TransportationConverter SolutionsEfficient components from REO

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Content:

•Fromdevelopmenttofinalproduct.............................................................. P.7

•Factors-pollution,humidity,acoustics,position,fire,overvoltagecategory... P.8

•Materialselection.......................................................................................... P.9

•Analysistechniques,normsandstandards................................................... P.10

•Fullprototype.............................................................................................. P.12

•Typetest..................................................................................................... P.12

•Componentsforauxiliaryconverter............................................................. P.15

•OverviewofProducts................................................................................. P.16

•Inductiveandohmiccomponentsforthemaindrive................................... P.18

•OverviewofProducts.................................................................................. P.20

•REOplus-globalqualityandlocalservice.................................................... P.22

•Productionsitesandsalesoffices................................................................. P.24

•Shortdescriptionofeachsite...................................................................... P.25

•Water-cooledcomponentsforrailway......................................................... P.27

•Water-cooledchokes................................................................................... P.28

•Water-cooledresistors................................................................................. P.30

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TransportationConverter Solutions Efficient components from REO

Precision

Safety

Robustness

Reliability

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Rail,High-Speedtrainsormetroliners,oneofthesafestmeansoftransport,isadvancingintoevermoreremotecornersoftheEarth.Therailwaynetworkisconstantlyexpanding,helpingcountriescometogether,andisanenginedrivingeconomicgrowthandprosperity.

REOhassetitselfthetaskofcontributingtomakingtrainseversafer,todayandinthefuture.Withmainsfilters,inductorsandtransformers,weensurethatEMCproblemsareeliminateddirectlyatthesource.Theresultisthatvoltagechanges,short-circuitsandanyotherproblemsassociatedwithelectricitycannotpresentahazardtorailwaypersonnelorpassengers.Compliancewithinternationalnorms,theexploitationofthelatesttechnologiesanddecadesofexperiencemakeREOastrongpartner.

REO manufactures components for two main areas of railway technology:

A) Auxiliary converters: • Transformers from 16 2/3 up to 30 kHz• Boost-/Buck converters• EMC-Filter• Sinusoidal filter• Current transformers• Charging resistors from IP 00 - IP 65, available for watercooled systems, too.

B) Main drive:• EMC HV chokes• Leakage transformers• Flow Controls• Fe-chokes• Absorption circuit chokes• Components for onboard power supplies• Damping resistors• Current transformers• Filter chokes

InitsCentreofCompetenceinBerlin,REOtodaydevelopsrailwayengineeringcomponentstomeettherequirementsofworldwiderailwayorganizationsand,thankstopartnershipswithcompaniesintheUSA,China,IndiaandGermany,theyareabletobemanufacturedquicklyandefficientlywiththehigheststandardsofquality.Inconjunctionwithitsworldwidesalesnetwork,REOcanrespondquicklyatanytime.

Withgreatattentiontomodernproductionmethods,efficientworkflow,closecooperationwithuniversitiesandtheconstantfurtherdevelopmentandimprovementofprocesses,everydayREOprovideselectricrailwaylinebuilderswithproductsthatcontributetothesafety,functionalityandglobalgrowthofrailtechnology.

WiththeIRIScertificationofthesubsidaryinBerlin/HennigsdorfandtheISOcertificationinChinaandtheU.S.,REOdemonstratesqualityatthehighestinternationalstandards.

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Content:

•Fromthedevelopmentstagetotheendproduct.................................P.7

•Influencingfactors-pollutiondegree,moisture,position,

firebehaviour,overvoltagecategory......................................................P.8

•Selectionofmaterials............................................................................P.9

•Analyticaltechniques,normsandstandardsapplied................... P.10,P.11

•Completeprototypeconstruction........................................................P.12

•Typetesting........................................................................................P.12

Keypoints Influence factors Material selection

Tailor-made components right up to the end product

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Key points

Allrailwaytechnologycomponents-fromtransformerstolineinductorsandfilters-aredevelopedtomeetthestandardorspecialrequirementsofourclients.Noproductcangointooperationwithoutthesefundamentallydefinedrequirements:

• Safety: Trainshavebeeninuseasameansoftransportformorethanacentury.Thedemandsplacedon materialsbecomeevergreater,inpacewithongoingtechnicaldevelopment.Toensurethatthe safetyandcomfortofpassengersarenotimpaired,everycomponentusedinatrainmustmeetthe currentnormsandstandards.Owntestsandaccreditedtestinglaboratoriesprovethesafetyofour components.

