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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

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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”.

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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

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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

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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

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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

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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

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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

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Abbreviation Details

MBU Middle Basic Unit

MC Motor Coach

MCB Miniature Circuit Breaker

MCH Master Control Handle

MCU Main Control Unit

MMI Man Machine Interface

MSDPL Medha Servo Drives Pvt. Ltd.

MU Multiple Unit

MVB Multifunction Vehicle Bus

NDE Non Driving End

NDTC Non Driving Trailer Coach

PS Power Supply

PWM Pulse Width Modulation

RDSO Research Design and Standards Organization

RPM Revolution per Minute

TC Trailer Coach

TCMS Train Control & Management System

TE Tractive Effort

TI Traction Inverter

TM Traction Motor

TSA TRAKTIONS System Austria

UIC International Union of Railways

VCB Vacuum Circuit Breaker

VVVF Variable Voltage Variable Frequency

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CAMTECH/E/2019-20/EP-05/TM of Train Set/1.0 1

Booklet on Traction Motor & Gear Box of Train Set December, 2019

CHAPTER 1

GENERAL DESCRIPTION

1.0 INTRODUCTION

Train set 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. Depending on the

requirement, the amount of power i.e. number of powered coaches can generally vary from

50% to 100%. 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.

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.

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.

Fig-1: Train Set (Vande Bharat Express)

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

1.1 IMPORTANT TECHNICAL DETAILS

Particulars Details

Number of Coaches in Basic Unit 4 car per Basic Unit (BU)

DTC-MC-TC-MC (End BU)

NDTC-MC-TC-MC (Middle BU)

Train formation 16 coaches- 4 BU per train

% Motoring 50%

Maximum test speed 176 kmph

Maximum service speed 160 kmph

Typical alloutrun 8 km

Average acceleration from 0-40 kmph 0.8 m/sec2

Deceleration 0.8 m/sec2

1.2 CONFIGURATION AND PROPULSION SYSTEM

The Train Set consists of four basic units of four coaches each.

The configuration of end basic unit is as follows - DTC+ MC+ TC + MC

The configuration of middle basic unit is as follows - NDTC+MC+TC+MC

Where

DTC : Driving Trailer Coach MC :Motor Coach

TC : Trailer Coach NDTC :Non-Driving Trailer Coach

Train set is provided with IGBT based energy efficient 3phase 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).

Complete propulsion system is supplied by M/s Medha for the first prototype 16 car

train set. The fully suspended traction motor is developed by M/s Medha along with M/s.

TRAKTIONS SYSTEME AUSTRIA (TSA) and M/s ECE Engineering, Poland.

Fig-2: End Basic Unit

Fig-3: Middle Basic Unit

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CAMTECH/E/2019-20/EP-05/TM of Train Set/1.0 3

Booklet on Traction Motor & Gear Box of Train Set December, 2019

Total 16 Car Formation – 4 X 4 Basic Units - Each Basic Unit with Four Cars

Fig-4: 16 Car Formation

1.3 DISTRIBUTION OF EQUIPMENT

Distributions of equipment among various coaches of train set areas follows:

Description Equipment

DTC Under-frame - compressor, battery, battery charger

NDTC Under-frame - compressor, battery, battery charger

MC Under-frame- line and traction converter, traction motor and gear

drive assembly, brake chopper resistor

TC Under-frame - traction transformer, auxiliary converter

Roof - Pantograph, VCB

ALL

Coaches Brake skid (End & Middle), and isolating transformer for pantry load.

Under slung water tank capacity 1200Lts approx.

Pre wired Cables trays on under frame for power and control cables.

Roof mounted packaged unit (RMPU) at both ends on each coach

1.4 DRIVING TRAILER COACH (DTC)

It is a non-powered vehicle with a driver cab at one end. The driver cab is furnished

with a pre-fabricated driver desk. All driving operations are possible from driver desk.

Feedback from all system in all the coaches / basic units is available for viewing on the

driver desk. For this 10.4” touch based TFT display is provided on driver desk for showing

combined status.

Various gauges are also provided on driver desk for knowing MR, BP, BC and

parking brake pressure. The driver will also be able to control the Passenger Information

System (PIS) from the driver desk.

Fig: 16 Car Formation

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

It also consists of battery box, battery charger and compressor mounted under-slung.

Rest of the DTC apart from the driver cab is passenger saloon area, which consists of

pantry, RMPU control unit, mono block pump controller, CRW, GCRW panel and various

end wall panels. It is an air-conditioned coach. All passenger comfort related load can be

controlled by driver from driver cab.

