RU50060U1 - HIGH VOLTAGE STATIC CONVERTER FOR PASSENGER CAR - Google Patents

Abstract

A high-voltage static converter for a passenger car is designed to complete the electrical equipment of passenger cars with autonomous power supply and air conditioning. This is an electrical conversion device that provides power to various consumers of the car network. The converter itself is powered by a high-voltage contact network of direct or alternating current, providing low-voltage power for consumers of direct and alternating current at the output. The design is made in the form of two car boxes, in one of which the high-voltage part is located, and in the second - the low-voltage part. The entire device consists of assembly units in block-modular design, the mass of each of which does not exceed 10 kg. The block-modular design of the device allows you to vary the set of components that determine the capabilities of the entire device in providing energy to potential consumers, determined by the technical requirements and wishes of the customer. The connection of the high-voltage and low-voltage parts of the device is carried out by an electric cable. Both car drawers have slotted windows in the rear wall and radiators on the outside, blown by air currents when the train is moving. The radiators of the first car box, where the high-voltage part is located, are insulated from the body for the purpose of electrical protection and can additionally be blown by a fan

(one or more), also mounted on the rear wall of the housing. In addition, the first car box provides electrical insulation of heat-conducting plates, on which the heating power elements of the high-voltage part are fixed, from the body and radiator in the opening of the slotted windows in case of a possible breakdown of high voltage. In the second car box, where the low-voltage part is located, the blocks and modules that make up the assembly units are also placed on heat-conducting plates, but these plates are mounted directly on radiators in the openings of the slotted windows. These design solutions allow for intensive heat removal from heating elements and create protection against breakdown of high voltage, which ensures stability and reliability of the device. Access to the contents of both car boxes is possible through the doors of the front walls, which are tilted upwards and locked in a horizontal position, which, in case of bad weather, can serve as a protective peak for maintenance and repair personnel. Free access to structural elements, due to the location of assembly units in one layer, and the presence of rotary devices on printed circuit boards that rotate the plane of the printed circuit board around a vertical axis for easy access to elements, allow you to quickly repair and replace failed modules or radio elements without dismantling whole block. The low weight of one assembly unit greatly facilitates the physical execution of the work.

Description

Technical field

A high-voltage static converter for a passenger car is designed to complete the electrical equipment of passenger cars with autonomous power supply and air conditioning. This is an electrical conversion device that provides power to various consumers of the car network. The converter itself is powered by a high-voltage contact network of direct or alternating current, providing low-voltage power for consumers of direct and alternating current at the output.

State of the art

One of the main trends in the development of rail transport is to increase the comfort of passenger transportation. Modern passenger carriages are being built and modernized taking into account the increasing demands for comfort. The cars are equipped with air conditioning, heating, ventilation. They necessarily have sockets for using household electrical appliances, designed for power supply ~ 127/220 V or = 12/24 V, as well as units for charging batteries.

Well-known manufacturers of converting equipment for railway transport are developing new high-voltage static converters with high reliability, small dimensions and weight, convenient designs for operation and repair.

So, for example, State Unitary Enterprise “VEI named after Lenin, a member of the LM Electro holding (http://lme.nodex.ru), produces the VPV-35-U1 high-voltage wagon converter, which is designed to power consumers of the wagon network with a voltage of 110 V and 550 V DC. It is powered directly from a contact network with a voltage of 3 kV DC, or from a power transformer of a locomotive with a voltage of 3 kV AC with a frequency of 50 Hz. The converter is housed in two withdrawable sealed drawers inserted into a common compartment attached to the carriage frame. Full power at the output of the ERW is provided both during the movement of the car and in the parking lot. Permissible ambient temperature during operation: from minus 40 ° С to plus 40 ° С. Resistance to mechanical influences corresponds to group M25. Autonomous liquid cooling. The overall dimensions of one box are 1060 × 880 × 625 mm. Total weight - not more than 400 kg.

The disadvantage is the limited number of output rated voltages, and from the point of view of design - non-modular design, which does not allow you to quickly vary the output characteristics of the Converter. It is also difficult to carry out repair work, since to carry out these works it is necessary to roll out heavy boxes from under the car. Repair of these converters is needed. carry out in a depot or in specially adapted parking lots.

The Ukrainian organization Dneprovagonremstroy (http://dvrb.com.ua/electoroborud.html) is engaged in the repair and, in particular, modernization of passenger cars. At the same time, a fundamentally new power supply system is installed in passenger compartment wagons, powered by a 3000 V intercar line via a car transformer. The carriage converter is located in the carriage high-voltage hardware box 2Я.111.У1, and includes a high-voltage static converter SG 600 380 BP, input reactance SG 600 417; SG 600 419 transformer, three-phase static inverter SG 600 388 SP, SG 600 418 reactance. On retractable bogies 84 TNZH - 300 110 V batteries are located. Also there is a separate hardware car box for connecting external voltage of a three-phase network 380/220 V 50 Hz.