•Weight: Trainsarebeingusedevermorerapidlyandevermoreextensively,insufficientlyoptimized equipmentmeansstressonthetrain,fewerpersonscanbetransportedandspeedandeconomy isreduced.IntelligentmethodsinmaterialsselectionandFEM-calculationmeanthatREO componentsareofparticularlylowweight. • Space requirements: Manycomponentshavetobedevelopedinsuchawaythat,togetherwithotherproducts,theyfit intotheavailablespace.Theoptimaluseofspace,andcompliancewithspecifiedmechanicaland electricalrequirements,formthebasisofourdevelopmentwork.

• Costs: Theoptimizationofoperatingcostsplaysaparticularlyimportantroleinrailwayengineering.To remaincompetitive,trainmakershavetorationalizecostsbutwithoutendangeringpassenger safetyintheprocess. Withthelatestsoftware,simulationandtestingtechniques,weensurethatthenecessary developmentworkisalreadyoptimallyusedinadvance.

Tests/Analyses technologies Full prototype Type test Final product

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Influencing factors

Besidesunitsizeandweight,therearemanyotherfactorsthatinfluenceacomponent,suchas:

Environmental conditionsIfacomponentisusedontheoutsideofthetrain,thedegreeofpollutionitisexposedtoisanimportantfactor.Dirtcangetintocomponents,impairingtheirfunctionalityandshorteningtheirusefullifetime.REOcomponentscanbedesignedforapollutiondegreeofuptoPD4andatemperatureof-50°Corworse.TheclearanceandcreepagedistancesarerealizedaccordingtoDINEN50124-1.

MoistureWetnessandmoisture,inconjunctionwithtypicalrailwaycontaminationandhightemperatures,canimpairfunction.Ifmoisturegetsintoelectricalwindingsorcablingsystems,short-circuitsandthermaloverloadingmayoccur.Withtheaidofaspecialcoatingandvarioussealingtechniques,REOproductsachieveahighprotectionclassandareparticularlyresistanttodirt,moistureandotherenvironmentaleffects.

AcousticsEspeciallyinthefieldofrailwaytechnologyacousticsplaysagrowingrole.REOdevelopsandusestechnologies,processesandmaterialsthatallowtomeetandexceedtheacousticrequirementsandstandards(DINEN60076-10).Thus,evenlevelsbelow85dBsoundpressurelevelcanberealized.Asstandard,theairbornesoundismeasured,andifdesiredastructure-bornenoisecanbedone,too.

Position of equipmentThepositionofrailwaycomponentsplaysanequallyimportantroleintheirdesigncalculation.Factorslikeweightmanagementandtrainconstructionareimportantissues.

Preventive fire safetyThebehaviourofmaterialsinafireplaysacrucialroleinpassengersafety.Allmaterialsusedarepreparedincompliancewiththeapplicablenormsandaretestedbyaccreditedtestlaboratoriesfortheirbehaviourwhensubjecttoafireanditssideeffects.Thetestreportsandthecorrespondingdocumentationaremadeavailabletoclients.StandardssuchasEN45545,DIN5510andNFF16101areself-evident.

Protection grades:IP00 - IP65 Pollution level:PD1 - PD4

Fire protection standards: EN 45545, DIN 5510, NF F 16-101 / NF F 16-102

Tailor-made components

Choke,developedaccordingtocustomerspecificationsandusedunderthefloor.

Specialsiliconecoating

Forasinusoidalcurrent,andimprovedacoustics

Keypoints Influencefactors Materialselection

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Selection of materials

Theoptimizationofunitsizeandweightisdependentontheselectionofthecorematerialsandwindingmaterials.REOhasmanyyearsofexperienceinthemanufactureofinductorsandtransformersandcanselecttheoptimalmaterialsforaspecificproject.Directandfocussedanalysisoftherequiredmaterialpropertieshelpsminimizethecosts.

