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Powerline —
Drive automation for locomotives
Authors: Powerline is a complete concept for the automation of drive systems in diesel-hydraulic
and diesel-electric locomotives. Its modular structure provides a high level of flexibility and
Werner Knoll ensures straightforward integration in new-builds as well as in locomotive repowering pro-
Project Manager Powerline Project Engineering jects. This article describes how Powerline can be integrated in different types of locomotive
and explains the functional principles of the individual components.
Michael Welte
Project Manager Powerline Development 1. OVERVIEW OF SYSTEM The central interface in the Powerline system is the
Powerline was developed as a modular sys- ‘Power Automation Unit, Engine’ component (PAU
tem with various different functional modules Engine) (Fig. 1) which has the primary tasks of link-
in order to support both diesel-hydraulic and ing various locomotive control systems to the MTU
diesel-electric locomotives and in order to give diesel engine — via bus technology or hardwired
locomotive manufacturers a high degree of inde- signals — and of adapting external engine peripher-
pendence. The concept offers exceptional flex- als. PAU Engine also looks after the complex task
ibility in the selection and adaptation of func- of managing the locomotive’s cooling plant (con-
tions to suit individual locomotives. Figs. 1 and 2 trol and monitoring) in order to ensure that the die-
provide an overview of Powerline applications in sel engine operates in compliance with emissions
various locomotive types with the focus on the certification standards. In addition, PAU Engine
individual electronic components. also has a standardized Ethernet service interface
www.mtu-online.com
providing the user with simple and wide-ranging console via the locomotive control system. Where Engine Control Unit (ECU) and PAU Engine per-
diagnostics facilities for the diesel engine and faults arise, PAU Engine also manages the alarms form the same functions in all locomotive types.
Powerline electronics using standard tools. using a system of yellow and red alarm signals.
The primary functions of PAU Traction are to
Typical signals between the locomotive control Other electronic components such as ‘PAU monitor and control the traction generator and to
and PAU Engine include engine start, engine Traction’, current and voltage transformers and a provide additional monitoring, protection and con-
stop and target speed but the component also power output stage are also available for AC/DC trol functions. These include an anti-slip function
processes other vital information such as speed, locomotives (Fig. 2). In this system, PAU Traction in which PAU Traction detects wheel-slip on the
lube oil pressure and coolant temperature and acts as an interface with the traction generator locomotive and initiates appropriate countermeas-
makes them available for display on the driver’s and its associated components. The electronic ures such as reducing the power available to the
traction motor. Other important functions include
Fig. 1: System overview of diesel-hydraulic and diesel-electric AC locomotives field weakening for the traction motors, i.e. elec-
trical gear change, and rectifier monitoring.
Fig. 2: System overview of dieselelectric AC/DC locomotives In order to meet other important requirements and
to safeguard the flexibility needed, Powerline com-
ponents also offer the possibility of adapting and
parameterizing all software functions to suit the
relevant locomotive environment. This provides
an exceptionally flexible system which can be cus-
tomized to match each individual locomotive type.
2. INTEGRATION IN DIFFERENT
LOCOMOTIVE TYPES
The system components described can be inte-
grated in three different locomotive types.