Fig-5: Driving Trailer Coach (DTC) internal &external view

1.5 MOTOR COACH (MC)

Motor coach is a powered

vehicle with four axles each equipped with a 3

phase asynchronous Traction Motor (TM).

Traction motors are fully suspended i.e.

traction motor weight is not loaded on to the

wheel directly. This reduces the un-sprung

mass, resulting in better ride comfort.

The motor coach consists of two Line

and Traction Converter units (LTC), one for

each bogie mounted under-slung. Brake

chopper resistor is also mounted under-slung.

Transformer secondary cable for both LTC

units from power transformer come from

trailer coach through under-slung mounted IV

coupler.

It also consists of passenger saloon

area, pantry, RMPU, mono block pump

controller, electrical cabinet and various end

wall panels. It is an air-conditioned coach.

Fig-6: Motor Coach (MC) internal &external view

1.6 TRAILER COACH (TC)

Trailer coach has the pantograph for current collection, vacuum circuit breaker and

HV isolator mounted on the roof. For operation of the 16 car, two pantographs will be used.

It also consists of auxiliary converter unit and power transformer mounted under-

slung. Power to LTC units of both motor coaches is distributed from same power

transformer. Auxiliary converter feeds the hotel load of four coaches. It also consists of

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CAMTECH/E/2019-20/EP-05/TM of Train Set/1.0 5

Booklet on Traction Motor & Gear Box of Train Set December, 2019

passenger saloon area, pantry, RMPU, mono block pump controller, electrical cabinet and

various end wall panels. It is an air-conditioned coach.

1.7 NON DRIVING TRAILER COACH (NDTC)

It is similar to DTC except driver related interface. It also consists of battery box,

battery charger and compressor mounted under-slung. It also consists of passenger saloon

area which consists of pantry, RMPU control unit, mono-block pump controller, CRW,

GCRW panel and various end wall panels. It is also an air-conditioned coach.

Fig-7: Pantograph and RMPU on Trailer Coach (TC)

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

CHAPTER 2

3 PHASE AC PROPULSION SYSTEM

2.0 POWER SCHEMATIC OF TRAIN SET

Below figure shows the block diagram of the power schematic of the train set.

The 25kV OHE voltage is connected to the transformer primary winding through the

pantograph and Vacuum Circuit Breaker (VCB). During maintenance when transformer

primary winding is not connected to the OHE line, an earthing switch (connected in parallel

to VCB) is used to ground the transformer primary winding and pantograph for safety.

2.1 TRACTION TRANSFORMER

Traction transformer is mounted under slung of trailer coach (TC).There are 1 primary

winding, 4 traction windings and 2 auxiliary windings in traction transformer. One

transformer feeds to two motor coaches. Traction transformer is oil cooled with help of oil

pump and blower which cool the radiator through which oil is circulated using the oil pump.

Important parameters of traction transformer are:

Continuous voltage: 19 – 27.5 kV

3 Frequency range: 47 – 53 Hz

Total transformer continuous rating is 2880 kVA under 22.5 kV OHE voltage.

Each traction winding continuous rating is 603 kVA

AC - DC

Converter

Pantograph

Circuit Breaker

Transformer

25 kV AC Overhead Line (OHE)

DC - ACMotor Converter

2 x 3 Phase Motors

DC - ACAuxiliary Converter

3 Phase AC Output

Transformer

RectifierAC - DC

Battery

DC Output

2 x 3 Phase Motors

ConverterMotorDC - AC

Transformer

Converter

AC - DC

- ve return through wheel and running railAxle Brush

Fig-8: Block Diagram of Electronic Power and Auxiliary Services

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CAMTECH/E/2019-20/EP-05/TM of Train Set/1.0 7

Booklet on Traction Motor & Gear Box of Train Set December, 2019

Each auxiliary winding continuous rating is 234 kVA

Peak power rating is 3616 kVA, each traction secondary peak rating is 787

kVA and auxiliary is 234 kVA.

Total approximate weight of transformer is 4900+/-3% kgs.

2.2 LINE AND TRACTION CONVERTER (LTC)

Each motor coach has 2 nos. of Line and Traction Converters (LTC) mounted

under slung and each control two traction motors of a bogie. Input power to line converter

comes from transformer kept in adjacent trailer coach. Line and traction converters are

forced air cooled. Each traction converter cubicle consists of one-line converter, DC link,

one traction inverter and line & traction control unit.