The disadvantage is the non-modular design of the components, as well as low maintainability due to the bulky design, heavy weight, and inconvenient access.

A more advanced approach to the development of converters for the railway was taken by the German company Siemens. This company has developed a standard range of converters called Siebest, which are divided by power class. The main feature is the modular design of each type of converter.

In an article published in the journal “Railways of the World” No. 6 - 2000 (www.css-mps.rn) entitled “Modular power supply system for passenger cars”, the structure of a modular power supply system for cars and a table of standard modules are given.

Depending on the specific requirements for the purpose of a particular converter, the necessary modular blocks are placed in a universal container. This complete container is installed under the bottom of the car.

As a prototype, we consider the design of the power supply unit for passenger cars (abbreviated as BEV), which is supplied to the railways of the Russian Federation by the DUEWAG AG department of Siemens AG (Germany).

The BEV unit is connected to the electric line of a train of 3000 V DC or AC and serves to power electric consumers of cars in the train, including air conditioning devices.

The BEV block is located in a carriage painted in aluminum frame. The individual components of the converter are designed as standardized air-cooled modules. Outside the power modules there are radiators for heat dissipation. With a large output power, high ambient temperature and during a train stop, the radiators are forcedly cooled by a fan located in the center of the frame. A modular power supply system, as a rule, consists of one input high-voltage module and several output (depending on customer requirements).

In front of the frame under the cover is a power unit with an input converter module, an inverter and a battery charger. Magnetic parts are located at the rear of the chassis. Each module can be replaced if the diagnostic system indicates a malfunction. Control elements, contactors, fuses, sensors are accessible through the front and rear covers. The fan can be removed from below. If necessary, the entire power unit can be completely replaced.

Overall dimensions of the BEV (L × B × H): about 2000 × 1900 × 520 mm.

Weight: not less than 1000 kg.

Despite the great advantages of such an enlarged modular design, the prototype has its drawbacks. These are large dimensions and weight. Extraordinary efforts are needed to push the car box, weighing more than a ton. The mass of individual modules is also large. This complicates the maintenance and repair work. As for the heat sink, heat dissipation occurs inside the frame on modular radiators, and almost always requires the operation of a fan located also inside the frame. Natural blowing of radiators when the train is moving is not very effective.

The purpose of creating a utility model is the creation of such a design of a high-voltage static converter for a passenger carriage that provides good heat dissipation from power elements, which determines stable and reliable operation of the device with respect to electrical parameters, while providing convenient access to blocks and modules for repair or replacement failed power elements without dismantling the entire unit, and also greatly facilitates the physical implementation of repair and maintenance work. In addition, the design should allow changing the composition of the components of the device depending on the technical specifications and customer requirements in a short time with minimal labor.

Utility Model Essence

The essence of the utility model lies in the design of the device - a high-voltage static converter for a passenger carriage - in

in the form of two car boxes, in one of which the high-voltage part is located, and in the second - the low-voltage part. The entire device consists of assembly units in block-modular design, the mass of each of which does not exceed 10 kg. The connection of the high-voltage and low-voltage parts of the device is carried out by an electric cable.

Both car drawers have slotted windows in the rear wall, and fixed radiators on the outside of the rear walls, blown by air currents when the train moves. The design provides efficient heat removal from the heating elements through radiators. The radiators of the first car box, where the high-voltage part is located, are isolated from the body for the purpose of electrical protection and can additionally be blown by a fan (one or several), also mounted on the rear wall of the body. In addition, the first car box provides electrical insulation of heat-conducting plates, on which the heating power elements of the high-voltage part are fixed, from the body and radiator in the opening of the slotted windows in case of a possible breakdown of high voltage. In the second car box, where the low-voltage part is located, the blocks and modules that make up the assembly units are also placed on heat-conducting plates, but these plates are mounted directly on radiators in the openings of the slotted windows. These design solutions allow for intensive heat removal from heating elements and create protection against breakdown of high voltage, which ensures stability and reliability of the device.

Access to the contents of both car boxes is possible without extending the car box, through the doors of the front walls, which can be tilted upwards and locked in a horizontal position, which, in case of bad weather, can

serve as a protective visor for maintenance personnel. Free access to structural elements, due to the location of assembly units in one layer, and the presence of rotary devices on printed circuit boards that rotate the plane of the printed circuit board around a vertical axis for easy access to elements, allow you to quickly repair and replace failed modules or printed circuit boards without dismantling the entire unit. The low weight of one assembly unit (not more than 10 kg) greatly facilitates the physical performance of the work. The replacement time for any printed circuit board is 1-2 minutes.

