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AC Traction Inverters

Presentation forBombardier

byQingdao Zener Electric Co., Ltd

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Introduction to the parent company:GNDC CO., LTD

Company profileSince 1977 GNDC CO., Ltd has focused on

manufacturing quality products related to power electronic field. Started from our first product –thyristor triggering board, we have produced tens of thousands of DC motor drives, temperature control units, UPS’s, power supplies, various assembled PCB’s…. in the past ages .

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Introduction to the parent company:GNDC CO., LTD

Our current business plan is to focus on designing and manufacturing the following :

1. Frequency inverters for AC motor drives2. Active front ends for 4-Q converters3. Active filters for better electricity quality4. Traction inverters for light rail trains5. High power semiconductor stacks for

industrial and military use

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Introduction to the parent company:GNDC CO., LTD

Our visionCreating products that will help save energy and promote better living and help the environment.

Our missions1. We strive for innovative technologies and products2. We are committed to grow with our customers3. We need to create an environment where ideas

are encouraged, recognized and rewarded. 4. We want to help our employees grow personally

and professionally.

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Introduction to the parent company:GNDC CO., LTD

Quality AssuranceExcellence in quality and reliability is our primary goal.

We believe it is more economical and efficient to prevent defects from occurring in advance than correcting them afterwards, we start with product design and beingstressed throughout the entire manufacturing cycle. Quality assurance is responsible for all phases of quality from design evaluation through material procurement, in process inspection during the manufacturing cycle, product test, shipping and field reliability tracking.We are an ISO9001 certified manufacturer.

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Introduction to the parent company: GNDC CO., LTD

AffiliatesPan Hao Co., Ltd

(www.panhao.com)Semcor (Qingdao) Electronic Co., Ltd

(www.semcor.com.cn)Qingdao Zener Electric Co., Ltd

(www.zener.com.cn) Qingdao Zencon Electric Co., Ltd

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Light Rail Traction

The Zener Traction Drive System (ZTDS)

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Light Rail

600 or 750VDC supply

City use

Frequent stop / start

Typically 30 tonne / unit

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Introduction

The use of inverters is well known, but there are special requirements for rail

Electrical

Mechanical

System

All these must be met to make a reliable system

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Introduction

Electrical Requirements…Powered from DC overhead line or 3rd rail

Wide voltage range, typically –30% to +20%

Large, high energy transients on the DC supply

Interface to the train system

Torque control by steps

Large overload capacity

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Introduction

Mechanical Requirements…Space is always a problem on a train

Compact design essential

Equipment must withstand shock and vibration

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Introduction

Other System Requirements…High reliability is essential

Running costs must be minimized by efficient energy use

Capital cost must be as low as possible

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The System

Slow charge circuit

-

+

RC

Overhead line

LLightning Arrestor

Pantograph

Regenbraking

Resistive braking

Circuit breaker

INDUCTIONMOTOR

Track return circuit

Rectifiersub-station

750VDC Nominal

(20kA short circuit)

IGBTINVERTER

Distributed L, RDistributed L, R

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Technology

Power semiconductor (IGBTs, diodes) sub-systems

Allows 150% and 200% overload

Control system specially designed by Zener for traction drive applications

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International Technical Standards Compliance

Most Commonly applied standard is

International Electrotechnical Commission (IEC) standard

1287-1 Power converters installed on board rolling stock

The equipment presented here meets this and other standards.

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Power sourceSupply voltage range for contentious operation -30% to +20%. For a 750VDC system this is 525 -900V

Low voltage limit is necessary for emergency operation of the railway when some of the track side power supplies (rectifier sub-stations) are not working

High voltage limit is to allow the use of energy saving regenerative braking with the least use of wasteful resistive or mechanical braking

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Electrical TransientsHigh inductance in overhead wire (~1.5mH/km)

High fault currents possible

Large stored energy (0.5 x L x I2)

Proper design for transient voltages is essential for a reliable system

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Electrical Transients…

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Interface to the train controls systemZTDS provides two kind of interface

24VDC control interface using relay contacts and electronic relay "coils" that allows control of the driving or braking torque step as well as signalling of fault conditions

Industry standard MODBUS serial communications protocol

Allows access to a wider range of control features and reporting of operating conditions including fault status, currents, voltages and power measurements in real time

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ZTDS Control SystemHigh performance Texas Digital Signal Processor (DSP)

Driving / braking in multiple steps

Slow charge control for inverter DC link

2 line LCD display & keypad for testing / maintenance and parameter setting

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ZTDS Control SystemRS-485 serial interface (MODBUS protocol)

Relay contacts for status signals

Highly reliable hardware

Can drive two AC traction motors in parallel -Reduce the overall cost

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Outline

The traction application – mechanical overviewTraction motor environment - bogie constructionInduction motor performanceTorque productionDecoupling flux and torqueSensorless operationControl topology, description

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Traction requirements

The traction system needs to provide sufficient force parallel to the rail (tractive effort) for:

AccelerationClimbing slopesFrictionWindage

A regenerative capability is normally required for energy efficiency

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Light Rail Bogie

Brake disc

AC traction motor

Gearbox

AC traction motor

Figure 2 Light rail bogie

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Light Rail Bogie – from below

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Under vehicle

No spare space!

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Wheel and Rail

Tractive effortF = Torque x radius

Maximum tractive effortF = μ x axle weight

Axle weight

Reaction force on rail

Torque applied by traction drive

μ = coefficient of adhesion

Figure 1Basic Forces

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Advantages of AC TractionMore rugged traction motors

Environment is very harsh - vibration, shock, waterImpact on the motor case, obstruct ventilation openings etc.