Thefollowingoptionsareavailable: • aluminium • copper • iron • amorphousandnanocrystallinematerials • carbonfibre-reinforcedplasticsandinsulatingmaterials

Inaddition,theselectedproductdesignhasasubstantialinfluenceonmechanicalandelectricalcharacteristics:

• cylindricalair-coreinductors • iron-coreinductors • toroidalair-coreinductors

Thetypeofcoolingshouldalsobedecidedinadvance.REOoffersvarioustypesofcooling:

• AN,AFaircooling • watercooling

Protection grades:IP00 - IP65 Pollution level:PD1 - PD4

Fire protection standards: EN 45545, DIN 5510, NF F 16-101 / NF F 16-102

Specialsiliconecoating

Tests/Analyses technologies Full prototype Type test Final product

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Tests/analytical techniques

Tests/analyticaltechniquesAfterelectricaldesigncalculation,andduringmechanicaldesign,thecomponentsundergovarioustestswiththeassistanceofsimulationtoolsandanalyticaltoolsbeforetheygointoprototyping.

SuchsimulationtechniquesasFEManalysisbasedonsolid3Dmodelsgiveinformationaboutphysicalmagnitudes.Thesearefurtheranalysedasaconsequenceofdesigncalculation,andproductoptimizationmeasuresareundertaken,ifrequired.

Thesevarioussimulationtechniquespermitworkingwiththeoptimizationoftimeandcost,sincethefindingsaccumulatedinthesimulationprocesscansubsequentlybeimplementedintheprototyping.Thisprocedureenablesthoseproblemsthatmaycrop

Here is an overview of some of the main types of analysis:

3D magnetic-field simulationComprehensiveelectromagneticandthermalcalculationscanbeperformedbasedonthethree-dimensionalfinite-elementmethod(3DFEM).

FEM thermal simulationBesidestheelectromagneticthree-dimensionalfieldcalculation,thermaldesigncalculationbasedonFEMisalsoofgreatsignificanceforREO,becauseitpermitsalookinsideanactualproductandsubsequentlysuppliesimportantfindingshereaboutlocalhotspotsthatcouldendangertheexpectedusefullifetimeofaproductinthemediumterm.

Thismakesitpossibletodesignproductsthermallyinthedevelopmentphasebeforeproductionbegins.Thisensuresthatthefinishedproducthasalonglifespan.

FEM analysis of structural mechanicsPhysicalfactorsinfluencingthecomponentaresimulatedusingtheFEManalysis,basedon3DCADmodeldesignedusingSolidWorks.

Thisenablesthefollowingcalculationstobemade:

• staticanddynamiclinearandnonlinearstressanalysis • frequencyanalysis • analysisoflifetime • designcalculationofscrewstrength • weldingseamcalculation

Tailor-made components

Keypoints Influence factors Material selection

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Norms and standards used by REO: - IRIScertified(Rev02,V2.2) - EN15085CL1 - DINEN60310/VDE0115Part420/IEC60310:Railwayapplications-Traction transformersandinductorsonboardrollingstock - EN12663-1:Railwayapplications-structuralrequirementsofrailwayvehiclebodies - EN15085-1bis-5:Weldingofrailwayvehiclesandcomponents - IEC61373:Rollingstockequipment–Shockandvibrationtests. - EN50125-1:Railwayapplications–environmentalconditionsforequipment - DINEN60076-10:Determinationofthenoiselevel - EN50124Railwayapplications-insulationcoordination(basicrequirements -clearancesandcreepagedistancesforallelectricalandelectronicequipment) - IEC60085:Electricalinsulation-thermalevaluationanddesignation - DINEN61378and60076:Convertortransformersandpowertransformers - UnderwritersLaboratoriesInc.(UL)certificationforREOsystemsofinsulatingmaterials inthermalclassesF(155°C)andH(180°C)inaccordancewiththeUL1446standard. - ULandTÜVcertificationforREOEMCfilters,inductorsandbrakingresistors - Fireprotectionstandard:EN45545,DIN5510,NFF16-101/NFF16-102,BS6853

Tests/Analysestechnologies Full prototype Type test Final product

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Construction of prototypesAftertheanalysisandtestingphaseissatisfactorilyconcluded,theproductismanufacturedasasampleusingtheresultsderivedfromtheFEManalysis.Thisisacompletein-houseprototype.AllprototypescanbecompletelymanufacturedintheproductionfacilitiesinHennigsdorfandKyritzutilizingin-housemetalwork,CNCmachiningcentre,insulatingmaterialsworkshopandweldingbays.