The block-modular design of the device allows you to vary the set of components that determine the capabilities of the entire device in providing energy to potential consumers, determined by the technical requirements and wishes of the customer.

Utility Model Attributes

The high-voltage static converter for a passenger car consists of assembly units in a modular block design and includes high-voltage and low-voltage parts located in a subcar structure containing a fan. The whole carriage structure is made in the form of two carriage boxes with radiators on the rear walls and the doors of the front walls that are tilted upward and fixed in a horizontal position. The first car box has a removable protective cover at the back. The radiators of the first car box, in which the high-voltage part of the device is located, are separated from the rear wall of the housing by an insulating gasket. On the same rear wall there are one or more fans. Radiators of the second car box,

in which the low-voltage part of the device is located, mounted directly on the rear wall of the housing. There are slotted windows on the rear walls of both car boxes. The connection of the high-voltage and low-voltage parts of the device is carried out by an electric cable.

The weight of one assembly unit does not exceed 10 kg.

The assembly units of the first car box include modules of a current-limiting reactor filled with a heat-conducting compound, modules of high-frequency isolation transformers, high-voltage semiconductor modules, and low-voltage rectifier modules. High-voltage semiconductor modules and high-frequency isolation transformer modules are mounted on heat-conducting plates made of aluminum alloy, which are attached to radiators in the opening of slotted windows through heat-insulating insulating films.

The blocks and modules that make up the assembly units of the low-voltage part are mounted on heat-conducting plates made of aluminum alloy, which are attached directly to the radiators of the second car box in the opening of the slotted windows.

The blocks that make up the assembly units of the low-voltage part are made on printed circuit boards equipped with rotary devices that rotate the plane of the printed circuit board around the vertical axis.

List of drawings

Figure 1. The design of the first car box.

The drawing shows the design of the car box with the front wall in the form of a closed door and a protective casing of the rear wall. The section of the housing shows the contents of the first car box in the form of a conditional image of the modules of the high-voltage part. Some of them are mounted on heat-conducting plates, and those, in turn, are mounted on radiators in the openings of the slotted windows on the rear wall. Other modules are located on the inner side wall of the car box. In addition, in the context of a part of the protective casing, a radiator and an insulating gasket are seen separating the radiator from the casing.

Fig 2. The design of the second car box.

The drawing shows the design of the second car box with a partially cut front wall. In the depths of the box shows the location of the assembly units in the form of conditional components mounted on heat-conducting plates, which are mounted directly on the radiators of the rear wall of the housing.

Utility Model Implementation

The high-voltage static converter for a passenger car is made in the form of two subcar boxes: the first 1 (Fig. 1) and the second 2 (Fig. 2) with upward-folding doors 3 on the front walls. The radiators of the first drawer 4 are separated from the rear wall of the housing by an insulating gasket 5. Fans are fixed to the same rear wall 6. The fans and radiators are closed by a removable protective casing 7.

The first car box 1 contains modules of a current-limiting reactor 8 filled with a heat-conducting compound, and high-frequency decoupling modules

transformers 9, high-voltage semiconductor modules 10, low-voltage rectifier modules 11.

High-voltage semiconductor modules are mounted on heat-conducting plates 12 made of aluminum alloy, attached to radiators 4 in the opening of the slotted windows 13 through insulating heat-conducting films 14.

The second car box 2 contains modules of storage reactors filled with a heat-conducting compound 15 for a battery charging unit, blocks of adjustable inverters 16 for powering the air conditioning compressor motor and fresh air ventilation, and output units 17, in accordance with the intended purpose. All modules and blocks are assembled directly each on its own heat-conducting plate 12 made of aluminum alloy, mounted from the inside through the opening of the slotted window 13 to the radiators 4, mounted on the rear wall of the housing.

Both car boxes have terminal blocks 18 on the inside walls and openings with inserted pipes 19. Through these pipes, the end of the input power cable 20 is inserted into the first box on the left and the first end of the connection cable 21. On the left, the second end of the connection cable is inserted inside the second box cable 21, and on the right - the end of the output cable 22, the ends of the cables are fixed to the connectors of the corresponding terminal blocks.

Description in dynamics

High-voltage static Converter for a passenger car works as follows.

