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RESEARCH, DESIGN & DEVELOPMENTProvision of Capacitor Bank in LHB EOG AC Coaches of Rajdhani/Shatabdi Express Trains to Enable Augmentation of Coaches

Improvement in Reliability of Power Supply System in Self Generating AC Coaches

Development of Induction Heating Based Pantry Equipments

Reverse Cycle Air Conditioning System

staff. These pantry cars will be fitted with RMPU and induction cooking equipment for making more hygienic food. The induction heating based cooking works out to be cheaper than LPG or resistive heating element based cooking.

The scheme for providing capacitor bank in LHB EOG AC coaches of Rajdhani/Shatabdi Express trains for improving power factor has been designed and

At present most of the Air conditioned coaches developed by RDSO. With the introduction of the are working with 1100 Ah batteries supply system. Due power factor correction scheme, electrical load to any failure of these batteries, the AC coaches fail capacity of the Rajdhani/Shatabdi Trains has been which results in en-route detention and refunds to increased. Railway Board has issued guidelines for passengers.addition of two more coaches in Rajdhani/shatabdi

Express trains based on the report of RDSO. The cost To avoid this type of failures and to augment the of this modification is very low but the return in the form power supply, RDSO has prepared a scheme of 2 X of extra revenue is very high as now two additional 650 Ah battery power supply with 2 X 25 KW coaches can be attached with the existing alternators and 2 x 25 KVA inverters. In this scheme, Rajdhani/Shatabdi trains. one set of 650 AH battery is working as standby. This

scheme has already been implemented and ICF has turned out 10 coaches so far, which are working satisfactory in different zonal railways. Single line block wiring diagram of 2 x 650 AH battery supply system is as under:-

RDSO has developed the scheme for provision of induction heating based cook tops in Non AC coaches, Air-conditioned self-generating coaches and LHB EOG type Rajdhani express pantry cars. Presently, the air conditioning system is having

heater coils which provide warm air inside the coach Induction heating based cooking technology is during winter. Every year, there are few cases of absolutely safe from fire on spillage of oil and also the smoke emission from these heating coils. RDSO has direct heating of container enhances overall efficiency. designed and developed an air conditioning system Further, this system is odorless, time saving, having without heating coils which will provide warm air to the precise heating control and easy to operate by cooking passenger in winter. The equipment works on the concept of reverse cycle operation of refrigeration system. One such coach has been provided with this air conditioning unit which has been working in a Mail/Express train. Coaches with reverse cycle operation are more energy efficient and the possibility of fire is also eliminated as resistive the heating element is not there in this type of RMPU.

M MM COM P C OM P

C C C C C

1 Kva r 1Kvar

1Kvar 3 Kvar

3 Kvar

MCB

RYB

B MotorCondense r M otor

Condenser Motor

Comp M otor Comp Motor2.5 A MCB

2.5 A MCB 2.5 A MCB

6 A MCB 6 A MCB

Annexure-2

Scheme for provision of capacitor bank inShatabdi/Rajdhani Coaches

Induction Heating Based Pantry EquipmentsInstalled in Rajdhani Express Pantry Car

25 KW

ALT-1 ERR

U

- VE

25

KV

AU

/SIN

VE

RT

ER-1

BATTERY-1 650 AH + V E

- VE

25 KWALT-2

ER

RU

25K

VA

U/S

INV

ER

TER

-2

BATTERY-2

650 AH

+ V E

- VE

TR

AN

SF

OR

ME

RR

EC

TIF

IER

UN

IT(P

RE

-CO

OL

ING

)

+ VE

- V E

4 15 V. , 3- PH A SE A C E XT ER NA L SU P PLY

F RO M PR E- C OO L IN G S O CK ET 1 / 2

RSW-2 250 A

RSW-4 250 A

RSW-3 250 A RSW-5

250 A

LAPTOP /M OBILE

CHARG IN G

RM PU-1

LOAD

RM PU-2LOAD

SINGLE LINE BLOCK WIRING DIAGRAM OF POWER GENERATION & DISTRIBUTION SCHEM FOR SG AC COACHES WITH 2 NOS. 110 V.,650 AH BATTERY SETS

