Propulsion System
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Transportation Systems Group Technology
„Modern electrical propulsion systems for rolling stock“
Lausanne, September 2005 Andreas Fuchs TS GT DP
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 1
Transportation Systems
Modern electrical propulsion systems for rolling stock
Group Technology
1. Comparison of DC and AC traction machines 2. System aspects and general requirements for traction converters 3. State of the art IGBT-technology, an overview 4. The traction converter family SIBAC® ¾ Modular Building Blocks ¾ SITRAC® improved traction control system ¾ Railway vehicles with IGBT-traction converters (examples) 5. Conclusion
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 2
Transportation Systems
Motorcar Marienfelde-Zossen
Group Technology
Construction year Number of units Supply voltage Continuous power Top speed
Copyright © Siemens AG 2005. All Rights Reserved.
1903 1 AC Three phase 2.2 MW 210 km/h
TS GT DP, Fuchs
Folie 3
Transportation Systems
Comparison of DC- and AC-Traction Motor
Group Technology
Traction drive of: rated power: maximum torque: maximum speed: mass (without gear): moment of inertia:
E103: 1230 kW at 1520 min-1 8530 Nm for 5 minutes 1600 min-1 3550 kg 120 kg m2
E152: 1633 kW at 2280 min-1 6840 Nm constantly 4000 min-1 2800 kg 18,4 kg m2
1200
910
Dimensions:
870
Copyright © Siemens AG 2005. All Rights Reserved.
855
TS GT DP, Fuchs
Folie 4
Transportation Systems
High performance hollow shaft drive
Group Technology
Motor 1TB2824 voltage current rated power max. torque
Copyright © Siemens AG 2005. All Rights Reserved.
= 1840 = 590 = 1630 = 10500
TS GT DP, Fuchs
V A kW at 1485/min Nm
Folie 5
Traction converters have to work at various catenary voltages and have to cope with a wide output power range
Transportation Systems Group Technology
Characteristic, Parameter
Typical range
•
Catenary voltage
DC 750 V ... 3000 V AC 15 kV ... 25 kV
•
Power of the propulsion system
0,5 ... 2.0 (3,5) MW
•
Reliability
1000 Fit / IGBT + driver (1 Fit: 1 failure / 109 h)
•
Failure behaviour
Restricted to converter module
•
Mechanical construction
• •
Copyright © Siemens AG 2005. All Rights Reserved.
Flat underfloor converter cubicle for EMU and Metro Switchgear cubicle or locomotives TS GT DP, Fuchs
Folie 6
Transportation Systems
Chopperless multi system converter with 6,5 kV IGBTs
Group Technology DC 3kV / 1.5kV LF ~3 M AC 15kV 16 2/3Hz
Ud
Cd
25kV / 50Hz
~3 M
4QC
Copyright © Siemens AG 2005. All Rights Reserved.
DC-Link
PWR
TS GT DP, Fuchs
Folie 7
Transportation Systems
IGBTs with different blocking voltages are offered by several semiconductor suppliers in a housing with the same footprint
Group Technology
Module design of a 1.7 kV – 1200 A IGBT
Module design of a 6.5 kV – 600 A IGBT
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 8
Transportation Systems
Typical variation of the base plate temperature during the lifetime of an IGBT in a traction converter (EMU operation)
Group Technology
Power semiconductor devices, due to the operation of railway vehicles, have to withstand a high number of load cycles during lifetime
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 9
Transportation Systems
Thermal cycling capability of the base plate and the bondwires (traction IGBT)
Group Technology
Traction IGBT Introduced technologies: • Al SiC-base plate • Polyimid passiviation on the chip surface Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 10
Transportation Systems Group Technology
The traction converter family SIBAC® Compact inverter Up to 3 kV line voltage Air cooled or water cooled
IGBT Building Block SIBAC® BB Up to 3 kV line voltage Air cooled or water cooled
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 11
Transportation Systems
Typical output power limits of SIBAC® IGBT traction converters
Group Technology
Power Capability of IGBT-Converter-Modules
4
3-parallel-IGBTs
3,5
max. possible mech. Power [MW]
3
2-parallel-IGBTs
BB - forced air (BB 750 F, BB 1500 F)
2,5
BB - water (BB 1500 W , BB 3000 W )
2
2-parallel-IGBTs
CC - forced air (CC 750 F, CC 1500 F)
1,5
single-IGBT 1
single-IGBT
CC - water (CC 1500 W , CC 3000 W )
0,5
0 0
750
1500
2250
3000
3750
intermediate-circuit- or line-voltage [V] Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 12
Transportation Systems