High voltage from the main train bus, for example, a constant voltage of 3000 is supplied through the pipe on the left wall of the first car box

to the terminal block 18, and from there to the modules of the current-limiting reactor 8. Next, the voltage is supplied to the N channels of the series-connected high-voltage semiconductor modules 10. From the outputs of these semiconductor modules, an already processed voltage is applied to each module of the high-frequency isolation transformers 9, N times less than the input voltage. The windings of the same name of these transformers 9 are connected to low-voltage rectifiers 11, the outputs of which are interconnected in such a way that as a result they can obtain two constant stabilized voltages: 400 V and 160 V, which are supplied to the output terminal block of the first car box located on the right wall. Through the connecting cable 21, these two voltages are supplied to the terminal strip of the second car box located on its left wall. The voltage 160V through the storage reactor 15 of the second car box is supplied to the battery charge unit and those output units that are designed to power DC consumers. A voltage of 400 V is supplied to the units of the adjustable inverters 16 for supplying alternating current to the air conditioner compressor motor and fresh air ventilation and to the output units 17 for supplying other planned consumers.

The radiators 4 of both drawers dissipate the excess heat transferred to them from the heated components through the heat-conducting plates 12 to the surrounding space, and while the train is moving, these radiators are cooled by the oncoming air flow, and when parked in the summertime, it is used to blow the radiator of the first car box, which is heated more one or more fans 6, located under the protective casing 7.

Blocks of adjustable inverters 16 and output blocks 17 are made on printed circuit boards with hinged radio elements and modules of power electrical components, and the printed circuit boards are equipped with rotary devices that rotate the plane of the printed circuit board relative to the vertical axis for convenient access to the repaired unit and replace failed power elements without dismantling the entire unit.

In the event of failure of the high-voltage static converter, the design allows you to quickly make operational repairs or replace individual components during parking. To do this, the repair worker opens up the doors of the front walls of the car boxes, fixes them in a horizontal position in the form of a visor and gets access to the components. A visor protects the contents of the box and maintenance personnel from atmospheric agents. The location of all assembly units in one layer over the entire inner surface of both boxes, as well as the low weight of each such assembly unit (no more than 10 kg), ensure the convenience and speed of work. Any printed circuit board changes in a time not exceeding one minute. To repair any power module, it is only necessary to tilt (turn) the corresponding printed circuit board, blocking access to it, and replace this power module with a spare one.

Concrete example

A high voltage voltage converter for passenger cars can be implemented with the following parameters:

L × B × H = 1870 × 730 × 690 mm:

Weight: 550 kg - the first car box and 350 kg - the second car box.

Material of car boxes: 2 mm thick steel sheet

Material of radiators: aluminum alloy AMG-6.

As a storage reactor, you can use the reactor MIYUN.672161.001.

As a module of high-frequency isolation transformers, transformers MIYUN.672422.002 can be used.

As high-voltage semiconductor modules, you can use modules SM200DI 34KA.

As insulating gaskets and insulating films, you can use the material polyamide (caprolon) TU 6-05-988-87.

To ensure reliable thermal contact of aluminum plates with a radiator, heat-conducting films of the PART No: CM20-AC type can be used.

A material like KU-ALF5H can be used as insulation.

As a low-voltage output part of the converter, the static converter ПЧ-24-У1 ТУ 16-00 MBDI 435321.001 ТУ developed at the Institute of Electromechanics (Istra) can be used.

Claims (5)

1. High-voltage static converter for a passenger carriage, consisting of assembly units in block-modular design and including high-voltage and low-voltage parts, placed in a subcar structure containing a fan, characterized in that the subcar structure is made in the form of two car boxes with folding up and horizontally locked doors of the front walls, the rear walls having slotted windows, and the connection of the car boxes with each other is carried out with an electric cable, while the first car box, in which the high-voltage part of the device is located, has a protective cover at the back, under which fans and radiators are mounted on the rear wall, mounted on the body through an insulating gasket, and the second car box, in which the low-voltage part of the device has radiators mounted on the rear wall of the housing from the outside without insulation. 2. The high-voltage static converter for a passenger car according to claim 1, characterized in that the weight of one assembly unit does not exceed 10 kg. 3. The high-voltage static converter for a passenger car according to claim 1, characterized in that the assembly units of the first car box include thermoconductive reactor modules filled with a heat-conducting compound, high-frequency isolation transformer modules, high-voltage semiconductor modules and low-voltage rectifier modules, and high-voltage semiconductor modules and modules high-frequency isolation transformers are installed on heat-conducting plates made of aluminum alloy, which are mountable to the radiators in the aperture windows through the slotted insulating heat-conducting film. 4. The high-voltage static converter for a passenger car according to claim 1, characterized in that the blocks and modules included in the assembly units of the low-voltage part are mounted on heat-conducting plates made of aluminum alloy, which are attached directly to the radiator of the second car box in the opening of the slotted windows. 5. High-voltage static converter for a passenger car according to claim 1 or 4, characterized in that the blocks included in the assembly units of the low-voltage part are made on printed circuit boards equipped with rotary devices that provide rotation of the plane of the printed circuit board relative to the vertical axis and quick replacement a printed circuit board that has failed in a time not exceeding 1 ÷ 2 min.