Emerging Technologies for new generation EMUs
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1 Emerging Technologies for new generation EMUs Technology for new generation AC/DC EMUs in Mumbai Page 1 Septermber 2008 Industry Sector, Mobility Division
2 What is an EMU? It is an Electrical Multiple Unit used for main line, urban & suburban Traffic High acceleration & deceleration Generally fixed formation Distributed power concept Door width is more for quick exchange of passengers Page 2 Septermber 2008 Industry Sector, Mobility Division
3 The EMUs worldwide From Suburban trains to solutions for Mainline and Mass transit Main line Trains* - Velaro (High speed) Mainline Regional* Metro Trains Light Rail (LRT) Mono Rail Long Distance Suburban Travel Urban Mass Transit Urban Mass transit Point to Point Distributed Power Distributed Power Distributed Power Distributed Power Distributed Power Speed 200 ~350 km/h >250 km/h High Speed Moderate No. of passengers Vehicles with high compressive strength Speed up to160 km/h High number of passengers PPHPD Passsenger per hour per direction Vehicles with high compressive strength High Acceleration Speed up to 100 km/h Very high no. of passengers up to 15,000-80,000 PPHPD Light weight vehicles * Includes passenger amenities High Acceleration Speed up to 100 km/h Moderate no. of passengers up to 5,000-25,000 PPHPD Light weight vehicles High Acceleration Speed up to 100 km/h Moderate / Low no. of passengers up to 5,000-16,000 PPHPD Light weight vehicles Page 3 Septermber 2008 Industry Sector, Mobility Division
4 Types of EMUs Velaro E 350 max. speed (kph) ICE Velaro RUS Velaro CN 160 Desiro ML ICE T Venturio UK Venturio 120 Desiro Classic Desiro UK ICE and ICE T are registered trademarks of Deutsche Bahn AG. average distance between stops (km) 50 Page 4 Septermber 2008 Industry Sector, Mobility Division
5 Types of EMUs DESIRO UK DESIRO Classic, Slovenia DESIRO OΣE, Greece DESIRO ET ERL, Malaysia Page 5 Septermber 2008 Industry Sector, Mobility Division
6 Types of EMUs ICE 1 ICE 2 ICE TD ICE 3 Page 6 Septermber 2008 Industry Sector, Mobility Division
7 Types of EMUs Velaro CN China Velaro E Spain Velaro RUS Russia Page 7 Septermber 2008 Industry Sector, Mobility Division
8 EMU a revolution for main line as well Technology: Locomotive Driven Trains Push-Pull Train Evolution (e.g. Thyristor GTO) Revolution PP EMU EMU Evolution (e.g. 350 km/h, Compliance with TSI, GTO IGBT, ETCS) Velaro RUS Distributed Traction (EMU) Velaro E Velaro CN ICE 3 Evolution Power Car (Push-Pull PP) ICE V ICE 1 Evolution ICE 2 Revolution ICE is a registered trademark of DB AG Page 8 Septermber 2008 Industry Sector, Mobility Division
9 Equipment & Sub-systems of an EMU Propulsion Equipment Transformer Traction Converter Traction Motor Micro Processor Control Auxiliary Power Supply Equipment Auxiliary Converter Battery Battery Charger Roof Equipment Pantograph Breaker (VCB or HSCB) Lightning Arrestor, CT, PT Train Integrated Management System Central Control Unit Compact I/Os, SIBAS KLIPs etc. Brake Electronic Control Unit Carbody Carbody Shell Seats, Windows Automatic & Semi Automatic Couplers Gangways etc. Doors Door Leaves Door Drives. Passenger Information & Cab Equipment Master Controller, Driver s display Passenger Information & communication system Saloon Equipment Lights, fans Bogie Complete & Brake Equipment Bogie Frame, Wheels & Axles Primary & Secondary Suspension etc. Parking Brake Brake Shoe Air Compressor Cab & Saloon Air-Conditioning Equipment Compressor Condenser & Evaporator Unit Parking Brake Ducting & Diffusers Page 9 Septermber 2008 Industry Sector, Mobility Division HVAC Unit
10 Equipment & Sub-systems of an EMU Couplers, driving cab Vehicle body Interiors Bogie Traction converter Control Unit Traction motor Page 10 Septermber 2008 Industry Sector, Mobility Division
11 Current International Technology of Car Body Material Comparison from Customer s Point of View Steel Stainless Steel Aluminium*) Cost of Material ++ - Labour Cost Integration of Interfaces for fastening Weight of Carbody Structure - + Corrosion Resistance Maintenance + - Industrial Design/Complex Shapes Surface Coating/Painting - + Fire Resistance w/o additional Insulation Heat Insulation *) Large Extrusions Page 11 Septermber 2008 Industry Sector, Mobility Division