Type testing

AtREO,everyrailwaycomponentundergoescompletetypetestinginaccordancewithEN60310.Thisincludesthecompleteverificationandvalidationofthedesign,partiallybyexternalaccreditedcompanies.Testing in accordance with EN 60310 includes the following tests, among others:

• acoustics measurement • temperature test • partial discharge measurement • high potential test and high-current test • shock and vibration testing (external) • salt and mist testing (external) • EMC testing

Componentssubmittedbyaclient,suchasfrequencyconvertersetc.,canbeintegratedwithourspeciallyfittedtestingstationswiththeirmodularunits.

Safetyhasabsolutepriorityinrailtravel:faultsinthisexactingfieldofengineeringcanhavecatastrophicconsequences.Sorailwaysaresubjecttospecialadditionalnormsdealingwithmechanicalstability,shockadvibration,andresistancetoEMC.

Millionsofpeopleusetrainsastheirmeansoftransporteveryday.Forthisreason,countlessinternationalstandardsandnormsareapplicabletorailwaystoensurepassengerssafety.Ourengineersdevelopreliablerailwaycomponentsbasedonthesenormsandthosedemandedbyclients.

Thedifferentstages:Constructionphase,3-Dmodel,finalproduct.

Tailor-made components

Keypoints Influence factors Material selection

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Thedifferentstages:Constructionphase,3-Dmodel,finalproduct.

Tests/Analyses technologies Fullprototype Typetest Final product

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Content:•Componentsforauxiliaryconverters................P.15

•Overviewofproducts.......................................P.16

Our product range Components for auxiliary converter

Keypoints Influence factors Material selection

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Components for auxiliary converters

Electricrailwayshaveanextraordinaryenergydemand,e.g.forheating,airconditioning,lightingorcookinginthebistrocar.Alloftheseperipheralapplicationsnormallyrequireasupplythatisdifferentfromtheavailableelectricitysource.Inadditiontoprovidingoptimumpowertothesefacilitiesthereisalsoanimportantrequirementtoensureelectromagneticcompatibilityfortheprotectionofpassengers.Theseauxiliaryconvertersmustmeetthetoughrequirementsofrailwaytechnology:shockandvibrationresistance,highprotectionlevelsandalonglifearejustafewexamplesofthesedemands.

REOdevelopsandmanufacturescomponentsforthispurpose,oftenavailableasstandardproductsbutalsoprovidingfastturnaroundofspecialdesigns-foreveryapplicationtherightsolution!

©Urbanhearts-Fotolia.com

Tests/Analyses technologies Full prototype Type test Finalproduct

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REOChargingresistors(upto3kW)*

–highpowerdensity,widevarietyofconnectionoptionsandpossiblecombinationsof

severalresistorsinoneprofile(typeofprotectionuptoIP67)

REOmainschokes750V-1500V*

–incastdesignforingressprotectionuptoIP65;Usedforreducingcommutation

lossesandharmonics;veryrobustandgoodheattransfer

REOEMC-Filter*

withhighattenuation(upto100dBfromsimpletobroadspectra)inapracticalprofile

housingforvariableinstallationandwithlowheatingguaranteed

Many REO components are also available in a liquid-cooled design (direct cooling).Alternatively, a water-cooled sub-element can be used (indirect cooling), which is combined with the REO-component.

In this simple way, a liquid-cooled system can be easily achieved with all the benefits of a modern water cooling.For more information on water cooling in rail technology, see page 26

1

1

2

DC

3AC 230V

ConverterInput �lter HF- transformers 3-Phase-Converter Sinusoidal�lter

Precharging resistor

3

4 5

6

Input

or

2

Our product range Multitude of applications

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REOdv/dt-filter(690V/to150A)*

–forlimitingthevoltageriseattheoutputfromtheconverterwithhighinductance,

lowtotallossesandminimalleakagefield(typeofprotectionuptoIP65)

REOSinusoidalfilter(690V/1200A)*

–forgivingsinusoidalformtocurrentandvoltage.Forexample,usedinairconditioning

systemsagainstnoise(protectionuptoIP65)

REOCurrenttransformers(0-1000A)*

–insuitabledesignforAC/DCmeasurementsupto150kHzinrailwayapplications,

distinguishedbyshortresponsetimesandexcellentlinearity.