Important parameters of LTC are:

Input voltage : 950 V AC at 25 kV AC

Input current : 639 A

Weight : <800+/-50 Kg

Dimension : 2250*1220*700 mm

Line and traction converter rating : 554 KVA

High Voltage

Line Converter

Line Converter

Line Converter

Line Converter

Aux. Converter

Aux Converter

Figure : Block diagram of Traction TransformerFig-9: Block diagram of Traction Transformer windings

Fig-10: Line and Traction Converter

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Fig-11 :Power Schematic of Train 18 with emphasis on Traction Converters in Motor Coach

8

CA

MT

EC

H/E

/20

19

-20

/EP

-05

/TM

of T

rain

Set/1

.0

Decem

ber, 2

01

9

B

oo

klet on

Tra

ction M

oto

r & G

ear B

ox o

f Tra

in S

et

P2

P1 CT1

-+

R1

R2

K2

1

1

K1-1

HEAT SINK - 1 HEAT SINK - 2

Q8

Q6Q1

Q3

Q2

Q4

Q5

Q7

C4

Q15

Q13

Q12

Q10

Q11

Q9 Q14

Q16

HEAT SINK - 4HEAT SINK - 3

-+

+ -

+-

-+

-+

TM1

TM2

P3

P4

P5

CT3

CT4

PT2

CT2

Brake Chopper Resistor Assembly

R5

R6

PT1

ESW

P7 P8

P8P7

PT1

R6

R5

CT2

PT2

+-

+-

-+

-+

+ -

C4

1

1

+ -

-+

+-

-+

+-

OHE

HVCT1

HVPT

PT1

PT2

TR

AN

FO

RM

ER

TR

AC

TIO

N

Q9 Q10

Q12Q11 Q15 Q16

Q14Q13CT3

CT4

P5

P4

P3

TM1

TM2

Q1

Q3

Q2

Q4

Q5

Q7

Q6

Q8

HEAT SINK - 1 HEAT SINK - 2HEAT SINK - 3 HEAT SINK - 4

P1

P2

CT1

K1-1

K2R1

R2

HIGH VOLTAGE EQUIPMENT

HVCT-2

Brake Chopper Resistor Assembly

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CAMTECH/E/2019-20/EP-05/TM of Train Set 9

Booklet on Traction Motor & Gear Box of Train Set December, 2019

2.2.1 Line Converter

The line converter interfaces with transformer secondary traction winding AC

voltage on one side and DC link on the other side. The line converter consists of single

phase full bridge rectifier with IGBTs as active switching devices. The DC link consists of

earth leakage detection circuit, DC link capacitor bank and brake chopper circuit (for over

voltage protection).

Main function of line converter is to maintain stable DC link voltage at 1800 V

irrespective of line and load variations at unity power factor.

Fig-12: Block Diagram of Line Converter

2.2.2 Traction Inverter

The traction inverter consists of a 3-

phase full bridge inverter with IGBTs as

active switching devices. Main function of

traction inverter is to convert the DC input

voltage to 3-phase Variable Voltage

Variable Frequency (VVVF) output and to

control the traction motor torque in both

motoring mode and braking mode. Each

inverter controls two traction motors in

parallel.

2.2.3 Line & Traction Control Unit (LTCU)

Line & Traction Control Unit (LTCU) controls both the line converter and traction

inverter and communicates with the Main Control Unit (MCU) through CAN interface. All

the LTC's are similar in construction.

Fig-13: Traction Inverter Schematic diagram

C1

Q7

Q5

Q4

Q2

Q3

Q1 C2Q6

Q8

HEAT SINK - 2HEAT SINK - 1

K1-1

1

1

K2

R2

R1

+ -

CT1P1

P2

+Ve

- Ve

Q19

Q20

Q21

Q22

Q23

Q24

C5

TM2 TM1

+

-

+

-

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Page 22: TRACTION MOTOR & GEAR BOX OF TRAIN SET - Indian Railways on... · TRACTION MOTOR & GEAR BOX OF TRAIN SET Hkkjr ljdkj GOVERNMENT OF INDIA jsy ea=ky; MINISTRY OF RAILWAYS dsoy dk;Zky;hu

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

CHAPTER 3

TRACTION MOTOR AND GEAR DRIVE

3.0 TRAIN SET PARAMETERS

S. No. Description Value

1. Wheel diameter:

New Wheel

Half worn

Fully worn wheel

952mm

915mm

877mm

2. No of Traction Motors per MC 4

3. Maximum Tractive effort of MC 106 kN

4. Max power at wheels per Motor Coach during motoring 1296 kW

5. Gear ratio 5.158

6. Maximum braking effort 94 kN

7. Max power at wheels per Motor Coach during braking 1567 kW

8. Gear efficiency 98.00%

3.1 TECHNICAL DATA OF TRACTION MOTOR

S. No. Description Details

1. Designation 3 phase AC Asynchronous Traction

Motor

2. Designed by TSA

3. Make Medha

4. Type designation TME 49-35-4

5. Weight of traction motor drive with half

coupling

1000 kg ±3%

6.