1 Diesel engine
2 ECU (engine control unit)
3 POM
4 PAU Engine
5 Electronics control cabinet
6 Cooling plant (cooler fans)
7 Fluid transmission
1 Diesel engine
2 ECU (engine control unit)
3 POM
4 PAU Engine
5 Electronics control cabinet
6 Three-phase synchronous generator
7 Rectifier
8 Convertor
9 Cooling plant (cooler fans)
10 AC traction motors
shows the core Powerline components and the lo- motors (Fig. 5). In addition to the Powerline com- In this way, the PAU Engine electronics plat-
comotive control system. For the sake of simplicity, ponents already mentioned, this configuration form facilitates linkage between a range of MTU
individual sensors and actuators such as hydraulic also involves PAU Traction for generator control. engines and various different locomotive con-
fluid level sensors and fuel pumps are not shown. trol systems, e.g. 8, 12 and 16-cylinder Series
4000 R41 engines (UIC II, 850—2,200 kW);
2.2. DIESEL-ELECTRIC AC/AC LOCO 3. POWERLINE AS AN ELECTRONICS 8, 12, 16 and 20-cylinder Series 4000 R43
MOTIVES PLATFORM (EU IIIA/UIC IIIA, 1,000—3,000 kW) and
Integration of Powerline in a diesel-electric loco- The flexibility of the rail automation system can 4000 Rx4 engines (EU IIIB/UIC IIIB, 1,000—
motive with AC/AC technology (Fig. 4) involves also be described in terms of platform electron- 2,700 kW, from 2012) as well as 12-cylinder
the same components as for diesel-hydraulic ics where a universal electronic module utilizes model 1600 R50 engines (EU IIIB/EPA Tier 4,
locomotives. The drive units on this type of loco- standardized interfaces to link the engine control- 690 kW, from 2013) (Fig. 6). Whilst PAU Engine
motive are three-phase AC motors fed via the ler with the locomotive control system, thus func- links MTU diesel engines with the locomotive
converters as shown. tioning as a central linking element. In the case control systems, the electronic module PAU
of Powerline, PAU Engine is the central electronic Traction performs the same function in respect
2.3. DIESEL-ELECTRIC AC/DC LOCO module which facilitates linkage with the electron- of the various traction generators. PAU Traction
MOTIVES ic engine controllers (ECU) for the various MTU also has standardized interfaces and facilitates
Powerline also supports diesel-electric AC/DC rail diesel engines as well as providing a standard- the connection of various traction generators
locomotives which operate with DC traction ized interface with the locomotive control system. with the locomotive control system so that DC
Series 1600 R50 (EU IIIB) Series 4000 R41 (UIC II) Series 4000 R43 (EU IIIA/UIC IIIA) Series 4000 Rx4 (EU IIIB/UIC IIIB)
traction generators as well as three-phase syn- For connection to the locomotive control system, The concept of using prefabricated function mod-
chronous generators with rectifiers can be linked PAU Engine provides numerous rail-specific hard- ules allows simple and fast adaptation to locomo-
to locomotive control. ware interfaces in the form of binary and analog tives from different manufacturers and also accom-
signals as well as standardized bus interfaces such modates different types of traction generator.
as CANopen. The module also benefits from addi
4. CORE POWERLINE COMPONENTS tional interfaces for linking external engine periph-
Like PAU Engine, PAU Traction provides rail-spe-
erals such as fuel pumps, air filter monitoring, cific interfaces in the form of binary and analog
4.1. ENGINE CONTROL UNIT (ECU) diesel engine cooling plant control and additional signals for locomotive control and has CAN-
The ECU is MTU’s electronic engine controller coolant level sensors. bus communication with the engine controller
with integrated engine management. It is mounted (ECU). However, it also has additional interfaces
directly on the diesel engine. The ECU is a stand- PAU Engine also has an interface with the driver’s for linking external traction generator peripher-
ard MTU component which is used in a range of console in the locomotive. This allows it to pro- als such as current transformers for measuring
different applications including the rail, marine, vide a range of data such as control signals for traction motor current and voltage transformers
distributed power generation and C&I sectors. alarm lamps and display instruments covering for measuring generator voltage and monitoring
Adaptation to the relevant application is achieved engine speed, coolant temperature and lube oil rectifier fuses, rectifier temperature and traction
using different parameter sets depending on the pressure etc. Obviously, PAU Engine also provides generator winding temperature. PAU Traction
engine type and application sector. The primary an interface with the ECU in the form of a further also has interfaces with the driver’s console in
tasks of the ECU include start sequence control, CAN bus. the locomotive. These can be used to transmit
speed control and engine monitoring. The ECU various signals including, for example, genera-
also has an engine safety system. In order to guarantee this extremely high level tor voltage, generator current and mean traction
of flexibility and functionality, PAU Engine also motor current to analog display instruments.
4.2. POWER OUTPUT MODULE (POM) facilitates the transmission of diagnostic data
POM is an optional module for starter con- for commissioning. This allows access to vari- Likewise, PAU Traction provides an Ethernet
trol and also functions as a terminal board for ous diagnostic and commissioning functions via interface facilitating fast and simple diagnosis
the starter cables. Like the ECU, it is mounted a standard Ethernet interface and a Web browser and commissioning without the need for special-
directly on the engine. The POM is controlled without the need for special-purpose diagnos- purpose tools. Function and application of the
directly via the ECU. tic tools. Commissioning and troubleshooting Ethernet interface have the same “Look and Feel”
throughout the entire Powerline system is thus for PAU Engine and PAU Traction so that diagno-
4.3. POWERLINE AUTOMATION UNIT considerably simplified. sis of an entire Powerline system is straightfor-
ENGINE (PAU ENGINE) ward and intuitive.
