BOOKLET

ON

TRACTION MOTOR & GEAR BOX

OF TRAIN SET

Hkkjr ljdkj GOVERNMENT OF INDIA

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(For Official Use Only)

Maharajpur, GWALIOR - 474 005

CAMTECH/ E/ 2019-20/ EP-05/ TM of Train set/ 1.0

December, 2019

End User : Train Set Maintenance Staff

BOOKLET

ON

TRACTION MOTOR & GEAR BOX

OF TRAIN SET

(DRAFT)

QUALITY POLICY

“We at RDSO Lucknow are committed to maintain and

update transparent standards of services to develop safe,

modern and cost effective railway technology

complying with statutory and regulatory requirements,

through excellence in research, designs and standards by

setting quality objectives, commitment to satisfy

applicable requirements and continual improvements of

the quality management system to cater to growing

needs, demand and expectations of passenger and freight

traffic on the railways through periodic review of quality

management systems to achieve continual improvement

and customer appreciation. It is communicated and

applied within the organization and making it available

to all the relevant interested parties”.

FOREWORD

Train set (Vande Bharat Express/ Train 18) is the concept of multi-unit distributed

traction for main line train operations like Electric Multiple Units (EMUs) and Diesel Electric

Multiple Units (DEMUs) already in service for sub-urban services.

Train-set is a set of rail coaches coupled mechanically and electrically with driving cabs

at both ends and distributed traction power across the coaches. In Train Set, 50% coaches are

powered coaches i.e. motor coaches.

The most important advantage of high-speed train set is the weight reduction effect. In

this, the traction system equipment is distributed over a train-set, and tractive axles throughout

the train-set can obtain the required tractive effort without executing a heavy axle load. As a

result, the maximum axle load is reduced.

Train set coaches are equipped with modern bolster-less design bogies with fully

suspended three phase AC asynchronous traction motors.

To ensure wide dissemination of knowledge on Train Sets and its traction equipment,

CAMTECH, Gwalior has prepared this booklet on “Traction Motor and Gear Box of Train

Set”.

I am sure that this booklet will be useful for field maintenance staff of Train Set in their

day to day working and improving the reliability and safety of coaching stock on Indian

Railways.

CAMTECH Jitendra Singh

Date: 31.12.2019 Principal Executive Director

PREFACE

Train-set is a set of rail coaches coupled mechanically and electrically with driving cabs

at both ends and distributed traction power across the coaches. In Train Set, 50% coaches are

powered coaches i.e. motor coaches.

The distributed power train-sets have lighter axle loads, allowing operation on lighter

tracks, where locomotives may be prohibitive of higher axle loads. Another side effect of this is

reduced track wear, as traction forces can be provided through many axles, rather than just the

four or six of a locomotive.

All propulsion equipment and power components such as traction motors, line &

traction converters, auxiliary converter, air compressor, battery box, battery charger, brake

chopper resister are mounted under the frame.

Train set coaches are equipped with modern bolster-less design bogies with fully

suspended traction motors, pneumatic secondary suspension and anti-roll bar.

Train set is provided with IGBT based energy efficient 3 phase propulsion system and

regenerative braking. In each basic unit of four cars, there are two motor coaches (MCs) and

two trailer coaches (TC, NDTC or DTC).

This booklet on "Traction Motor and Gear Box of Train Set” is prepared with the

objective to disseminate knowledge on the subject. This booklet contains general description of

Train Set, three phase propulsion system, brief on traction motor and gear box etc. This also

comprises OEM’s recommended preventive maintenance schedules and spares to be kept at

maintenance depots.

It is clarified that this booklet does not supersede any existing provisions laid down by

Railway Board/ RDSO, OEMs. This handbook is for guidance only and it is not a statutory

document.

I am sincerely thankful to RDSO/ UTHS directorate, OEM M/s Medha Servo Drives

Pvt. Ltd., Hyderabad, and all field personnel who helped us in preparing this booklet.

Technological up-gradation & learning is a continuous process. Please feel free to write us for

any addition/ modification in this handbook.

CAMTECH, Gwalior Manoj Kumar

Date: 27.12.2019 Joint Director /Mechanical

CONTENT

Chapter No Description Page no.