Continuous rating

Power 265.26 kW (electrical)

7. Shaft output 252 kW (mechanical)

8. rpm 3338 rpm

9. Voltage 1375 V

10. Current 123 A

11. Frequency 112.3 Hz

12. Slip at full load 0.89%

13. Power factor 0.9

14.

1 hour rating

Power 291.88 kW (electrical)

15. Voltage 1375 V

16. Current 136 A

17. Frequency 112.4 Hz

18. Slip 0.99%

19. Shaft output 277 kW (mechanical)

20. Power factor 0.9

21. rpm 3337 rpm

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CAMTECH/E/2019-20/EP-05/TM of Train Set 11

Booklet on Traction Motor & Gear Box of Train Set December, 2019

S. No. Descri

ption

Details

22. Motor efficiency at rated power 95.00%

23. Maximum working speed of TM 4992 rpm

24. Maximum frequency 167.5 Hz

25. Maximum temperature index of

winding insulation

237°C

26. Type of suspension Fully suspended motor with partly

suspended gear drive

27. Speed at 160kmph with full worn

wheels (877mm dia)

4992 rpm

28. Type of cooling Self ventilated, air cooled

29. Air entrance temperature ≤ 50°C

30. Protection system IP 20 (machine protected solid objects

greater than 12 mm)

31. Class of insulation material Class 220

32. Terminal box protection degree IP 65 (machine protected against

ingress of dust)

33. Overall dimensions 1431 (L)x1157 (W) x 701 (H)

34. Constructional details viz. Rotor bar

and rotor end ring arrangement,

overhang to terminal box connection

etc.

Rotor bar and end ring joints

protected by use of high strength

alloy shrink ring. All overhangs

suitably supported.

3.2 CONSTRUCTIONAL DETAILS OF TRACTION MOTOR

Traction motor provided in train set motor coach is a 3-phase asynchronous

self-ventilated machine.

Fig-14: Train set bogie with traction motor and gearbox assembly

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

3.2.1 Main assemblies of drive complete system

Fig-15: Main assemblies of traction drive complete

3.2.2 Stator

The stator consists of lamination stack, which are

fitted in a cast metal housing. The stator windings are

shaped copper coils, which are wound from insulated

rectangular profile - banded with additional coiling

insulation and into which slots equipped with a slot lining

are inserted.

The connections (“circuitry") of the stator coils

take place on the non drive side (NDE). The stator

winding is insulated in accordance with TSA standard and

conforms to insulation class 220 in accordance with

IEC60349-2.

Fig-16: Stator

3.2.3 Rotor

The rotor lamination stack made of layered

dynamo sheets is mounted on a solid motor shaft and

clamped on both sides by rotor moulding press rings.

On the non-drive side (NDE), the lamination stack is

secured further with a ring shrunk onto the shaft.

Short circuit bars and short circuit rings are welded

on both sides. Shrink collars made up of high-strength,

non-magnetic material absorb the loading from the

centrifugal force load on the short circuit rings.

Fig-17: Rotor

A. Traction Motor

B. Gear Box

C. Gear coupling

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CAMTECH/E/2019-20/EP-05/TM of Train Set 13

Booklet on Traction Motor & Gear Box of Train Set December, 2019

3.2.4 Motor connections

Terminal box is located on top of the

motor and provided with cable glands.

Fig-18:Motor Terminal Box connections

3.2.5 Traction Motor bearings

The motor shaft is mounted with ceramic rolling element bearings at both DE

(Driving End) & NDE (Non Driving End) in the stator housing. The details are as under.

DE (Driving End) : Deep groove ball bearing - 6217 M/HC5C4HS0

NDE (Non Driving End) : Cylinder roller bearing - NU1012 MR/HC5C4

Advantages of Ceramic bearing (Hybrid bearing)

Bearings balls are made from Ceramic material

Bearing insulated at rollers

No deformation at higher speed

No deformation at higher temperature

No wear & tear of the rollers

Traction motor bearing lubrication re-greasing details

Fill the grease -

DE Bearing : 21 gms

NDE Bearing : 9 gms

Grease type : Shell Gadus S3 V2220C 2

Fig-19: Removing of used grease from waste grease cover from DE side & from

NDE side (shown by arrow)

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

3.2.6 Motor Cooling

The motor is air cooled by a fan mounted at the non-drive end (NDE) of the rotor

shaft, air flow is mainly routed through heat exchange channels at the external periphery

of the magnetic stack, one part is ducted inside the rotor, cooling air is filtered at the

inlet (grid type).