Low maintenanceNo brushgearUsually no ventilation openings

Multiple motors may be driven by one inverterEconomy

Improved wheel slip performance conditions

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Challenges of AC Traction

More complex controlDigital Signal Processors (DSP) allow complex control structures to be implemented economically and reliably

Speed sensor usually required on the motorLowers reliabilityAdds costTakes space

Speed-sensorless control can avoid this!

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Speed-sensorless control

Induction Motors

Inverter switches(6)

Pulse Width Modulator

Voltage vector generatorWith 15% 3rd harmonic

Voltage controlFlux control

Field weakening control

Torque controller(PI control)

I

Overhead wireDC supply

Torque reference

L-C Filter

Id,qId,q

Iq(Itorque)

VBus

Id,q

Φ VrefMagnitude

Freq

Vref

Freq

Operating region limiting functions

Figure 4 Sensorless control scheme

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Torque Production – Induction Machine3-phase

AC supply 1. Rotating magnetic field

2. Current induced in rotor conductors

4 pole machine shown

N

N

S

S

N

N

S

S

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Induction Motor Characteristics

Torque

Motor shaft speed

+

(driving)

-(regeneration)

Synchronous speed

Shaft speed = stator frequency

No rotor current

No torque produced

Breakdown torque

Breakdown torque

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Induction Motor Characteristics

Constant torque Constant power Reduced power

Figure 3 Induction machine operating regions

Speed

Breakdowntorque

Rated torque

Torque

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DecouplingDecoupling

Separates torque and magnetic flux production by “untangling” the stator current information

Simplifies the control structure(so that it can be like a DC machine)

Key element of field oriented control.

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Decoupled Control

By definition:

Decoupled control = separate flux and torque control

By implication:Separate (constant) flux control→ decoupled control → torque control

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Typical SpecificationInput voltage 450-900VDC

Maximum operating input voltage 1200V

Exceptional peak input voltage 1500V

Output voltage 480V RMS

Output current Depending on actual requirement

cosϕ 0.85 to 0.9

Output frequency 0.5Hz to 150Hz

Overload Depending on actual requirement

Switching frequency 1 kHz

Ambient temperature 25 to +40°C

Capacitors lifetime -100,000 hours at 1000V at 70°C without over voltages

Cooling fluid Filtered air

Altitude <1200m above sea level

Humidity Non-condensed 85%

Mechanical protection IP00

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Some photos about ZTDS

Our ZTDS applied in Dalian light rail train

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The DSP control for ZTDS

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The simulation load for ZTDS development

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What is our latest development?

Now we can supply the traction inverter for the input voltage 1500VDC which is widely used for light rail train and under-ground subway system.

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What else we can supply

Emergency ventilation inverters, battery chargers….Please see our sales reference below:

Qty Description Ratings Fleet Operator Zener Partnumber

386 Emergency ventilation inverter and output transformer

Input: 110Vdc Output: 55Vac/45Hz/3 ph feeding

step-up transformer.Inverter based on MSC-3R30

New Delhi DMRC ZM00304

208 Emergency ventilation inverter and output transformer

Input: 110Vdc Output: 55Vac/45Hz/3 ph feeding

step-up transformer.Inverter based on MSC-3R30

Hong Kong MTRC ZM00304

110 Battery charger and LV power supply

Input: 600Vdc (from overhead line) Output 24Vdc / 90A

Yarra Trams, Z1/Z2 Class passenger trams operating in Melbourne, Australia

Y0037

22 Battery charger and LV power supply

Input: 415V/50Hz/3-ph/PWM (unfiltered from inverter)

Output 24Vdc / 120A

V/Line passengers, Sprinter DMU intercity railcars operating in regional Victoria, Australia

ZM00100

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Sales reference further

48 Air conditioning inverters 10A and 24A

Input: 415Vac 50Hz/3-phOutput: 415V/50Hz 10A

(ZM00044) and 24A (ZM00045)

Queensland Rail (QR)Rockhampton to Brisbane Tilt

Train passenger vehicles

ZM00044 & ZM00045

280 Emergency ventilation inverter and output transformer

Input: 120VdcOutput: 61Vac/35Hz feeding

step-up transformer

Millennium passenger trains operating in metropolitan Sydney, Australia

ZM00308

900 Emergency ventilation inverter

Input: 120VdcOutput: 55V/21Hz supplying

fan motor

Tangara and K Class passenger trains operating in metropolitan Sydney, Australia

ZM00300

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Battery Chargers for Rail and Tram Vehicles

．Custom designed and manufactured to the highest quality. ．Comply with international railway / rolling stock standards. ．Type testing to IEC 61287-1:1995-07 Power converters installed on board rolling stock Part 1:

Characteristics and test methods. ．Proven reliability – references available on request. Lifetime support & back up. The Sprinter Battery Charger was designed to provide a significant increase in capacity, replacing an earlier Zener model. The new design achieved an improvement in output from 70A to 120A with no increase in weight or footprint. In addition, a number of new enhancements were incorporated, including limited operation under phase loss conditions, large illuminated current and voltage displays and improved dynamic performance.

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Battery Chargers for Rail and Tram Vehicles

The Z1 / Z2 Tram Battery Charger was designed to operate from the tram 600Vdc overhead line. A special requirement of the tram operator was that the charger had to withstand inadvertent connection to the rail overhead line – 1500V – at rail and tram crossing points, without failure. The winning design included a 2000V continuous withstand capability with automatic restart, eliminating the need for driver intervention. Over 100 units were supplied and in seven years of operation, no unit has requiredservice.

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Thank you for your attention

Qingdao Zener Electric Co., LtdTel: 0532-88701773

Fax:0532-88701478

http://www.zener.com.cn