PAU Engine is the central link element between 4.4. POWER AUTOMATION UNIT
the locomotive control system and the MTU die- TRACTION (PAU TRACTION)
sel engine control. It is an automation module PAU Traction is the link element between the 5. POWERLINE ACCESSORIES
with interfaces and functions specifically devel- traction generator and the locomotive control Additional MTU components are available to
oped for rail applications. Unlike ECU and POM, system. Like PAU Engine, PAU Traction is an elec- extend the Powerline system and cover supple-
PAU Engine is not engine-mounted but is located tronic automation module with rail-specific inter- mentary requirements.
in the locomotive’s switch cabinet. PAU Engine faces and software functions and is located in the
is used in applications ranging from locomotive locomotive switch cabinet. PAU Traction has the 5.1. REMOTE SERVICES
new-builds to locomotive repowering projects task of linking traction generators from different An optional data acquisition module can be
and special-purpose vehicles. manufacturers with the locomotive control sys- installed in the locomotive which makes it possi-
tem. Unlike PAU Engine, PAU Traction is normally ble to transmit all important measuring and diag-
In order to achieve the level of flexibility already used primarily for repowering projects and for nostic data to an MTU remote server via GSM
described, PAU Engine has around 140 hardware special-purpose vehicles. Obviously, PAU Traction modem. The rail operator’s service staff can then
channels in various forms. This allows straightfor- is always used together with PAU Engine in these access the data on the locomotive worldwide via
ward adaptation to different new and repowered types of locomotive. an encrypted Internet link.
locomotives as well as to various special-pur-
pose vehicles. Each of these hardware channels PAU Traction provides around 90 hardware chan- Scanning the locomotive data means that pre-
is supported by tested and proven rail software. nels for linking different traction generators and ventive action can be taken in good time on the
The function is activated and parameterized via their associated peripherals to the locomotive basis of fault reports. Downtime and faults on the
internal PAU Engine operating parameters. control system. This allows straightforward adap- locomotive can thus be considerably reduced and
tation to the conditions prevailing in repowered even avoided completely. Running scans on cur-
This modular system utilizing pre-allocated hard- locomotives and special-purpose vehicles. As with rent diagnostic data also makes it possible to opti-
ware channels and pre-defined standard software PAU Engine, each hardware channel is supported mize service and maintenance scheduling for the
functions facilitates fast and straightforward by tested and proven standard rail software which entire fleet of vehicles.
adaptation to different locomotives from different can be activated and parameterized via PAU
manufacturers. Traction operating parameters.
Fig. 8: Detailled diagram of the product development process up to safety test completion 8. DEVELOPMENT BASED ON THE V-MODEL
MTU develops all its hardware and software
components on the basis of the widely recog-
nized V-model (Fig. 8). This procedure helps to
avoid system-based faults during the product
development process. As the entire development
process is accompanied by a TÜV consultant, the
V-model provides auditable documentation verify-
ing process-compliant development. These docu-
ments are the credentials which verify the safe-
ty of the rail components and sub-assemblies
which will one day be used in rail systems trans-
porting both passengers and hazardous goods.
including receipt review, implementation and be reliably implemented, all electronic compo- This support is available right from the quota-
conclusion review. nents are developed, further developed (if nec- tion phase in the form of consultation on all of
essary), tested and manufactured at MTU. the standard functions required, selection of
New software functions under development are suitable standard components and important
checked by an independent ‘verifier’ to confirm It is, of course, possible that manufacturers of information on the safety functions of the MTU
that all of the specified requirements are covered electronic sub-components such as capacitors system. Customer-specific solutions obviously
and to verify compliance with the development or ICs, could discontinue supplies during the also play a central role in these consultations.
process. In addition, during the system test, a lifetime of the warranty. In such cases, all elec- In the project engineering phase, the next step
‘validator’ checks to ensure that the function, as it tronic devices affected are further developed is detailed consultation on the functional inte-
is implemented in the product, meets the speci- by MTU’s in-house R&D section to make them gration of the electronic components from MTU
fied requirements. An independent, external con- compatible with the new sub-components avail- in the locomotive control system. The various
sultant analyzes the development process and able on the market. different technical solutions available are also
the safety functions it incorporates. If the relevant compared and evaluated in order to identify the
development standards and procedural models In order to ensure a swift response to such best possible system solution.