*higherperformancesonrequest

3

4

5

6

Output

DC-link

or

or

or

REOBoost/Buckconverter

ThechokeisusedinapplicationswhereDCvoltagesareconvertedintoanother

(higherorlower)DCvoltageinavehiclepowersupplyandisoperatedatavoltageof

500V..1100.

Chokesaremanufacturedwithcopperwindingsandamorphouscore.

REOHF-Transformer

TheHFtransformerisusedforexampleatavoltagesupplyasanisolating

transformer.Asafeseparationandlowpartialdischargevoltagesare

characteristic.

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Content:

•Componentsforsafetyinrailway.......................P.19

•Overviewofproductsforauxiliaryconverters.....P.20

Our product range for the main drive Inductive and resistive components for railway engineering

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Excellent components for safety in railway technology

Withtheuseofmoderninverterengineeringinelectrictrains,techniquessuchaspulse-widthmodulationareused,generatingvoltagepulseswithashortrise-timetoachievehighpowerratings.Howeverthistechniquehasseveralissueswhichcancauseundesirableeffects,suchasthelossofmotorpower.Someoftheseproblemsare:

•EMCissues •Harmonicdistortion •dv/dtproblems •Voltagesurges •Short-circuitcurrents •Interferencecurrents

Inadditiontothesephenomenathereisalsotheneedtoabsorbexcessiveenergysuchasswitch-onortransientcurrentsurges,causedbystarting-upandslowing-downatrain,toprovidethemostefficientmotorperformance.

Solutions from REO

Sincemostoftheseproblemsoccursimultaneously,itismostimportantforREOtoatakeaholisticviewofthesystem.REOprovidesclosely-matchingsolutionsforinductiveandresistivecomponentsusedaroundthetrain’sdrivemotorsystemandforauxiliaryapplications;fromasinglesource–thisensuresthatthemostefficientdesignfortheapplicationandanoverallawarenessduringtheearlystagesofthedevelopmentphase,areavailable.

AsaleadingsupplierofcompleteinductiveandresistivesolutionsREOoffersawiderangeofcomponentsfortheenhancedperformanceofrailwaydrivesandtrainelectricalequipment.

•AC-chokes •Dampingresistors •Filterresistors

•Short-circuitResistors •Groundingresistors •Interferencechokes

•Invertertransformers •Chopper-Chokes •Absorptioncircuitchokes

•AC-Transformers •Powertransformers •Auxilarytransformers

•Combinations •Brakingresistors

•Assembliesofspecialcomponentsforenergyregeneration

REOdemonstratesaparticularstrengthacquiredthroughlongexperiencewithinductors.Thebroadbaseofcompletedprojectsinrailwaytechnology,guaranteesagoodresult,particularlyforcustomizedsolutions.

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REOthree-phasetransformer

–iscompletelyimpregnatedandmountedinarobustcasing

toprotectofthewindingagainstexternalinfluencingfactors.

Thistransformerisusedforsupplyingvoltagetokitchen

appliancesinahigh-speedtrain.

REOdampingresistor

TheNTTR159resistorisusedasadampingresistorinserieswithafilter

capacitorinatractionpowerconverteronthe3-kVDCmains.

Customer-specific components

Besidesthestandardcomponentsforuseintheconverter,REOofferscustomer-specificproducts-asindividualcomponentsorasacompletesolutioninacontainer.

Theoverridingcriteriainrailwayengineeringareavailabilityforoperationandpassengersafety.Here,REOofferscustomizedsolutionsthatwedevelopstepbystepinclosecooperationwithourclient.

ThisguaranteesthatREOlineinductorsandtransformersareoptimallysuitedtoyourapplication.Ourdevelopmentmethodsemphasizemaximumusefullifetime,cost/benefitoptimizationandsafety.

REOthree-phaseconvertertransformer

–isemployedinauxiliaryconvertersforthe

galvanicseparationoflinkDCvoltageup

to2000VDC.Specialimpregnationserves

toprotectthetransformeragainstexternal

influencingfactors.

Our product range for the main drive Inductive and resistive components for railway engineering

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REOaircorelinechokes

–isdesignedforuseinelectricrailways

operatedonDCnetworks.