Fig-20: Air outlet/ inlet of traction motor

3.2.7 Speed sensor

For monitoring the speed, a speed sensor is mounted in the stator housing.

Fig-21: Speed sensor location in stator

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CAMTECH/E/2019-20/EP-05/TM of Train Set 15

Booklet on Traction Motor & Gear Box of Train Set December, 2019

3.2.8 Pt100 Temperature Sensors

For monitoring the stator temperature, Ptl00 temperature sensor is positioned in the

stator housing.

Fig-22: Temperature sensor location in stator

3.2.9 Traction Motor Water Flood Level

Traction motor : Water flood level : 400 mm from Rail level

Water draining from stator housing in rainy season by opening the drain plug

(53)

Fig-23: Flood Water drain plug (53)

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

3.3 TECHNICAL DATA FOR GEAR BOX

S. No. Description Details

1. Designation Partly suspended gear box assembly

2. Type designation GKD 1-52-372A

3. Dimensional drawing TSA016533

4. Weight of gearbox unit with half

coupling and without oil m Gearbox

490kg

5. No. of teeth of Main Gear 98

6. No. of teeth of Pinion 19

7. Gear ratio 5.157

8. Gear system Single stage spur gear

9. Center distance between Pinion

and Main gear

372 mm

10. Gear Box : Oil lubrication Type /

Make

Servo SynGear 75W-90LL / Indian

Oil Make

3.4 CONSTRUCTIONAL DETAILS OF GEAR BOX

Fig-24: Gear Box Assembly

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CAMTECH/E/2019-20/EP-05/TM of Train Set 17

Booklet on Traction Motor & Gear Box of Train Set December, 2019

Fig-25:Gear Box Sub-Assemblies

3.4.1 Drive Complete

Partly suspended drive with bogie frame fixed motor and axle-mounted gear. Motor

shaft and gearbox input shaft are connected by a coupling that transfers torque and

compensates for displacements between motor and gearbox.

The main gear is mounted directly onto the wheel set shaft and transfers torque

directly to the wheel set shaft.

Fig-26: Drive Complete

1. Axle 5. Taper roller bearing – 2 nos.

2. Main Gear 6. Cylindrical roller bearing – 2 nos.

3. Pinion 7. Four Point contact bearing

4. Flexible coupling

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

3.4.2 Gear Box Description

The gearbox is a helical gear with oil sump splash lubrication.

Fig-27: Main Components of Gear Box

D : Gear box assembled

2 : Pinion

14 : Coupling Half gear box side

21 : Reaction Rod complete

610 : Main Gear

W : Wheel set Shaft

3.4.3 Motor & Gear half Coupling

A curved teeth coupling connects motor

with gearbox. The coupling is torsional rigid, the

halves are self-centering by the teething. The

coupling consists of two halves whose flanges

are bolted together.

Fig-28: Motor Coupling

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CAMTECH/E/2019-20/EP-05/TM of Train Set 19

Booklet on Traction Motor & Gear Box of Train Set December, 2019

The coupling is lubricated by oil and is hermetic sealed to the outside by two steel

bellows, so leakage can be suspended. For the regular oil change both coupling halves are

equipped with drain plugs, this can be performed on the installed coupling without

disassembling from the shafts.

The coupling halves are mounted onto the shafts by tapered press fits, including

oil injections for mounting and dismounting.

The coupling transfers torque and compensates radial, axial and angular mis-

alignments between motor and gearbox.

At the general overhaul the coupling has to be checked visually for checking the

ability for further use in operation.

A slipping bush is installed at the gearbox side to protect the gearbox of too high

shock torques that can be generated in the motor in case of a converter short circuit.

The coupling is insulated, this ensures that the gearbox bearings are not affected by

discharging currents of the rotor.

3.4.4 Connection Gearbox to Wheel Set

The main gear is directly mounted onto the wheel set shaft by a cylindrical shrink fit

(the main gear is heated up for the joining operation), including oil injections for

dismounting.

3.4.5 Gear box Housing

The gearbox housing is casted. The gearbox housing is designed to high stiffness and

low noise radiation and protects oil level indicators from direct hits by rocks from the track.

