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  • BOOKLET

    ON

    TRACTION MOTOR & GEAR BOX

    OF TRAIN SET

    Hkkjr ljdkj GOVERNMENT OF INDIA

    jsy ea=ky; MINISTRY OF RAILWAYS

    dsoy dk;Zky;hu mi;ksx gsrq

    (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