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Derek Nelson MORGAN ADVANCED MATERIALS

RAIL PRODUCTS APPLICATION GUIDE

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Electrical Carbon Application Manual Rail Products


Rail transportation remains a key product group for Morgan Advanced Materials, servicing the needs globally for both freight and people moving applications. As a Global leader of highly performing carbon materials suited for both heavy loaded freight and lightly loaded people moving applications..Morgan are a widely accepted leader in the provison of value added materials to both a strong OEM base including General Electric and EMD-Caterpillar, as well as the provision of a wide range of products including pantograph carbons and earthing brush solutions to a global end user market. This Application guide will look at the various products as utilised in;

• Diesel Electric Locomotives • Metro or Transit Systems • Tram - Light Rail Systems

Combined with a basic view of the systems employed , in order to achieve “Energy transfer” within a rail system. Further information relating to products suited for Rail applications can also be found on the Global Electrical Portal Within the Electrical Toolkit Section.

https://morganet.morganplc.net/mgamasia/eltools/SitePages/Home.aspx The Fundamentals for the performance of carbon brushes in Rail Applications remains the same as for all other areas into which we supply Electrical Carbon; For a DC Machines we aim for a carbon material which allows spark free “Switching” of conductor coils during machine rotation, We strive for a balance between material performance and commutator running surce optimum performance. Material are generally in the Electrographitic family of materials, emplying dual wafer designs to cater for rapid changes in commutating energy. For AC Machines our aim for a carbon material is “Collection” or transfer of current to an from a Slip ring surface. We strive for excellent ridability and patina formation, protecting the rotating slipring surface. Materials for power generation applications which predominantly run on Stainless Steel Slip Ring are based ouround our Natural Graphitic family of materials.


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Diesel Electric Locomotives Diesel Electric Locomotives have been the well-established mode of transportation within heavily industrialised countries including North America, Australia, Europe and China for many years. Locomotive applications are generally used for Freight Haulage, although in some cases Diesel engines are used to haul passenger cars for people moving. Diesel Electric Locomotives by the nature of their design are designed for Low Speed, High Load applications, for which Morgan Advanced Materials have been a global market leader with respect to high performing carbon materials designed to cater for both the loading, coasting and environmental conditions as seen in the arduous haulage applications. Two of the main Global locomotive manufacturers General Electric and EMD (Originally Electro Motive Division of General Motors, now owned by Caterpillar), have been long standing OEM customers who are supplied ALL carbon materials which are produced by Morgan Advanced Materials. Across the globe a well-established in-service base of DC technology Diesel Locomotives remains operational, however recent trends have shown major manufacturers to be employing AC Traction motor and electronic convertor packages over legacy DC technology. Basic Fundamentals of Diesel Electric Locomotive Workings

Diesel Electric locomotives employ a Diesel Engine which in turn drives a DC Generator or AC Alternator, which then in turn via conversion packages supply power to DC Traction Motors which propel the locomotive. GE Locomotive Images


From a Carbon Perspective my experience generally tells me not to get caught up on the OEM Locomotive type, but to concentrate on the Traction Motor Fitted to the locomotive, as this tends to be where our internal knowledge base sits, ie GE761 Traction Motor, we know the brush, the holder, how many in a set, the OEM accepted Carbon grade etc.. This approach holds true for many rail applications.. GE Locomotives The key applications on GE locomotives are;

• Alternator brush The Alternator brush are usually in Grade R318 as approved by General Electric. R318 is a Resin based graphitic material, which provides a low friction, high lubricating performance on Steel slipring sets. Although uncommon, the design of this brush is generally dual wafer providing rideability and maintaining sufficient contact with the slipring surface in portions of high vibratory duty cycles.

• Grid Blower Motor Brush The grid blower brush is traditionally a 2 wafer design brush in Grade T583 as approved by General Electric, with common designs being used in both Rail and Mining applications. This is a standard DC motor application with 4 brushes per set, with T583 material being a treated grade providing excellent commutating and film forming characteristics.

• Traction Motor Brush Dependent upon the design of the traction motor ie GE761, GE752, GE793, GE772, and GE776 the carbon brush may differ in design. Common Grades in use are T900, T959, and T593. All materials are approved by General Electric and are application specific to the traction motor which is specified by General Electric, Traction brushes as employed in “most” General Electric traction motors are of 2 wafer reaction brush designs, again aimed at providing brush contact stability over a wide range of environmentally challenging operating conditions.

