aspects: easy to handle(small and lightweight) and to exchange Liquid-cooled PEBBs for high power converters (highestcompactness and long lifetime) Air-cooled PEBBs for many types of auxiliary convertersTwo-level power module

T R A C T I O N S Y S T E M S F O R L O C O M O T I V E S A N D H I G H - S P E E D A P P L I C AT I O N S10—Cutting-edge control technologyHigh-performance control softwareState-of-the-art adhesion control Key for the quantitative performance of the locomotiveor the train and for reducing maintenance cost due toless mechanical wear Superior determination of actual vehicle speed andperfect wheel-slip/slide control for all types of drivenaxle configurations (single axle or bogie control) Exceptional adhesion performance, see references onpage 12 and 14Optimized line voltage impact Minimization of line harmonics Faster homologation Stabilization of the line voltage by active damping underweak line conditions, resulting in higher availability ofvehicles with ABB tractionExamples of other innovative ABB softwarefunctions Various system control functions for reducing energyconsumption in cooling, auxiliaries, and diesel engines Converter emergency operation mode to clear trackeven when TCMS is fault De-icing function for the catenary Integration of energy storage controlReduced mechanical wear of the vehicle Reduced wear of motors, gears, wheels, and the bogies Minimization of harmonics in the motor current for allspeed-torque regimes Reduced vibrational oscillations Suppression of torsional oscillations of the driven axlesin a bogie—Traction diagramŹƔƔƝƠƢ ŪƙƂū!!!!!!!"# %ƇƞƓƓƒ ŪƙƛŨƖū ƆƣƜƜƗƜƕ ƠƓơƗơƢƏƜƑƓƈƠƏƑƢƗƤƓ ƓƔƔƝƠƢ !

11—Cutting-edge control technologyExcellence in software developmentControl code consistency and traceability Simple, transparent and intuitive code, programmed ina modular and visual function block language Used consistently from the design phase through todetailed implementation, in real-time simulation testsand finally during fine-tuning under commissioningand homologation Perfect traceability of requirements and specificationsto the operative version of the traction system softwareSpeeding up of commissioning and homologation Fast commissioning and homologation due to:-- Quality and transparency of the software development-- Simple adjustment of parameters during commissioningand homologation-- Minimization of line harmonics-- Rigorous and automated testing of the control softwarein a real-time simulation environment Reduced lead time between commissioning and firstroll-out Faster project delivery and substantial cost savings as a resultof shortened vehicle commissioning and homologationSafe testing of non-standard operational modes Real-time simulator extending the software validationto situations inaccessible on the test track (e.g. speedlimitations, very unlikely system failures) Faster project deliveryFlexible adaptation of the control software Control software change requests facilitated by leadingedge software development environment Sustainable quality of traction system control over thelifetime of the vehicle

T R A C T I O N S Y S T E M S F O R L O C O M O T I V E S A N D H I G H - S P E E D A P P L I C AT I O N S12—Retrofit and modernizationsCooperation with operatorsInteresting business cases for retrofit Need to replace converters or other traction chaincomponents while the major part of the locomotive orhigh-speed train are fit for another 20 years of operation:-- Availability and cost of spare parts-- Unsatisfactory reliability and performance Additional benefits (‘mid life crisis as a chance’):-- Energy savings-- Easy maintenance concepts-- Lifetime extension for retained components, e.g. motors-- Reduced heat and noise generation-- Higher compactness and lower weight of new tractionchain components-- Optional change of fleet mission, e.g. hybrid ormulti-system operation, higher speed or tractiveeffort, higher on-board power Return on investment scales with the size of themodernized fleetAssessmentRe-engineeringRe-cyclingABB support for assessment Which traction chain components to keep, to upgradeor to replace Performance potential of the complete traction chainfor new duty profiles RAMS (reliability, availability, maintainability, safety)potentialDemanding tailor-made engineering Traction chain retrofit engineering for an existingvehicle by far more challenging than for new designs ABB with a wealth of experience in engineering andproject managementDeep partnership with the customer Flexible to utilize the customer’s workshop capacitiesfor the retrofit project Training and empowerment of the customer’s operationsand maintenance staffRe-buildingRe-homologationRevenue—Project example for energy savings through retrofitOld traction chainNew traction chain167 % Energy input143 % Energy input100 % Energy at wheel100 % Energy at wheel10.3 % Transformer7.5 % Transformer18.1 % Converter4.7 % Converter18.2 % Motor and gearbox12.2 % Motor and gearbox7.6 % Vehicle parking8.4 %* Vehicle parking12.4 % Power head auxiliary systems9.9 % Power head auxiliary systems15 % lower losses*Higher percentage value due to reduced total losses