12 Current International Technology of Car Body Material Comparison Stainless Steel, Aluminium Amount of repair work Relationship material cost/manufacturing cost Coating Fire resistance meeting point Investment costs of manufacturing Low weight construction Strength Amount of maintenance work Page 12 Septermber 2008 Industry Sector, Mobility Division
13 Current International Technology of Bogies Bogie Key Decision factor of operators Safety Safety against derailment stability up to maximum speed Comfort Ride comfort Acoustics Speed Travel time Wear Wheel profile wear, track wear Lifetime prediction Page 13 Septermber 2008 Industry Sector, Mobility Division
14 Current International Technology of Bogies Bogie Cost in operation low portion of original equipment Bogies account for 15 % of railway vehicle value! OPERATOR high portion in total cost of operation Roughly 40 % of LCC Costs of railway vehicles are caused by Bogies! 85% 15% 40% 60% Carbody, Traction, Interior, etc. Carbody, Traction, Interior, etc. Bogie Bogie Page 14 Septermber 2008 Industry Sector, Mobility Division
15 Current International Technology Electrical components Auxiliary converter Sibac traction converter Sibas 32 Traction Motor 1TB2016 IGBT Based Traction Converter and Auxiliary Converter Microprocessor based traction, braking and train control system (sensor less operation, no speed or temperature sensor) Regenerative braking for energy recovery Extensive diagnostic memory for failure analysis State-of-the-art microprocessor based Train Management Systems Self ventilated 3 phase asynchronous traction motors Extensive audio visual Passenger Information systems HVAC Units Page 15 Septermber 2008 Industry Sector, Mobility Division
16 Siemens Contribution in EMUs Development and evolution in recent years Experience + Innovation = Desiro ML Vehicle Platform 2008 Siemens as supplier for traction; traction with GTOs CP 2300 / 2400 Portugal 1992 Siemens builds partially under licence; traction with GTOs Desiro ET Malaysia Full Siemens vehicle; traction with high voltage GTOs 2000 Desiro EMG 312 Slovenia 2001 Full Siemens vehicle; traction with IGBTs 2004 Desiro ML Platform Desiro OSE Greece - various types of traction: Diesel or electrical - various train configurations: 2 to 4 cars - various entrance heights: 600, 800, 1000 mm Page 16 Septermber 2008 Industry Sector, Mobility Division
17 Mumbai EMUs Current Stock with DC technology Brief Details of Network Length Route km over 302 Number of stations More than lines Western, Central & Harbour Caters to 6.1 Mio commuters every day Only network in India with 1.5 kv DC (conversion to 25kV in progress) Number of trains 2200 (approx.) Brief Details of existing DC Stock 9 car rakes 200 (approx.) Page 17 Septermber 2008 Industry Sector, Mobility Division
18 Mumbai EMUs Need for AC/DC EMUs Conversion from 1.5 kv DC to 25 kv AC system voltage Changeover from DC traction to AC traction technology Existing 1.5 kv DC DC Motors high Maintenance resistor switch bank, DC motors no regeneration jerky low adhesion no slip/slide control high power loss in starting Intermediate 1.5 kv DC and 25 kv AC 3 phase AC motors low maintenance converter controlled AC motors regeneration jerk free improved adhesion slip/slide control ease of diagnostics Future 25 kv AC power supply 3 phase AC motors low maintenance converter controlled AC motors regeneration jerk free improved adhesion slip/slide control ease of diagnostics Page 18 Septermber 2008 Industry Sector, Mobility Division
19 EMU Mumbai Scope of supply Major items Propulsion Equipment Transformer Traction Converter Traction Motor Micro Processor Control Auxiliary Power Supply Equipment Auxiliary Converter Battery Charger Roof Equipment Pantograph Breaker (VCB & HSCB) Lightning Arrestor, Current Transformer Voltage transformer Brake resistor AC DC changeover switch Train Integrated Management System Central Control Unit (CCU) SIBAS KLIPs etc. Brake Electronic Control Unit (BECU) Brake Equipment Parking brake Air Compressor Main compressor, air dryer, air filter Cab & Saloon Air-Conditioning Equipment Ventilation system (only in MRVC) Saloon Equipment Lights Fans Passenger Information & Cab Equipment Master Controller, Driver s display Passenger Information & communication system Driver s desk, Head light, tail light Cables & accessories Power cables Control cables Intervehicle jumpers & couplers Fire detection and extinguishing system Page 19 Septermber 2008 Industry Sector, Mobility Division