Thespecialconfigurationoftheinductor

permitsfullfunctionalityevenunderextreme

conditions.

REODCfilterchoke

–asacomplete,ready-to-useunitconsistingofchoke,

cooling-airduct,suspensionandconnections.

REOREOLeakagetransformer

TheREOleakagetransformerensuresharmonizedcurrentandvoltage

outputs,filteringharmonics,andlimitingtheripplecurrent.Withthe

spatialseparationoftheprimaryandsecondarywindingsandthe

resultingintentionalincreaseinthemagneticleakagefield,theREO

leakagetransformerachievesaloosemagneticcoupling.

REOTransformerwithsupportframe:

Arrangementformountingonthevehiclerooforunderthefloorto

supplyvariouskitchenappliances.

REOabsorptioncircuitchoke:

Absorptioncircuitinductorforamulti-systemvehicle(25kV,50HzAC

mains,5kV,16.7HzACmains,3kVDCmains,1.5kVDCmains)

Theinductorisemployedincombinationwithacapacitorinthecooling

systemoftheconvertercontainertocreatearesonantcircuitfora

specificresonantfrequency.

Therobustconstructionisdesignedforsecureassembly,withspecial

dampingelementsabsorbingvibrations.

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• REO Unity • REO at your side• REO Service

Content:

•REOplus-globalqualityandlocalservice.................. P.22

•Productionsitesandsalesoffices............................... P.24

•Briefdescriptionofeachsite..................................... P.25

REOplus Global quality and local service

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• From the simulation model to mature end product

• Taking into account international certifications and standards

• Verification of all technical parameters, long-term measurements

• Documentations and tests with all products

REO at your side• Certified production processes

• 1:1 production transfer• Same test and production

equipment

REO Unity• All from one single source :

Components in and around the frequency converter - as stand-alone

products or designed as a complete system (including housing, fan, etc.)

• Customized solutions

REO Service

Worldwide sales network

Withaworldwidesalesnetworkandaverycomprehensiveproductportfolio,REOcanreactrapidlytoyourwishesanywhereintheworld-nomatterwhatlanguageyouspeak.Besidesourwideselectionofstandardproducts,wecanofcourseofferyoutailor-madesolutions,developedspeciallytomeetyourwishes.

OurproductionfacilitiesinChina,IndiaandtheUSAareequippedinexactlythesamewayasthoseinGermany,andcanmakeeveryproduct1:1.

Evenafterthe1000thproductionrun,aREOproductalwayshasthesamequality,everywhereintheworld.Usingthesamesoftware,withdevelopmentanddesigninGermanyandintensivecommunicationsbetweenourlocations,weensurethatREOproductsarealwaysuptothelateststateoftheart.

TheREOgroupismadeupofcompanieswithmanyyearsofexperienceasmanufacturersofinductivewindings,locatedallaroundtheworld.BasedinGermanyandwithitstechnicalengineeringknow-howhousedinitsCentreofCompetenceinBerlin,theREOGroupprovidesitsrailwayengineeringclientswithalltheadvantagesofacompanyproducinglocally.

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WithproductionlocationsintheUSA,China,IndiaandGermany,REOoffersdecisiveadvantagesworldwide.

Technology: REOisareliablesourceofmaturetechnologyfortheworld.WithdevelopmentfocusedattheCentreofCompetenceinBerlin,manufacturingmeetsthesamequalitystandardsateveryproductionlocation.Productionmonitors,standardizedproductionequipmentandtheuseofthesamesoftwareworldwideensure1:1manufactureeverywhereintheworld.

Finance: Asagroupofcompaniesoperatingworldwide,REOhasastrongfinancialbackgroundthatmakeslong-termcooperationsecure.

Cost-efficiency: REObenefitsfromlocalsiteconditions,whichenableittofunctionsubstantiallymoreefficientlyandflexiblyasregardsthepricing.

Speed: Localproductioneliminateslongtransportationroutes.SoREOcanalsomeetshort-termdeliverydeadlines.

Service: Anengineerwhocansolveaclient‘sproblemsinthelocallanguageandonsite,ismuchmoreefficientthanonewhooperatesacrossgeographicalandculturaldivides.REO‘sbranchesworldwideenableittodojusticetothisrequirement.