13—Service and supportNew era of industry partnershipEmpowering the customer Pragmatic maintenance concept for efficient adoptionof on-site maintenance by customer’s service personnel:-- Customized trainings-- Strong diagnostic tools-- Modular repair-- Commissioning support-- Product maintenance-- Upgrades Commitment to customer support with flexible ABB servicecontracts spanning multi-year periods:-- Clever spare part logistics-- Repairs, on-site service-- Field operating statistics and analysis-- Support line and expert support The BORDLINE Service philosophy:-- Deep partnership with the customer’s serviceorganization, providing focused services in areas ofthe industrial partner’s expertise-- Smooth commissioning and early operation phase-- Guaranteeing high converter availability after thewarranty period and through the entire life cycleField Serviceand RepairsTraining andConsultancyRemote Supportand DiagnosticsBORDLINE ServiceField Data MonitorObsolescence ManagementSpare Partsand LogisticsReinventing spare parts logistics No more stocking of obsolete spare parts, no morewaiting for spares BORDLINE Service concept: The right spare parts –at the right site – at the required time Containerized consignment stocks with automaticreplenishment, optimized to suit the fleet requirementsService program for motors, generators, and transformers Please refer to service brochures TransForLife Solutions and motor/generator serviceUnique service network Global network of skilled experts and service sites forconverters, motors, generators, and transformers

T R A C T I O N S Y S T E M S F O R L O C O M O T I V E S A N D H I G H - S P E E D A P P L I C AT I O N S14—I N D I A N R A I LWAYS I C L A S S WAG 9/ WA P 7/ WA P 5New IGBT converters for electriclocomotives—BORDLINE CC1500 AC, LOT 6500/6700,BORDLINE M130/260 ACCustomer need Replacement of GTO (Gate Turn-Off thyristor) converterswithout any modification to mechanical loco design,interfaces, control, transformer, and traction motor Conversion from bogie control to single axle control Design suitable for old as well as new locomotives Resistent to high temperatur es Service-friendly solutionABB solution Design of new tailor-made IGBT-based (Insulated GateBipolar Transistor) converters High energy efficiency by reducing losses inthe transformer and motors New generation adhesion contr ol embedded inconverter control Conversion from bogie control to single axle controlCustomer benefits IGBT converters fully inter changeable withGTO converter series Significantly improved tractive effort underall conditions Haulage increased by 9 per cent to 5’500 tons Better energy-efficiency and less heat generation Higher availability in case of motor failur e dueto axle control Easy maintenance and r eduction of operatingcost—Indian Railways (IR), India

15—D I R EC T R A I L S E R V I C E S ( D R S ) I EU R O L I G H TTraction package for Diesel-electriclocomotives—BORDLINE CC1500 DE, traction motor,traction generatorCustomer need Reliable traction chain partner Minimum weight of traction chain for diesel-electricpropulsionABB solution Optimized system of generator, compact converters,and traction motors New traction chain platform, configurable for Bo-Bolocomotive with head end power/Co-Co locomotiveCustomer benefits High adhesion coefficient utilization reducingsand consumption and mechanical wearsignificantly The EUROLIGHT is curr ently the only dieselelectric locomotive available on the marketthat combines a low axle-load ( 20 t) with ahigh power rating, resulting in high operationalflexibility and low operating cost—Direct Rail Services, UK

T R A C T I O N S Y S T E M S F O R L O C O M O T I V E S A N D H I G H - S P E E D A P P L I C AT I O N S16—H AV E L L Ä N D I S C H E E I S E N B A H N ( H V L E ) I EU R O D UA LVersatile traction chain for dual-modelocomotive platform—BORDLINE CC1500 MS, traction transformer,auxiliary converter, traction motorCustomer need High tractive effort for heavy-haul freight operation High power electric and high power diesel propulsion Highly compact traction chain solutionABB solution Traction system solution for 15kVac and25 kVac electric lines and diesel operation Optimized system of traction transformer,traction converters and motors All traction components are engineered foroptimum overall performanceCustomer benefits High tractive effort and high power locomotive Compact and lightweight solution to stay withinaxle load limits Versatile traction platform for dual-mode locomotive platform for all standard line voltagesand multi-system solutions High energy efficiency—EURODUAL locomotive, HVLEPhoto:Stadler

17—D EU T S C H E B A H N ( D B) I I C E 1 (C L A S S 4 01)Traction converter replacement forhigh-speed trains—BORDLINE CC1500 ACCustomer need Replacement of old thyristor converters withoutany modification to mechanical power head design,interfaces, control, transformer, and traction motors Significant increase in energy ef ficiency andavailabilityABB solution Development and production of new IGBT-basedpropulsion converter for 4.8 MW power headwithin 13 months Innovative three-level converter technology Service concept for easy maintenance Reliable delivery of one power head r etrofitkit per weekCustomer benefits Reliable partnership for quick r efurbishmentof 38 power heads in the workshop of DB Energy consumption cut by at least 15 per cent Massive reduction in operating cost Massive gain in r eliability and availability—Deutsche Bahn , GermanyPhoto: DB