20 Mumbai EMUs Solution by Siemens Entire Propulsion and Electrical Package Transformers Auxiliary converter Traction motors Traction Converter Driver Desk Roof Equipment Passenger Information System (Example pictures) Page 20 Septermber 2008 Industry Sector, Mobility Division
21 EMU Mumbai Critical Requirements of Order Design to consider super dense crush load of 16 people/m 2 Equipments to withstand humid and salty environment with excessive vibrations Flood proofing of underslung equipment up to 760 mm of height above rail level. Design to consider 25% choking of air filters and radiator fins. Introduction of fresh air in cars to minimise Carbon-dioxide levels Regeneration of approx 30% energy Reduced specific energy consumption Siemens fulfils all these requirements Page 21 Septermber 2008 Industry Sector, Mobility Division
22 Siemens Local presence in India For EMUs Nashik: Local Engineering and Manufacturing of Traction Converters and Auxiliary Converters Kalwa: Local Engineering and Manufacturing of Traction Motors Local Service Support for Maintaining the fleet Page 22 Septermber 2008 Industry Sector, Mobility Division
23 Mumbai EMUs Technical data Technical Data Year Number of cars Power system AC 25/50 + DC 1.5 kv/hz Maximum power at wheel kw Maximum speed 100 kmph Weight t Track gauge 1676 mm Seats Numbers to be built Page 23 Septermber 2008 Industry Sector, Mobility Division (3-car units)
24 EMU Mumbai Train Disposition Page 24 Septermber 2008 Industry Sector, Mobility Division
25 Mumbai EMUs Principal Circuit Diagram DTC MC TC AC 25kV 50Hz DC 1.5kV DTC: Driving Trailer Coach MC: Motor Car TC: Trailer Coach TU: Transformer Unit TCU: Traction Converter Unit ACU: Auxiliary Converter Unit BR: Brake Resistor MAC: Main Air Compressor AAC: Auxiliary Air Compressor F: Fans TU 1 BR TCU ACU Battery AC 141V; 50 Hz 8 Lights Emergency 26 Ligths 26 Fans DC 110V F 8 Lights Emergency 26 Ligths 26 Fans F 3 3 M 3 M 3 M M 3 M 3AC 425V 50 Hz M 3 MAC AAC 8 Lights Emergency 26 Ligths 26 Fans F Page 25 Septermber 2008 Industry Sector, Mobility Division
26 Mumbai EMUs Most Important Features Dual Voltage operation Force air cooled IGBT based Traction converter and Auxiliary converter. Improvement in passenger comfort by ventilation units. Low energy consumption and low life cycle costs. High reliability and service friendly. Self-ventilated three-phase asynchronous traction motors, low maintenance. Train and traction control system by microprocessor based Sibas 32. Bus system and train communication network (TCN). Passenger information system. Up to 15 / 18 car formation. Load sensing to adjust braking. Fire detection and extinguishing system. Extensive diagnostic memory. Improved illumination for better visibility inside vehicles Ergonomic driver s desk Page 26 Septermber 2008 Industry Sector, Mobility Division
27 Mumbai EMUs Current Status 3 Trains in passenger service in Western Railway 11 Trains in passenger service in Central Railway Production of series trains in progress at ICF Page 27 Septermber 2008 Industry Sector, Mobility Division
28 Installation at ICF Car body Driving Trailer Car (DTC) Page 28 Septermber 2008 Industry Sector, Mobility Division
29 Installation at ICF Car interiors Ventilation system, fans, lights Page 29 Septermber 2008 Industry Sector, Mobility Division
30 Installation at ICF VCB LA Pantograph CT Brake resistor Motor coach - Roof Page 30 Septermber 2008 Industry Sector, Mobility Division
31 Installation at ICF Traction Converter Electrical Control Cabinet Auxiliary Converter Motor coach HT compartment Page 31 Septermber 2008 Industry Sector, Mobility Division
32 Installation at ICF Complete train Page 32 Septermber 2008 Industry Sector, Mobility Division
33 EMU a revolution for main line as well Technology: Locomotive Driven Trains Push-Pull Train Evolution (e.g. Thyristor GTO) Revolution PP EMU EMU Evolution (e.g. 350 kph, Compliance with TSI, GTO IGBT, ETCS) Velaro RUS Distributed Traction (EMU) Velaro E Velaro CN ICE 3 Evolution Power Car (Push-Pull PP) ICE V ICE 1 Evolution ICE 2 Revolution Move from suburban travel to Main line with distributed power ICE is a registered trademark of DB AG Page 33 Septermber 2008 Industry Sector, Mobility Division
34 Thank You for your attention Page 34 Septermber 2008 Industry Sector, Mobility Division
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