Manufacturing Sales office

REOplus Production locations and field sales offices

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REO-GPDInductiveComponentsPVT.LTD.isajointventurebetweenREOandGUJARATPLUG-INDEVICESPVT.LTD.GUJARATPLUG-INDEVICEShasbeenoperatingontheIndianmarketsince1985andisanactiveproducerofwindingsthere.

REO USA, inc: REOhasbeenrepresentedbyafieldsalesofficeintheUSAsince2000;Weinvestedina2118-m²productionhallin2010.REOUSAhasalsobeenISO-certifiedsinceJuly2011.

Themainfocusatthe„CentreofCompetence“inBerlinisondevelopmentandonsalesinthedomainoftransportationconvertersolutions.DevelopmentworkisdoneforinternationalmanufacturinginAmerica,China,IndiaandGermany(Hennigsdorf).TheCentreofCompetenceisaffiliatedtoastrategicglobalpurchasingdepartmentfortheareaofrailwayengineering.

REOSHANGHAIINDUCTIVECOMPONENTSCO.,LTD.OurpartnerfortheChinesemarket–specializesintheproductionofrailwaycomponents,inclosecooperationwiththeCentreofCompetenceinBerlin.Componentsforrailwayengineering(chokes,filters,transformersandcomponentsinandaroundthefrequencyconverter)foruseindrivetechnologyandinthedomainofrenewableenergysourcesareproducedinChinaA1577-m2productionhallandidenticalproductionandtestingequipmentensureexcellentquality.

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Content:

•DevelopmentsatREO.....................................P.27

•Watercooledchokes........................................P.28

•Watercooledresistors......................................P.30

Solutions of REO Watercooled components in railway technology

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Watercooling

Usingwater-cooledsystems,onecanconvertsignificantlyhighercapacitiesusingthesamesurfacearea-fromwhichincreasedcoolingefficiencyarises.

REOhaslongsincerecognizedthetrendtowardswatercoolingandhasoperateddevelopmentsinthewatercoolingareaforinductiveandresistivecomponents.ThishasenabledREOtobuildupacomprehensiveknow-howandawidespectrumofwater-cooledproducts.

Watercoolingisanexcellentsolution,especiallyfortheuseofinductiveandresistivecomponents,astemperaturebehaviorplaysamajorrolehere.Watercoolingenablesthetemperatureofthecomponentstobekeptatanoptimumlevelinauniqueway,ashighpowerlossesaredirectlytransportedoutofapplicationviathecoolinglines.Thisensuresalongerlifetimeforthecomponentsaswellasincreasedperformance.

Water cooling is a technique that pays off

Constructingthiskindofsystemmaybeinitiallyconnectedwithhighercoststhanwithregularforcedaircooling,however,theseinvestmentspayoffintheend.Variousbenefitscanbeachievedbywatercooling: • Highefficiencyandlownoiselevels • Minimizationofconstructionsizesupto80%withresistors • Effectivecoolingwithhighambienttemperatures • Verylowexcesssurfacetemperature • Increaseoflifetimewithnormaloperation • Constant,highperformance,astemperatureisdirectlydissipated • Onlycoolingtypeduringwhichthetemperaturemayfallbelowtheambient temperature • Verywellsuitedforindustrialapplicationsinwhichcomponentswithlowsurface temperaturesarerequired(woodandtextileindustriesorinexplosion-protected environments,windturbines)

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ThechokesareavailableinprotectivetypesIP00toIP65.REO-canrealizevarioustypesofwatercoolingforthesecomponents.Thismeansthetargeteddischargeoflossesviathecoolingcircuit-thelossesarenotdischargedintotheenvironment.Byusingwatercooling,thetemperaturesinthecomponentscanbegreatlyreduced-thismeanslessstressontheinsulationmaterialsandalongerlifetime.

Series CNW MC - for smaller components

•Reactorcastonametalplate,withintegratedcoolingchannels.Thiscomponentenablestargetedand optimizedcoolingforsmallerpowerlevelsandischaracterizedbyitssimpleintegrationintoexisting coolingsystems •Availablein4versions(IP00,IP20,IP20+EMVandIP64) •Current3-70A

Series CNW MD - for medium to larger power levels

•Chokeinanopendesign,forwhichthecoolingprofileisintegratedintothewinding.Withthistechnology,theheat canbedirectlytiedtoitssourceandcanberemovedeasily. •Completelyencapsulatedchokes,forwhich„waterpockets“,areconnectedtoawatercoolingsystem.Theseare constructedwithinthewindingsandencapsulatingcompounds.Thistechnologyunitestheadvantagesof encapsulationtechnologytoachieveahighprotectiveclassandtheeffectiveheatdissipationatitssource..

