A study on the technical development of propulsion and control system for

electric multiple unit

9th UIC

User-Producer

Interaction Conference

Seoul,

17-19 Oct

2006

Choi, Jong-Mook– Chief Researcher – Rotem Company

Summary

Technical Development of Network Control

Technical Development of Traction Motor

Technical Development of Traction Control

History of Traction System

Table of Contents

History of Traction System

Development of Traction SystemDevelopment of Traction System

DC MotorSeries Wound

DC MotorSeries Wound

DC MOTORDC MOTORDC MotorSeparateWound

DC MotorSeparateWound

Induction Motor

Induction Motor PMSMPMSM

ThyristorThyristor GTO ThyristorGTO Thyristor

Op-amp & Discrete Logic Device

Op-amp & Discrete Logic Device u-Processoru-Processor DSP & FPGADSP & FPGA

RheostaticRheostatic ChopperChopper 4Q Chopper4Q Chopper VVVF InverterVVVF Inverter

MOTORMOTOR

CONTROLINVERTERCONTROLINVERTER

SEMI-CONDUCTOR

SEMI-CONDUCTOR

PROCESSORPROCESSOR

IGBT (IPM)

Technical Development of Traction Control- Semiconductors

Development High Power IGBTDevelopment High Power IGBT

IGBT/IPMIGBT/IPM

3300V/1200A6500V/600A

3300V/1200A6500V/600A

Brand New Semiconductor in near Future?Brand New Semiconductor in near Future?

SiC Semiconductor SiC Semiconductor

Schottky Diode :600V/75ASchottky Diode :600V/75A

� Low Loss

� Operating in Higher Temperature

� High Frequency Switching

� SiC & Si Hybrid Inverter

� SiCGT : 4500V/100A

� Low Loss

� Operating in Higher Temperature

� High Frequency Switching

� SiC & Si Hybrid Inverter

� SiCGT : 4500V/100A

Technical Development of Traction Control- Semiconductors

Technical Development of Traction Control- Hybrid Propulsion System Advantages

Series-hybrid configurationSeries-hybrid configuration

Conventional Diesel Train

ENGINE GearHydraulic

Transmission

Hybrid Train

Wheel

Axle

ENGINE GGGG Converter Inverter MMMM Gear

Wheel

Axle

Battery(Energy Storage)

Technical Development of Traction Control- Hybrid Propulsion System Control

Operating Principle of Hybrid PropulsionOperating Principle of Hybrid Propulsion

ENG GGGG Con

Battery

INV MMMM

Acceleration

ENG GGGG Con

Battery

INV MMMM

Brake

Constant Speed Run

ENG GGGG Con

Battery

INV MMMM

Station

ENG GGGG Con

Battery

INV MMMM

Technical Development of Traction Control- Fuel cell Propulsion System Control

Operating Principle of Fuel cell PropulsionOperating Principle of Fuel cell Propulsion

MOTOR

FCC

Battery

DC/DCConverterController

BMS MCU

Gear

PCU

3φ

Inverter

DC/DCConverter

(V)

(A)

Power Line

Control Line

Fuel Cell

Fuel cell train is testing in Japan

Requirements : Development of high capacity fuel ce ll, and construction of hydrogen infra

ChargingM

SuperCap

Powering

Regenerating

M

SuperCap

ChargingM

SuperCap

Technical Development Traction Control- Energy Storage of Traction Inverter

Energy Storage of Traction Inverter using SuperCap.Energy Storage of Traction Inverter using SuperCap.

Station

(Charging)

Powering &

Regenerating Braking

Station

(Charging)

No need of catenary – Construction Cost ReductionNo need of catenary – Construction Cost Reduction

Technical Development of Traction Motor

PMSM

DDM

DC T/M

AC T/M

LIM

Reduction of Maintenance CostReduction of Maintenance Cost

Increasing of ReliabilityIncreasing of Reliability

Easy to MaintenanceEasy to Maintenance

Technical Development of Traction Motor

• Totally enclosed motor

• Gearless motor

• Applying long life bearing & grease

• Ductless motor

Reduction of maintenance cost Reduction of maintenance cost

Reducing energy costReducing energy cost

• High quality magnetic material

• Permanent Magnet Motor

• Reducing transmission loss

• High quality insulation material

• Low temperature rise

Increasing reliabilityIncreasing reliability

TractionTractionmotormotor

Key Technology of Traction Motor

Technical Development of Traction Motor

Two-circuit cooling system for an enclosed traction motor

Conventional self ventilation type traction motor

An Enclosed Traction Motor vs. Open Type Traction Mo tor

Heavier and larger than same capacity self-ventilation type traction motor (without forced cooling systems)

Lighter and smaller than same capacity enclosed traction motor (without forced cooling systems)

Longer maintenance interval

Shorter maintenance interval, but practical maintenance interval is 3 year overhaul and 6 year heavy overhaul.