Overview SITRAC: Siemens Traction Control
Group Technology Requirements of vehicle Inverter
Motor
Parameters
General
Functions
Projectspecific
STDSG / ZR
I/O
ICU / Application-SW
Power stage
Inverter functions (e. g. protection)
Control functions
General drive functions
SITRAC functions
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 13
Transportation Systems
SITRAC PWR block diagram of the control structure without speed encoder
Group Technology T ref
Torque control
+ R
T R ref
I Sq ref +
S
R
Rotorflux control
VD
Control of stator mesh = OFT (Optimal flux tracking)
I Sd ref
2
3
Inverse inverter model
gate signals
6
Inverter
I S mod 3
R
R
S
T Speed and parameter adaption
Motor model
_ +
IS
mod
IS
2
3
estimated parameters Motor
estimated speed
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 14
Transportation Systems
Sitrac – Hardware Inverter control unit for the compact inverter
Group Technology
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 15
Transportation Systems Group Technology
Electric Multiple Unit RENFE TREN 2000 Supply system: Train configuration: Rated power: Traction converter:
DC 3 kV 2 ... 5 sections, 50 % ... 60 % driven axles 0.6 MW / converter, 1C2M IGBT compact converter CC 3000 W
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 16
Transportation Systems
Electric Multiple Unit RENFE TREN 2000
Group Technology
Compact inverter SIBAC®
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 17
Transportation Systems
EuroSprinter Class 189 four-system locomotive for German Rail
Group Technology
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 18
Transportation Systems Group Technology
Chopperless multi system converter with 6,5 kV IGBTs DC 3kV / 1.5kV LF ~3 M AC 15kV 16 2/3Hz
Ud
Cd
25kV / 50Hz
~3 M
4QC
DC-Link
PWR
EuroSprinter Class 189 four-system locomotive for German Rail
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 19
Transportation Systems
SIBAC® Building Block
Group Technology
EuroSprinter Class 189 four-system locomotive for German Rail Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 20
Transportation Systems
Traction converter of the class 189 locomotive
Group Technology
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 21
„Modern electrical propulsion systems for rolling stock“
Lausanne, September 2005 Andreas Fuchs TS GT DP
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 1
Transportation Systems
Modern electrical propulsion systems for rolling stock
Group Technology
1. Comparison of DC and AC traction machines 2. System aspects and general requirements for traction converters 3. State of the art IGBT-technology, an overview 4. The traction converter family SIBAC® ¾ Modular Building Blocks ¾ SITRAC® improved traction control system ¾ Railway vehicles with IGBT-traction converters (examples) 5. Conclusion
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 2
Transportation Systems
Motorcar Marienfelde-Zossen
Group Technology
Construction year Number of units Supply voltage Continuous power Top speed
Copyright © Siemens AG 2005. All Rights Reserved.
1903 1 AC Three phase 2.2 MW 210 km/h
TS GT DP, Fuchs
Folie 3
Transportation Systems
Comparison of DC- and AC-Traction Motor
Group Technology
Traction drive of: rated power: maximum torque: maximum speed: mass (without gear): moment of inertia:
E103: 1230 kW at 1520 min-1 8530 Nm for 5 minutes 1600 min-1 3550 kg 120 kg m2
E152: 1633 kW at 2280 min-1 6840 Nm constantly 4000 min-1 2800 kg 18,4 kg m2
1200
910
Dimensions:
870
Copyright © Siemens AG 2005. All Rights Reserved.
855
TS GT DP, Fuchs
Folie 4
Transportation Systems
High performance hollow shaft drive
Group Technology
Motor 1TB2824 voltage current rated power max. torque
Copyright © Siemens AG 2005. All Rights Reserved.
= 1840 = 590 = 1630 = 10500
TS GT DP, Fuchs
V A kW at 1485/min Nm
Folie 5
Traction converters have to work at various catenary voltages and have to cope with a wide output power range
Transportation Systems Group Technology
Characteristic, Parameter
Typical range
•
Catenary voltage
DC 750 V ... 3000 V AC 15 kV ... 25 kV
•
Power of the propulsion system
0,5 ... 2.0 (3,5) MW
•
Reliability
1000 Fit / IGBT + driver (1 Fit: 1 failure / 109 h)
•
Failure behaviour
Restricted to converter module
•
Mechanical construction
• •
Copyright © Siemens AG 2005. All Rights Reserved.