Open design:

•Type: CNWMD •Current: 100-1200A •Protection: IP00...IP40 •Inductance: 5-147mH

Watercooled chokes A speciality of REO

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Encapsulated version with water-pockets •Type: CNWMD •Current: 100-3000A •Protection: IP00...IP65 •Inductance: 5-200mH

•Max.temperatureCNW953/180air-cooled: 205°C•Max.temperatureCNWD953/180water-cooled: 120°C•Max.temperatureCNWMD953/180water-cooledandpoured: 68°C

Theadvantagesofthewatercoolingmethodcanbeclearlyseenbasedonthemeasurements.All3variantsweretestedwiththesameload;whendoingso,theopenwater-cooledreactorhadatemperatureadvantageof52K.IntheCNWMDversion,thetemperatureinthereactorcouldevenbeloweredby137K.ThisadvantagewasachievedduetospecialencapsulationtechniquesandaspecialREOconstruction.Inaddition,thebehavioratdifferentinlettemperatureswasresearchedtotestthebehavioratdifferentoperatingconditions.

Water-cooled chokeThisthree-phaselinechokeutilizesasinglecastingofthecoilsandprovidesverygoodinductanceandminimalphysicaldimensions.

Advantages of water-cooled chokes

Temperature comparison CNW 953/180 air-cooled and CNW MD 953/180 watercooled

Time in s

CNW 953/180 air-cooled

CNW 953/180 encapsulated

Ambient

CNW 953/180

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Areavailablewithpowerlevelsfrom1to100kW.Coolingchannelsintroducedintotheheatsinkenableefficientcoolingandthespatialseparationoftheelectricalconductors-andcoolant-enablingsafeapplication.InadditiontothegeneraladvantagesoftheREOHMbrakingresistors,suchasmodularconstructiontoattainhigherpowerlevelsorthecompactdesign,thebrakingresistorshaveanoptimalstructureandpowerconsumption,enablingthemtoalsowithstandvibrationandshocktests.REOHMbrakingresistorsareanoptimizedcombinationofprovenandinnovativetechniques,sothatnothingstandsinthewayofitsusewithhighpowerclassesunderconditionsoflimitedspaceespeciallywhenusingwatercooling.

Series REOHM BW D158 /1600 • Brakingandloadresistanceforthedrivetechnology,industrialapplications. • Power:5–100kW • CoolingchannelsseriesBWD158:Aluminum(AlMgSi0.5)Di=10.5mm • CoolingchannelsseriesBWD160:CopperorstainlesssteelDi=10mm

Type: BW D 158 •Power: 1–100kW •Protection: IP20...IP65 •Resistancevalues: 0,2-850Ohm

Type: BW D 160 •Power: 5–100kW •Protection: IP20...IP65 •Resistancevalues: 0,2-850Ohm

Comparison of an air-cooled braking resistor with a liquid-cooled braking

BW 155/3000 BW D 158/3000 aircooled watercooledDimensions(LxWxH): 762mmx175mmx75mm 320mmx50mmx68mmSpacerequired: 0,134m² 0,05m²-60 % space savingSurfacetemperaturewithafullload: 387°C 35°C 90 % smalle surface temperature

Water cooled resistors Ideal for railway technology

Comparison surface temperature BW 155/3000 air-cooled and BWD 158/3000 watercooled

Surface temperature BW 155/3000

Surface temperature BWD D 158/3000

Leistung (W)

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Series REOHM BW D330

• ThisseriesBWD330isavailableasloadingordampingresistororbrakingresistorforrailway technologywithcapacitiesupto100kW. Liquidcoolingenablesspacesavingsupto88%.Asaspecialbonus,theresistorcanbeconnected easilyvianon-dripquickconnectors.

• 88%spacesavings • driplessquick-connections • Watercooling • electroniccontrol

Type: BW D 330 •Power: 10-100kW •Voltage: 900V •Resistancevalues: 0,1-30Ohm

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