have been complied with, the consultant then changes, MTU’s quality management system
issues a safety certificate for the system. continuously monitors the availability of all com- During commissioning of the locomotive, MTU
ponents used. If a supplier announces the dis- offers wide-ranging support in areas such as
continuation of larger electronic components, the engine start, static and dynamic engine load
9. SOFTWARE ADMINISTRATION assemblies affected are completely redesigned tests, generator testing and cooling plant test-
Flexibility through parameterization as mentioned and, if necessary, any software modifications ing. Prior to engine start, checks are run to
above, also involves a further aspect relating to needed are implemented. The interfaces with the confirm that all MTU electronic components
the product life cycle: software administration. locomotive environment, such as housings and have been correctly installed. The plant’s sig-
During production, it is essential that each elec- connectors etc., remain externally unchanged. nal interface is then tested before the engine is
tronic component receives the correct software started up. Locomotive-side auxiliaries such as
and the correct parameter set for the application compressors, battery charging and cooler venti-
in question. This requirement applies not only for 11. ELECTRONICS PRODUCTION AT MTU lation undergo tests during engine start-up.
series production but also for any replacement MTU’s electronic components are manufac-
parts which may be needed. In this context, the tured in-house and are fully tested for function- During the static load tests, specific engine per-
use of a software configuration management sys- ality. To ensure that components deliver a long formance points are checked at specified engine
tem ensures compliance with the specifications service life and high quality, all production pro- speeds. To achieve the best possible balance
of Standards EN50128 and EN50129. cesses are strictly linked to ISO9000 and IRIS for the locomotive drive module, the parameter
(International Railway Industry Standard) and are values for the electronic MTU components are
ECU software and order-specific parameter sets audited at regular intervals by external certifica- optimized. During the dynamic load tests, these
for each individual engine (e.g. engine-specific tion companies. parameters are then suitably modified in the con-
performance maps and order-specific plant text of ‘locomotive performance characteristics’.
parameters) are stored in a central MTU data- Inspection of the electronics components manu-
base. Identification is effected by means of glo- factured takes the form of automated tests using If the MTU traction components PAU Traction /
bally unique engine numbers. devices which safeguard consistent and repro- power output stage are involved, support is also
ducible test quality. All of the test results for available to the customer on pre-assembly of
Software administration for PAU Engine and PAU each individual component are recorded in a test the engine and generator as well as on flange-
Traction also utilizes a central MTU-wide data- log which can be accessed at any time. The rele- mounting and integration of engine and gen-
base where the order-specific parameter sets vant test logs can be identified using unique part erator in the locomotive. MTU is also on-hand
and the relevant PAU software for each order are and serial numbers allocated to the electronic during testing of the generator at the generator
stored. This system makes it possible to clearly components thus guaranteeing reliable identifi- manufacturer’s testing facility when procedures
identify the software and parameter sets for cation and traceability at all times. such as vibration measurements, torsional
each individual device in operation in locomo- vibration measurements and tests on generator
tives throughout the world at any time. self-heating are conducted.
12. CONSULTATION, PROJECT ENGINEER-
ING AND COMMISSIONING If required, MTU also provides support on cool-
10. REPLACEMENT PARTS Expert knowledge and experience are par- ing plant tests. The procedures involved define
The availability of replacement parts must, of ticularly vital during the planning, design and cooling control parameters not only to ensure
course, be guaranteed throughout the service calibration of the individual components. MTU stable temperature regulation for the diesel
life of the locomotive, which may be up to 30 offers its customers comprehensive support engine but also to maximize the service life of
years. MTU gives the rail operator a warranty to ensure that the final outcome is an ideal the cooler. The entire cooling plant is balanced
that replacement parts will be available for 30 drive concept with the best possible balance to achieve the best possible operating condi-
years. And in order to make sure that this can between the individual components. tions for the diesel engine.
PAU Engine
13. WORLDWIDE SERVICE builder and service staff to run diagnostics on in the future with the integration of new engine
MTU Friedrichshafen GmbH, Maybachplatz 1, 88045 Friedrichshafen, Germany, Phone +49 7541 90-0, www.mtu-online.com September 2012
MTU is the brand name under which the Tognum Group markets
engines and propulsion systems for ships, for heavy land, rail and
defense vehicles and for the oil and gas industry. They are based on
diesel engines with up to 9,100 kW and gas turbines up to 45,000 kW
power output. The company also develops and produces bespoke
electronic monitoring and control systems for the engines and
propulsion systems.