POSITION -1 O FF

POSITION -2

POSITION -3

POSITION -4

NO RM AL

INV. SUPPLY

EXTER NAL

PRE -COO LING SU PPLY

RSW- 2 & 3

PO SITION-1 O FF

PO SITION-2

PO SITION-3

PO SITION-4

INVER TE R-1

O FF

INVER TE R-2

RSW- 4

POSITION -1 O FF

POSITION -2

POSITION -3

POSITION -4

O FF

RSW-5

INVERTER -2

INVERTER -1

OFF

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xx

xx

xx

xx

315 A FUSE

250 AFUSE

250 AFU SE

250 AFUSE

250 A

FUSE

M ONO-BLOCK

PUM P

2 KVA TRF.

415 /190COS-2200 A

LIN

K

LIN

K

+ V E

- VE

+ VE

COS-3200 A

COS-4200 A

1

2

1

2

1 2

1

2

200 AFUSE

200 AFUSE

TO 50 % LIGHT +BERTH READING

LIGHT LO AD

FAN CIRCUIT

(CO S-1,CO S-2) & (CO S-3, COS-4)

POSITIO N-1

P OSITION -4

POSITIO N-5

POSITION -6

COS-1COS-2 COS-3COS-4

2 2

2

2

1

2

2 2

1

2

NORMAL CONDITION

INDEPENDENT WORKINGOF ALT-1,BATT-1,INV-1AND ALT-2,BATT-2,INV-2

DEFECTIVE BATTERY-2ISOLATED

DEFECTIVE BATTERY-1

ISOLATED

BATTERY CHARGINGTHROUGH EXTERNALPRE-COOLING SUPPLY

NOTE :- POSITION S 1,2,3,4,5,6,7 & 8 ARE A PPLICABLE

AS CO S-1,COS-2,CO S-3 & AND C OS-4 IN AB OVE

TABLE FO R CON DITIOS O F SY STEM

CONDITION OF SYSTEM3

3

POSITION -7

1 1

2 2

BOTH ALTERNATORSARE ISOLATED AND

WHOLE SYSTEMWORKS ONLY ONBATTERY 1 & 2

3 3

2 2

C ABLE SIZE

S YMB OL

S PECIFICATIO NTHIN WALLED E- BEAM CABLE TO RDSO SPECIFICATION NO.

ELRS/SPEC./ELC./0019-2002(REV.'0') WITH LATEST AMENDMENT

50 SQ . M M 35 SQ. MM 10 SQ . M M 4 SQ . M M 2.5 S Q. MM 1.5 SQ . M M

XXX XX /// // /

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xx

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XXX

XXX

XXX

XXX

/// ///

///

///

///

///

/// //////

///

XXX

////

//

//

////

XX

X

PO WER PA NEL

- VE

+ V E

1 2

TO 50 % LIG HT +BERTH READING

LIGHT LOAD

////

- V E

+ VE

XXX

XX

X

PO SITION-2

P OSITION-3

1 2

2 1

1

1

2

2

DEFECTIVE ALT. -1 /ERRU ISOLATED

DEFECTIVE ALT. -2 /ERRU ISOLATED

SYS TEM O FF

SYS TEM

O FF

2 2

POSITION -8 OFF OFF 1 1SYSTEM IN OFFCONDITION

315 A FUSE

315 A FUSE

315 A FUSE

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Development of V-belt Driven Permanent Magnet (PM) Alternator

Development of Sensor Less BLDC Fan

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Development of Long Life V belts

Presently, LHB coaches in spite of higher speed potential and safety, are limited to EOG / HOG version of train services due to space constraints for fitment of self-generating alternator on the bogie since bogies are fitted with disc brakes. Permanent Magnet alternator is having inherent advantages of smaller size and weight over conventional alternators. RDSO has developed 25/30kW Permanent Magnet (PM) alternator which can be fitted in LHB bogie. Two PM

Existing BLDC fan uses additional sensor alternators alongwith their controllers have been fitted magnet to sense the position of rotor using hall on coach no. 05063 and successfully running in field sensors.since last four months. This development enables IR

to develop self-generating LHB coaches in future. Field data show that 50% failures are due to shifting or breakage of sensor magnet.

As the alignment of sensor magnet is critical, fans often do not rotate after reassembly by Railway workshops.

To overcome all these issues and to improve reliability, sensor less BLDC fans have been developed.

Interchangeability of parts i.e. body, blade, guard, stator, rotor & PCB has also been ensured.

Specification for the BLDC fan has been revised and issued to manufacturers and Railways for compliance.

Specification was prepared for Long life V belts Rotor of PM Alternator

Stator of PM Alternator

PM Alternator

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with inclusion of aramid cord which can run upto IOH. Three vendors have developed the Long life V belts which were tested for life by carrying out the accelerated aging test for 400Hrs and results were

thfound satisfactory. During 25 Maintenance Study Group (MSG) meeting, it has been decided that field trials may be carried out at SR, NR, NFR, WR, CR, NWR.