T R A C T I O N S Y S T E M S F O R L O C O M O T I V E S A N D H I G H - S P E E D A P P L I C AT I O N S18—S W I S S FE D E R A L R A I LWAYS (S B B) I E E M 9 2 3Traction package for hybrid locomotives—BORDLINE CC750 MS, traction transformerCustomer need Hybrid system: 11/15/25 kVAC anddiesel-electric for ‘last mile’ operation High energy-efficiencyABB solution Very compact and lightweight tailor-madetraction transformer and two independenttraction converters Superb adhesion control system Low noise emissionCustomer benefits CO2 emissions will be reduced by morethan 4’000 tons per year with a first orderof 30 shunters for SBB Cargo Significant reduction of operating costs—Swiss Federal Railways (SBB), SwitzerlandPhoto: Stadler

19—M R S LO G Í S T I C A I H E 4/4Traction converters for most powerfulrack and adhesion locomotives—BORDLINE CC750 DCCustomer need High-power 3kVDC traction equipmentcontrolling individually six motors 5 MW locomotive power Recuperation at full load (downhill) Easy maintenanceABB solution Highly redundant traction system(six converters per locomotive) Well proven three-level medium voltagetechnologyCustomer benefits Massive energy savings due to energyrecuperation capability 780 kN tractive ef fort on ramps up to 104 ‰ Remote diagnosis system for easier service—MRS, BrazilPhoto: Stadler

T R A C T I O N S Y S T E M S F O R L O C O M O T I V E S A N D H I G H - S P E E D A P P L I C AT I O N S20—S W I S S FE D E R A L R A I LWAYS (S B B) I EC 2 5 0Traction package for low-floor electrichigh-speed trains—BORDLINE CC1500 MS, LOT 3000, BORDLINE BCCustomer need Traction solution for diverse market requirements (multi-system) Compact solution for low-floor train with maximum seating capacity High energy efficiencyABB solution Multi-system traction concept for various supply systems:25 kVac, 15 kVac, 3 kVdc, 1.5 kVdc Compact low-floor traction converter and traction transformer Traction converter with a height of only 400 mm Power circuit of ABB three-level technology Compact battery charger built withsilicon carbide (SiC) power semiconductorsCustomer benefits High energy efficiency and availability Maximum space and comfort for passengers—Swiss Federal Railways (SBB), SwitzerlandPhoto: Stadler

21—S W I S S FE D E R A L R A I LWAYS (S B B) I R E 4 6 0Traction converter replacement forelectric locomotives—BORDLINE CC1500 ACCustomer need Replacement of GTO converters State-of-the-art IGBT technical solution Improved reliability and availability for next 25 yearsABB solution IGBT based 3-level propulsion converter Improved energy efficiency Existing transformer and motors retained Compatible with legacy vehicle control unitCustomer benefits Significantly lower energy consumption Easy maintenance Lower total cost of ownership—Swiss Federal Railways (SBB), SwitzerlandPhoto: SBB

T R A C T I O N S Y S T E M S F O R L O C O M O T I V E S A N D H I G H - S P E E D A P P L I C AT I O N S22—S T K , LOTO S KO L E J , FR E I G H T L I N E R I E6 AC T D R AG O NPowerful traction package for electricfreight locomotives—BORDLINE CC1500 DC, auxiliary filterpackage, traction motorCustomer need High power traction equipment for 3kV DC locomotive Single axle control Configurable for six-axle and four-axle variants Reliable and service-friendly traction packageABB solution Highly standardized ABB traction systemcomprising DC line filter, traction converterwith integrated auxiliary converter andbattery charger, auxiliary filter packageand traction motorsCustomer benefits Powerful traction chain with standard modulesand high service level—E6ACT DragonPhoto: Newag

23—T R A N S N E T FR E I G H T R A I L ( T FR )Traction package for Diesel-electricfreight locomotive—BORDLINE CC1500 DE, battery charger, tractionmotor, GenSetCustomer need Customized traction chain solution Short time to marketABB solution Complete solution from one supplier All-in-one converter for traction and auxiliaryincluding integrated cooling Well-proven standardized power electronic buildingblocks (PEBB) and control unit Standardized software modules for motor,brake chopper and auxiliary converter controlCustomer benefits One partner for the entire traction chain Energy efficient traction chain Excellent maintainability—Photo: Transnet Freight Rail

—ABB Switzerland LtdTractionAustrasse5300 Turgi, SwitzerlandPhone: 41 58 585 00 00E-mail: sales.traction@ch.abb.com Copyright 2018 ABB. All rights reserved.Specifications subject to change without notice.3BHS340077 ZAB E09 Rev B 09.2018abb.com/railwayabb.com/tractionconverters

TRACTION SYSTEMS FOR LOCOMOTIES AND HIH-SPEED APPLICATIONS. ABB is the expert for traction converters, motors, transformers, and complete traction chain solutions. In deep and trustful partnerships with vehicle builders, refurbishers, and rail operators, we supply state-of-the-art traction systems.