Fig-29: Gear Box Housing

3.4.6 Gear box Support

The gearbox is supported by a reaction rod on the bogie frame. The reaction rod

incorporates two spherolastic bushings. During operation, the elastomers will wear and

must be checked regularly and exchanged when the end of the life time is reached.

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

3.4.7 Bearings

The input shaft is supported in the gearbox housing by two cylindrical roller bearings

and one four- point contact bearing for the axial forces. These bearings have single piece

solid brass cages.

The output shaft is supported by two tapered roller bearings. For the tapered roller

bearings pressed steel cages are used. All bearings are oil lubricated.

Bearing

Data

SKF Type FAG Type Replacement

interval in km

Input motor side Cylindrical roller NU 2217 NU 2217 30,00,000

shaft bearing ECML/C4 E-MPA/R120-140

wheel side Cylindrical roller NU 2217 NU 2217 30,00,000

bearing ECML/C4 E-MPA/R120-140

wheel side Four point ball QJ 217 QJ 217-N2-MPA- 30,00,000

bearing N2MA/C4H C4

Output motor side Tapered roller BT1- F-801207.01 30,00,000

shaft bearing 0054/VE679

wheel side Tapered roller BT1- F-801207.01 30,00,000

bearing 0054/VE679

3.4.8 Lubrication and cooling

The gears are lubricated by oil splash lubrication. The gearbox is cooled by

convection.

The design of the bearing area (oil stow provisions) ensures that a minimum

amount of oil remains in the bearing. A smooth start-up of the gearbox is allowed,

especially at low speeds and low environmental temperatures.

The gearbox includes an oil filling hole, an overfill protection, an oil sight glass

(changeable from outside) and a magnetic drain plug, which collects metallic wear

floating in the oil.

The oil level can be checked quickly and reliably through an oil sight glass, marked

with minimum and maximum. The oil lubricant for gear drive is Indian Oil Servo Syn

Gear 75W-90 LL

3.4.9 Sealing

Contact-free labyrinths are used to seal the shafts. The gearbox housing and covers

are sealed with liquid sealing substances. O-rings are used for sealing the bearing

cartridges, bearing covers and labyrinth covers.

During cleaning of the vehicles pay attention, that high-pressure water is not

directed into the labyrinth gaps, or protect them with covers.

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CAMTECH/E/2019-20/EP-05/TM of Train Set 21

Booklet on Traction Motor & Gear Box of Train Set December, 2019

3.4.10 Monitoring of the Gearbox

The magnet on the dip stick or the drain plug allows to check the conditions of the

gearbox visual.

Fig-30: Metal Abrasion on the permanent magnet

Metal abrasion on the permanent magnet

Status Required action

Grade Assessment

1 Normal None

Gearbox in normal condition

2 Acceptable

None

For a new produced gearbox during run-in until second

scheduled regular oil change (1st = initial oil change, 2

nd =

standard oil change interval)

No immediate action required

Draw oil sample.

Keep gearbox under observation, re-check the dip-stick in

reasonable time.

3 Unusual

None

For a new produced gearbox during run-in until second

scheduled regular oil change (1st = initial oil change, 2

nd =

standard oil change interval)

Replace oil

Draw oil sample.

Check gearbox bearings on wear. Replace components if

worn.

Drain the complete oil filling. If possible, flush the gearbox

with fresh oil. Fill in fresh oil.

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

3.5 TRACTION MOTOR PREVENTIVE MAINTENANCE SCHEDULE

(As provided by OEM M/s Medha Servo Drives Pvt. Ltd., Hyderabad)

S.No. Maintenance Task Every

25,000 km

or every

45 Days*

Every

1,50,000

km or

every

6 months*

Every

3,00,000

km or

after

1 year*

every

3,000.000

km or

after

10 years*)

1. Checking for external

damages of motor

cable, Speed sensor

cable & Temperature

sensor cable with

connector

2. Inspection of external

bolts for tightness √

3. Visual Inspection &

cleaning of air filters

and the air outlet grids

ventilation grid

4. Tightening of motor

cable connection

terminal bolts √

5. Water Draining the

stator housing √

6. Re-grease both bearings

of motor & removing

the used grease from

grease cover

7. Replace the Motor

bearings , Whole motor

reconditioning /

Periodic overhauling

(POH)**

* Which occurs first

** Maintenance work on uninstalled traction motor; km or years, whichever comes first.

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CAMTECH/E/2019-20/EP-05/TM of Train Set 23