Standby circuit has been developed to make available 75% electrical power to the coach in case the main ERRU becomes faulty. The stand-by circuit has been successfully tried in field and all the

major propulsion equipments have been type tested. manufacturers have been advised to implement the First prototype rake is under completion at ICF same. There is a provision in CIP/terminal box to Chennai and commissioning activity will commence switch over the stand by circuit in case of main ERRU shortly.goes defective.

Introduction of three phase propulsion system on Indian Railways has resulted in the regeneration of energy for more than 35%. With additional power

Conventional luminaries provided in SLR availability, features like improved ventilation, better

coaches get broken due to over loading of luggage illumination have been added for passenger comfort.

upto the roof which is a fire hazard. Therefore, Stainless steel grab handles, partitions, ergonomic

development of LED based light unit for SLR coaches design of driving cab, GPS based public address

has been undertaken and successfully completed by system are the other salient features of new EMU

PS&EMU Directorate of RDSO. These LED based stock for Mumbai area. To enhance the passenger

light units are under field trials on Northern Railway.carrying capacity, first 15 car 3 phase AC/DC EMU has also been introduced on both Central & Western Railway.

Energy efficient state-of-the-art 3-phase IGBT Based on the performance and energy saving based technology with maximum permissible speed of achieved through three phase propulsion system in 100kmph and the improved passenger amenities on Mumbai area, new specification has been framed to AC-DC EMUs has been introduced in Mumbai introduce the three phase electrics on EMUs/MEMUs Suburban. Under the GP-194 and MRVC Phase-I, for other zonal Railways.World Bank funded project, 115 rakes of 12 car have already been introduced on Central and Western

To harness the mechanical energy lost through Railway. Further, seventy two new AC EMU rakes will conventional friction braking system, the new EMUs be introduced under MRVC Phase-II project during the have been provided with regenerative braking feature. year 2013-14 & 2014-15. RDSO has already accorded With regenerative braking electricity is generated and the design approval for all the equipment and the transmitted to the overhead line. The regenerative braking feature, system is economical because it does

Development of Standby Unit to Improve the Reliability of ERRUs

Development of LED Based Light Unit for SLR Coaches

Introduction of Three Phase Propulsion System on EMUs/MEMUs

Regenerative Braking in EMUs

MRVC Phase-I

MRVC Phase-II

Pantograph

Current direction during powering mode

Transformer

Converter

M

M Current direction during regeneration

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not use friction elements and the electricity regenerated from the train’s kinetic energy is transmitted to the overhead line which is available to power other rolling stocks. RDSO has developed the programmed LED

A conventional DC EMU rake consumes nearly based head code to replace the existing tin plate/scroll 2.7 million units of energy every year while a new 3 cloth type head code, and provide GPS based phase EMU rake consume 1.6 million units of energy passenger information system to inform the every year. Thus, with 174 new EMU rakes after MUTP passengers for the next halting station. This will give Phase I, there would be a saving of nearly 191 million better visibility and readiness to the passengers. electrical units of energy per year. With per unit cost @ Further, the destination in the head code can be ‘4, the financial savings is 764 million per year after changed easily by the motorman whenever required MUTP Phase I. through the driver desk console.

A project has been registered with World Bank The entire system is controlled by a to obtain Carbon Credits on account of emission microprocessor and provides facility of programming reduction. The Project Idea note has been approved the destination stations other important information. by the World Bank. With the introduction of new The complete timetable can be fed in the system and technology energy efficient EMU rakes, a reduction of motorman only has to feed the train number to operate nearly 606 tons of CO emission per rake per year has LED based head code and GPS based passenger 2

information system for EMUs/MEMUs.been envisaged.

RDSO has developed stainless steel AC EMU coaches with BEML indigenously for the first time in the country. The complete car body is made out of austenitic stainless steel with high corrosion resistance property (except bolster region). Use of stainless steel enhances the aesthetics of car body and greatly reduces the maintenance. One rake has been successfully running in Eastern Railway since 10.09.2012. Manufacturing of second rake is in progress at BEML, Bangalore.

At present, there is no mobile/laptop charging point available in MEMU trains. During travel, passengers in MEMU coaches require mobile/laptop charging points. As per the directives of Railway Board, RDSO has designed and included the provision of 04. mobile/laptopcharging points in motor coaches and 06 charging points in trailer coaches in the specif ication of MEMU coaches. The mobile/laptop charging points are to be provided by RCF in MEMU coaches.

Development of LED Based Head Code & GPS Based Public Information System (PIS) for EMUs & MEMUs

Design &Development, Fabrication, Supply, Testing and Commissioning of Stainless Steel AC EMU Coaches.

Provision of Mobile/Laptop Charging Point in MEMUs

Stainless Steel BEML Build AC EMU

LED Based Head Code Based PIS