GE Alternator Brush GE Grid Blower Motor Brush

GE761 Traction

Motor Brush

GE761 Traction Motor brush Holder – Reaction type


EMD Locomotives EMD Locomotives basically follow the same principal, where we have a Generator, Auxiliary drives such as Starter Motor, Fuel Pump and the drive train of traction motors, where brushes are employed. Again the focus we generally have internally is understanding the model number of both the generator and traction motors as this generally provides information that allows us to identify product. As the OEM to EMD, via Greenville USA, our products for EMD designs are prefixed with “DE” for Diesel Electric applications, followed by numbers to signify the carbon grade, common EMD materials are DE8, DE7, DE7000, DE9000. The grades are treated materials, with generator grades such as DE8 having resin impregnations to cater for periods of low loading, whilst assisting in Patina formation. Typical EMD Brush Patterns

• Generator Brush Applications The Generators mainly used by EMD in Locomotive applications are either D12, D15, D25 or D32 Generator designations, with the D25 and D32 designs being the more common seen in the market. The OEM and well proven grade for EMD generator applications is Grade DE8. DE8 is a treated material designed to cater for a wide range of loads whilst providing an even patina under periods of no load experienced on Generator sets. The brush is usually of a 2 wafer design with an integrated plastic top located on the back wafer. This should generally be the only grade offered for EMD generators.

D77/D78 Brush D87B Brush D43 Brush D29 Brush


• Traction Motor Applications Over the years our grades have developed with EMD as an OEM as they seek higher performance from their traction motors, from Grades such as DE5 transitioning to DE7, and then on to the widely accepted premium materials DE7000 and DE9000. DE7000 was developed for “High Load – Low Speed” Freight type applications which are generally heavily loaded, compared to grade DE9000 which was developed for “Low Load – High Speed” Applications which can include passenger car haulage. These grades are the most commonly used materials for EMD traction motor applications. EMD Traction motors are categorised with a letter D then two to three digits to signify motor type. Typical designations are D29, D31, D43, D77, D79 and D87b. Each motor consists of four brush holders, with configurations as follows; D29/D31 – 4 brush Holders (2 Pocket) – 8 brushes per motor D43 – 4 brush holders per motor (3 pocket) – 12 brushes per motor D77/D79 – 4 brush holders per motor (3 pocket) – 12 brushes per motor D87b – 4 brush holders per motor (4 pocket) – 16 brushes per motor Brush configurations differ across the globe with respect to the number of wafers employed. From experience generally the USA employs 3 wafer (triplex) design brushes, whilst other regions globally utilise a 2 wafer brush design (duplex) brush. Outside of the USA, track configurations differ which initially led to brush failure issues with a 3 wafer design, hence the move to the 2 wafer duplex brush design. Traction brush patterns for both GE & EMD locomotives are produced via Morgan Advanced Materials USA, and enquiries must be directed to the USA Sales team in order that we manage these global key accounts on a coordinated approach.

Brush holders and replacement parts are not made in-house for EMD & GE applications, and for

many years have been sourced via previously owned Fulmer Company, which now form part of Wabtec www.fulmercompany.com Fulmer brush holder catalogue is available via the global

Electrical portal https://morganet.morganplc.net/mgamasia/eltools/SitePages/Home.aspx under Non Group supplier section .

D29/D31 Brush Holder D77 Brush Holder D87B Brush Holder D32 Generator Brush Holder

Brush Holder comes

in a Clock spring version pictured and

a constant force design


http://www.fulmercompany.com/https://morganet.morganplc.net/mgamasia/eltools/SitePages/Home.aspx

• Auxiliary EMD Brush applications Smaller low volume applications for EMD auxiliary applications such as Fuel pump, Starter Motor, Blower fan applications utilise National USA materials, however are generally in very low volumes. Grades such as AY, DE2, DE14 and 258 are employed on various applications, and can be identified using either the EMD part number which generally starts with a number four ie 40003298, this can be cross referenced via our USA team to provide required quotations. Other Diesel Electric Locomotives There are many other diesel electric locomotives used across the world with many in country builders in such regions such as China, Russia, South Africa and Japan. All locomotives employ the same technology (DC) to drive the traction motors and will have differing distribution of brushes per motor compared with GE and EMD. Configurations of 8, 12 and 16 brushes per motor are common. Gaining samples of fitted grades and understanding from the user the operating loadings, and environmental conditions will allow us to provide optimum high performance materials to suit local applications. AC Locomotives Alternating Current (AC) technology in recent times has become the technology of choice for new or replacement locomotive fleets. Diesel locomotive technology follows outlined technology as per the attached diagram with a diesel engine driving a generally static controlled alternator to provide power for the rectifier/inverter modules top provide power for traction motive power systems. This is the common mode of AC technology within freight haulage and less populated areas. Within environments where overhead electricity is available, AC locomotives commonly utilise a 25KV overhead system via a Pantograph assembly to provide power for rectification and conversion for AC traction motors. We will discuss pantograph carbons and overhead interface as we move toward Metro system applications.