Booklet on Traction Motor & Gear Box of Train Set December, 2019

3.5.1 Traction Motor Required Consumable During Maintenance Schedule

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

/● Designation Part number Quantity

Cylindrical roller bearing NU1012 TSA700099P0011 1

Deep groove ball bearing 6217 TSA700027P0022 1

● Speed sensor TSA013431P0001 1

● Used grease cover sealing TSA017339P0001 1

● Sealing for cable bushing TSA013974P0001 1

● Sealing for terminal box cover TSA017352P0001 1

● Sealing ring, A52x60x2,5-Cu TSA700105P0016 1

● O-ring, 144 x 1.5-72NBR 872 TSA700013P0144 1

● O-ring, 487 x 4 NBR 70 TSA700013P0101 1

● O-ring, 530 x 4 NBR 70 TSA700013P0102 1

● O-ring, 160 x 2 NBR 70 TSA700013P0100 1

● Resistance thermometer TSA017345P0001 1

It is necessary to stock the spare parts

● It is recommended to stock the spare parts

Part Description Part specification / Type /

Make

Quantity /

Rake

Screw locking agent medium

strength

LOCTITE 243

500 ml

Fitting paste MOLYKOTE P40 500 gm

Motor Roller Bearing Grease Shell Gadus S3 V220C 2 2 Kg

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

3.6 TRACTION GEAR BOX PREVENTIVE MAINTENANCE SCHEDULE

(As provided by OEM M/s Medha Servo Drives Pvt. Ltd., Hyderabad)

S.No. Maintenance Task After the

first

5,000km

Every

25,000

km or 45

Days*

Every

300,000

km or

once a

years*

Every

1,200,000

km or

after 4

years *

Every

1,600,000

km or

after 6

years *

Every

3,000,000

km or or

after 10

years *

1. First oil change to

remove debris** √

2. Check for damages oil

glass window** √

3. Ensure intactness of

Motor & gear box

mounting bolts with

Bogie**

4. Gear box oil level

check & top-up** √

5. Gear box oil change** √

6. Gear box alignment

verification /

adjustment** √

7. Changing elastomer of

reaction rod *** √

8. Grease change in the

coupling *** √

9. Inspection of Gear &

Pinion for damage*** √

10. General overhaul ***

including

Replace Pinion

bearings, Main gear

bearings, suspension

bearing from reaction

rod, All O-rings

(Periodic overhauling

(POH)

* Whatever comes first.

** Maintenance work on the installed traction drive.

*** Maintenance work on the de-installed traction drive.

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CAMTECH/E/2019-20/EP-05/TM of Train Set 25

Booklet on Traction Motor & Gear Box of Train Set December, 2019

3.6.1 Gear box oil filling & draining

For fresh oil filling: Use oil filling plug (22) for filling the fresh oil in the gear box

upto maximum level (26) shown in the below picture.

For used oil removing (draining) : Use oil drain plug (27) for removing the used from

the gear box shown in below picture.