Foreword iii

Preface iv

Contents v

Correction Slip vii

Abbreviations viii

1. GENERAL DESCRIPTION 01

1.0 INTRODUCTION 01

1.1 IMPORTANT TECHNICAL DETAILS 02

1.2 CONFIGURATION AND PROPULSION SYSTEM 02

1.3 DISTRIBUTION OF EQUIPMENT 03

1.4 DRIVING TRAILER COACH (DTC) 03

1.5 MOTOR COACH (MC) 04

1.6 TRAILER COACH (TC) 04

1.7 NON DRIVING TRAILER COACH (NDTC) 05

2. 3 PHASE AC PROPULSION SYSTEM 06

2.0 POWER SCHEMATIC OF TRAIN SET 06

2.1 TRACTION TRANSFORMER 06

2.2 LINE AND TRACTION CONVERTER (LTC) 07

2.2.1 Line Converter 09

2.2.2 Traction Inverter 09

2.2.3 Line & Traction Control Unit (LTCU) 09

3. TRACTION MOTOR AND GEAR DRIVE 10

3.0 TRAIN SET PARAMETERS 10

3.1 TECHNICAL DATA OF TRACTION MOTOR 10

3.2 CONSTRUCTIONAL DETAILS OF TRACTION MOTOR 11

3.2.1 Main assemblies of drive complete 12

3.2.2 Stator 12

3.2.3 Rotor 12

3.2.4 Motor connections 13

3.2.5 Traction Motor bearing 13

3.2.6 Motor Cooling 14

3.2.7 Speed sensor 14

3.2.8 Pt100 temperature sensors 15

3.2.9 Traction Motor Water Flood Level 15

3.3 TECHNICAL DATA FOR GEAR BOX 16

Chapter No Description Page no.

3.4 CONSTRUCTIONAL DETAILS OF GEAR BOX 16

3.4.1 Drive Complete 17

3.4.2 Gearbox Description 18

3.4.3 Motor Coupling 18

3.4.4 Connection Gearbox to Wheel Set 19

3.4.5 Gear box Housing 19

3.4.6 Gearbox Support 19

3.4.7 Bearings 20

3.4.8 Lubrication and cooling 20

3.4.9 Sealing 20

3.4.10 Monitoring of the Gearbox 21

3.5 TRACTION MOTOR PREVENTIVE MAINTENANCE SCHEDULE 22

3.5.1 Traction Motor Required Consumable During Maintenance Schedule 23

3.5.2 Traction Motor Spare Parts / Rake Needs To Be Kept At Train Set Depot 23

3.6 TRACTION GEAR BOX PREVENTIVE MAINTENANCE SCHEDULE 24

3.6.1 Gear box oil filling & draining 25

3.6.2 Consumable during maintenance schedule Traction Gear drive system 25

3.6.3 Gear Drive System : Spare Parts / Rake Needs to be Kept at

Train Set Depot 26

3.6.4 Gear Oil-Limits for Contaminations 27

REFERENCES 28

ISSUE OF CORRECTION SLIP

The correction slips to be issued in future for this booklet will be

numbered as follows:

CAMTECH/E/ 2019-20/ EP-05/TM of Train Set/1.0/ C.S. # XX date---

Where “XX” is the serial number of the concerned correction slip

(starting from 01 onwards).

CORRECTION SLIPS ISSUED

Sr.No. Date of Issue Page no. & Item no.

modified

Remarks

ABBREVIATIONS

Abbreviation Details

AC Alternating Current

ATC Auxiliary Traction Control

BCH Brake Chopper

BE Braking effort

BU Basic Unit

DC Direct Current

DCLV DC Link Voltage

DCS Key Driver control Switch Key

DE Driving End

DEMU Diesel Electric Multiple Units

DTC Driving Trailer Coach

EBL Emergency Brake Loop

EBU End Basic Unit

ED Electro Dynamic

ELD Earth Leakage Detector

EMU Electric Multiple Units

EP Electro Pneumatic

FQC Four Quadrant Converter

HWTL Hard Wired Train Line

ICF Integral Coach Factory

IEC International Electro technical Commission

IGBT Integrated Gate Bipolar Transistor

IR Indian Railways

IV Inter Vehicular

LC Line Converter

LTC Line and Traction Converter

LTCU Line & Traction Control Unit

MAE Medha AC-EMU

Abbreviation Details

MBU Middle