Flat underfloor converter cubicle for EMU and Metro Switchgear cubicle or locomotives TS GT DP, Fuchs
Folie 6
Transportation Systems
Chopperless multi system converter with 6,5 kV IGBTs
Group Technology DC 3kV / 1.5kV LF ~3 M AC 15kV 16 2/3Hz
Ud
Cd
25kV / 50Hz
~3 M
4QC
Copyright © Siemens AG 2005. All Rights Reserved.
DC-Link
PWR
TS GT DP, Fuchs
Folie 7
Transportation Systems
IGBTs with different blocking voltages are offered by several semiconductor suppliers in a housing with the same footprint
Group Technology
Module design of a 1.7 kV – 1200 A IGBT
Module design of a 6.5 kV – 600 A IGBT
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 8
Transportation Systems
Typical variation of the base plate temperature during the lifetime of an IGBT in a traction converter (EMU operation)
Group Technology
Power semiconductor devices, due to the operation of railway vehicles, have to withstand a high number of load cycles during lifetime
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 9
Transportation Systems
Thermal cycling capability of the base plate and the bondwires (traction IGBT)
Group Technology
Traction IGBT Introduced technologies: • Al SiC-base plate • Polyimid passiviation on the chip surface Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 10
Transportation Systems Group Technology
The traction converter family SIBAC® Compact inverter Up to 3 kV line voltage Air cooled or water cooled
IGBT Building Block SIBAC® BB Up to 3 kV line voltage Air cooled or water cooled
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 11
Transportation Systems
Typical output power limits of SIBAC® IGBT traction converters
Group Technology
Power Capability of IGBT-Converter-Modules
4
3-parallel-IGBTs
3,5
max. possible mech. Power [MW]
3
2-parallel-IGBTs
BB - forced air (BB 750 F, BB 1500 F)
2,5
BB - water (BB 1500 W , BB 3000 W )
2
2-parallel-IGBTs
CC - forced air (CC 750 F, CC 1500 F)
1,5
single-IGBT 1
single-IGBT
CC - water (CC 1500 W , CC 3000 W )
0,5
0 0
750
1500
2250
3000
3750
intermediate-circuit- or line-voltage [V] Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 12
Transportation Systems
Overview SITRAC: Siemens Traction Control
Group Technology Requirements of vehicle Inverter
Motor
Parameters
General
Functions
Projectspecific
STDSG / ZR
I/O
ICU / Application-SW
Power stage
Inverter functions (e. g. protection)
Control functions
General drive functions
SITRAC functions
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 13
Transportation Systems
SITRAC PWR block diagram of the control structure without speed encoder
Group Technology T ref
Torque control
+ R
T R ref
I Sq ref +
S
R
Rotorflux control
VD
Control of stator mesh = OFT (Optimal flux tracking)
I Sd ref
2
3
Inverse inverter model
gate signals
6
Inverter
I S mod 3
R
R
S
T Speed and parameter adaption
Motor model
_ +
IS
mod
IS
2
3
estimated parameters Motor
estimated speed
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 14
Transportation Systems
Sitrac – Hardware Inverter control unit for the compact inverter
Group Technology
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 15
Transportation Systems Group Technology
Electric Multiple Unit RENFE TREN 2000 Supply system: Train configuration: Rated power: Traction converter:
DC 3 kV 2 ... 5 sections, 50 % ... 60 % driven axles 0.6 MW / converter, 1C2M IGBT compact converter CC 3000 W
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 16
Transportation Systems
Electric Multiple Unit RENFE TREN 2000
Group Technology
Compact inverter SIBAC®
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 17
Transportation Systems
EuroSprinter Class 189 four-system locomotive for German Rail
Group Technology
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 18
Transportation Systems Group Technology
Chopperless multi system converter with 6,5 kV IGBTs DC 3kV / 1.5kV LF ~3 M AC 15kV 16 2/3Hz
Ud
Cd
25kV / 50Hz
~3 M
4QC
DC-Link
PWR
EuroSprinter Class 189 four-system locomotive for German Rail
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 19
Transportation Systems
SIBAC® Building Block
Group Technology
EuroSprinter Class 189 four-system locomotive for German Rail Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 20
Transportation Systems
Traction converter of the class 189 locomotive
Group Technology
Copyright © Siemens AG 2005. All Rights Reserved.
TS GT DP, Fuchs
Folie 21
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