Fig-31:Oil level indicator, drain plug and magnetic stick

Gear box Oil type -Servo Syn Gear 75W-90LL

Gear box oil change - After first 5000 Kms / 1 month and Every year / 3 lacs Kms

Traction Gear box assembly - 5.0 lit / Gear box

3.6.2 Consumable During Maintenance Schedule Traction Gear Drive System

Part description Part specification/ Type/ Make Quantity/ Rake

Screw locking agent

medium strength LOCTITE 243 1000ml

Fitting paste MOLYKOTE P40 1 Kg

Thread sealing agent LOCTITE 577 200 ml

ELRING CURIL T AC500158P0001 3000 ml

Gear box oil Make: Indian Oil

Servo syngear 75W-90LL 150Lit

Sealing –COPPER Ring

DIN7603-A21x26-CU TSA700105P0004 32

Sealing-COPPER Ring

DIN7603-A27x32-CU TSA700105P0001 64

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

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

/● Designation Part number TSA017119R1001

● Pinion 372A TSA017123P0001 1

● Main gear 372A TSA017124P0001 1

● Oil level indicator SP60 TSA006258P0005 1

Reaction link TSA013207R0001 1

Taper roller bearing TSA017122P0001 2

Cylindrical roller bearing

NU2217 TSA009164P00001 2

Four point bearing QJ217 TSA009053P0001 1

Adjustment sheet TSA017121P0001 1

O-ring, 290x5-N-P700-NBR70 TSA700013P0110 2

O-ring, 11x3-N-P700- NBR 70 TSA700013P0071 1

O-ring, 140x3-N-P700- NBR 70 TSA700013P0109 1

O-ring, 174x3-N-P700- NBR 70 TSA700013P0108 1

O-ring, 192x3-N-P700- NBR 70 TSA700013P0107 2

Sealing ring, 10x14x1-Cu TSA700105P0009 1

Sealing ring, 16x22x1.5-Cu TSA700105P0017 1

Sealing ring, 21x26-Cu TSA700105P0004 1

Sealing ring, 27x32-Cu TSA700105P0002 1

Sealing ring, 48x55x2-Cu TSA700105P0012 1

It is necessary to stock the spare parts

● It is recommended to stock the spare parts

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CAMTECH/E/2019-20/EP-05/TM of Train Set 27

Booklet on Traction Motor & Gear Box of Train Set December, 2019

3.6.4 Gear Oil-Limits for Contaminationsa

(Reference : TSA 121 Oil contamination limits 2012-10-30)

Gear case oil spectro-graphic analysis frequency three months

Designation Short name Limit (ppm)

Foreign particles (wear)

Iron Fe < 400

Chromium Cr < 15

Nickel Ni < 5

Molybdenum Mo <5

Aluminium Al < 60

Magnesium Mg < 25

Copper Cu < 100

Zinc Zn < 100

Lead Pb < 5

Tin Sn < 5

Siliconb Si < 60

Additivesc

Phosphorous

Sulphur

Lead

Zinc

Tin

Silicon

Chlorine

Magnesium

Molybdenum

Ph

S

Pb

Zn

Sn

Si

Cl

Mg

Mo

± 10%d

Additional measures

Dynamic viscosity 40 (at 40°C)

100 (at 100°C)

± 10%d

Water content -- < 0.3%

Total acid number TAN < 2mg KOH/gd

a The limits are valid for a typical oil and typical gearbox size, depending on the oil brand and oil amount in a gearbox

other limits may apply for an application. b Silicon is a foreign particle, but can also be used as an additive against foaming.

c The concentration of the elements in the oil depends on the oil composition, Lead, Zinc, tin, silicon, magnesium and

molybdenum are additives, but can be also foreign particles (wear). d The concentration must be compared with a fresh oil sample.

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

December, 2019 Booklet on Traction Motor & Gear Box of Train Set

REFERENCES

1. Design document for Traction Motor and Gear Drive for 3 phase AC Propulsion system for

Train 18. Document No. MAE675U/Traction motor /DD/CD-2342 Rev.0, made available

by M/s Medha Servo Drives Pvt. Ltd. Hyderabad.

2. Presentation on “Line and Traction Converter Train 18 type MAE 675U, made available by

M/s Medha Servo Drives Pvt. Ltd. Hyderabad.

3. Presentation on “Traction Motor and Gear Box of Train 18 Rake” given by technical expert

from M/s Medha Servo Drives Pvt. Ltd. Hyderabad during the seminar held at CAMTECH,

Gwalior on 16.12.2019.

4. Literature and photographs collected during field visit at ICF/ Chennai and Train set depot,

Shakurbasti, New Delhi, Northern Railway.

5. Discussion held on draft booklet on “Traction Motor and Gear Box of Train Set” during the

seminar held at CAMTECH, Gwalior on 16.12.2019.

6. Comments and suggestions received on draft booklet.

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To upgrade maintenance technologies and methodologies

and achieve improvement in productivity and performance

of all Railway assets and manpower which inter-alia would

cover reliability, availability, utilisation and efficiency.

OUR OBJECTIVE

CAMTECH is continuing its efforts in the documentation and up-

gradation of information on maintenance practices of electrical

assets. Over the years a large number of publications on electrical

assets have been prepared in the form of handbooks, pockets

books, pamphlets & video films etc. These publications have been

uploaded on the internet as well as rail net.

For downloading these publications please do following:

1. On internet visit :www.rdso.indianrailways.gov.in

Go to Directorates CAMTECH Publications for

download Electrical Engineering

2. On Railnet visit RDSO website at 10.100.2.19

Go to Directorates CAMTECH Publications for

download Electrical Engineering

For any further information regarding publications please

contact:

Director (Elect.) – 0751- 2470740 (O) BSNL, 9752447030 (CUG)

SSE/Electrical - 9755549297 (CUG)

E-mail at [email protected]

Fax to 0751- 2470841

Write at : Director (Electrical)

Indian Railways

Centre for Advanced Maintenance technology,

In front of Hotel Adityaz,Airport Road,

Maharajpur,Gwalior, Pin code – 474 005