Higher maintenance cost reflecting that the structure of motor is some complicated

Air flow of fresh airAir flow of fresh air

Air flow of internal circular air

Technical Development of Traction Motor

Application of PMSM (Permanent Magnet Synchronous Motor)

Statue

• High un-sprung Mass• Difficulty of maintenance• High impact on DDM

• Simple Construction• High Efficiency• Low Noise

Direct drive motor(DDM System)

• Complex Construction• High Noise

• Light size & weightIndirect drive motor

(Conventional System)

DisadvantageAdvantageIndex

Technical Development of Traction Motor

Linear Induction Motor (LIM)

Electro-magnet

Iron Rail

No adhesion : No slip, No sliding

Low Noise : < 65dB(A)

No rotation parts : Maintenance free

No friction : Comfortable Ride

Technical Development of Traction Motor

Requirements for PMSM technology

Development of High-quality magnet material

Demagnetization at high temperature

Reduction of Production cost

Requirements for LIM Technology

Improvement of efficiency and power factor

Reduction of the weight and size

Adoption of high conductivity material for reaction plate

Technical Development of Control Network- Networking Of Distributed Control Systems

Integration of decentralized systems

CCUCCUTCUTCU

DisplayDisplay

DIODIO

RadioRadio

BrakesBrakes

HVACHVAC DCUDCU

SIVSIV

ATCATC

Recent Networking of Control System1. International Standard

1) IEEE 1473-L network : North American area2) IEEE 1473-T network : European area

2. Combined IT technology3. Flexible Multiple Operation

*TCN : Train Control Network

Development of Communication Technology--> Minimal Wirings & Reduction of Interface Circuits

With CareRedundancy Network

HighSecurity

EasyWith careMaintenance

LowHighCost

EasyWith careCabling

Networks(TCN, Lonworks)

Wire cables

Technical Development of Control Network- IEEE 1473-T Network

IEEE 1473 T-Network

The Train communication network(TCN) with real time capability

Technical Development of Network Control– Korea High Speed Train HSR350X (T-Network)

-Driver’s Display UnitTCN(IEC61375-1), Display Backup

- CCU(Central Control Unit)TCN(IEC 61375-1, CCU Backup)

- KTXII : 10R + 10R Multiple Operation, TCN Networks

-HSR 350X : 7R fixed, TCN Network

* KTX : 20R fixed operation, TORNAD Network

Technical Development of Control Network– IEEE 1473-L Network

IEEE 1473 L-Network : NYCT EMU with multiple operat ion(4,4+4)

IEEE 1473 L-Network :1) Ireland DMU with multiple operation : 3, 6, 3+3 ,3+6, 3+3+3, 6+62) Central EMU with multiple operation : 4, 4+4, 4 +4+4

TC/CC (EN50155, CE certi)

NYCT EMU : Driver’s Console(Backup with CBTC monitor)

(Vital)

(Vital)

MVB Redundancy

PWM

Analog

MVB

Redundancy

Driving Mode

Selection

Technical Development of Control Network- System Redundancy Scheme

- System Backup, Network Redundancy

* Vital Functions control by CBTC system- CCU1/CCU2 backup(Hot standby)- WTB/MVB communication line backup- Propulsion/Brake Command : Hardware backup

- Driver’s Display Backup

Technical Development of Control NetworkControl System with Wireless LAN(IEEE 802.11 b/g)

Ethernet Network(10Mbps) :Control + Monitoring + Audio Signal + Video Signal

Technical Development of Control Network- Integrated Control System

AC train(Japan JR) :10R fixed train, DDM

Summary

The technology of Traction control system in near futu re

• Hybrid Propulsion system

- Electric control system of Environment friendship for electric multiple unit

- No need of catenary : Construction cost reduction

• PMSM (Permanent magnet synchronous motor) : High efficiency and Light size

• Fuel cell Propulsion system

The technology of Traction Motor in near future

• LIM (Linear Induction Motor) : Comfortable ride and Low noise

• Flexible Multiple Operation

Development of Train Network Technology

• Minimal Wirings & Reduction of Interface Circuits

Thank you…Thank youThank you……