Transit or Metro Systems Morgan Advanced Materials have a wide range of products suited to Rail Metro or transit systems which primarily operate in underground/above ground people moving systems. This part of the application guide will focus on “metro” systems and will be followed by “Light Rail or Tram systems” It should be noted that Commutator and Slipring supply are limited to Key OEM patterns produced in Mexico only. Commutator sales to justify the resource allocation need to be volume sales not a one off replacement, external companies such as Nelco – http://www.nelco-commutators.fr/ have commutator production as a core competency and can be utilised as a buy-sell product as required. DC Transit Metro Systems Metropolitan people moving train systems, traditionally utilise an Electrified overhead or third rail shoe system to provide power requirements. System voltages range from 25KV AC Supply voltages down to 600-750V DC systems, with common Supply voltages of 25KV AC, 1500V AC, 750V DC and 600V DC. Metro (EMU Electric Multiple Unit) & Light Rail (Tram) System Applications Pantograph Carbons Pantograph or carbon collectors fulfil the function of transferring electrical energy from a fixed overhead or rail mounted system to the train assembly. Historically the collector materials were either copper or cast iron, which although functional, over time demonstrated accelerated wear profiles to the fixed overhead copper conductors. Carbon collectors take the form of either segmented strips which are fitted and crimped or soldered to a copper or aluminium sheath, or a single extruded plain or metallised carbon strip which is bonded or crimped usually to an aluminium sheath.


http://www.nelco-commutators.fr/

Examples of collector carbons can be seen below ranging from small Shoe and segmented carbons, linear collectors, through to overhead mounted metallised and plain collector strips.

Detailed information relating to carbon collectors and their applications can be found on the global electrical portal at the links below; https://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Electrical%20Training%20Presentations/Old%20MECL%20(UK)%20Training%20Modules/Chapter%208%20-%20Carbon%20Current%20Collectors.pdf https://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Forms/AllItems.aspx?RootFolder=%2Fmgamasia%2Feltools%2FShared%20Documents%2FElectrical%20Training%20Presentations%2FPowerpoint%20Presentations https://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Forms/AllItems.aspx?RootFolder=%2Fmgamasia%2Feltools%2FShared%20Documents%2FMorgan%20Advanced%20Materials%20Documentation&FolderCTID=0x0120008E9062CB2853A04BA44E165FF3D4B442&View={EBB073DB-9579-4F48-AF63-6406AE7D1D0C} Overhead Pantograph carbons are selected based upon static current loadings, and during any design phase our application team based in the UK should be involved in material selection. As a “General “rule, the higher the system voltage (ie 25KV) the lower the current carrying capacity requirement. This has traditionally allowed Non metallised plain carbon strips to be utilised, whereas on lower voltage systems such as 1500V,750V,600V, current carrying capacity requirements have necessitated copper impregnated to be employed to meet current requirements. Recent trends in pantograph designs are tending toward the usage of single piece metallised “Auto Drop or ADD systems” for most applications. This has been necessary via two factors;

• Increased static loading via lighting, Air conditioning, and power distribution systems for personal comfort

• Regeneration of electronic braking energy back into the overhead system via the carbon collector. This has meant extra loading on the current carrying capacity of the carbon material employed, in many cases generating the need for the use of copper impregnated materials.

Linear, Segmented and Crane collector

profiles

Overhead pantograph assembly incorporating

Carbon Strips

3rd Rail shoe systems

Overhead pantograph assembly incorporating

Carbon Strips


https://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Electrical%20Training%20Presentations/Old%20MECL%20(UK)%20Training%20Modules/Chapter%208%20-%20Carbon%20Current%20Collectors.pdfhttps://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Electrical%20Training%20Presentations/Old%20MECL%20(UK)%20Training%20Modules/Chapter%208%20-%20Carbon%20Current%20Collectors.pdfhttps://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Electrical%20Training%20Presentations/Old%20MECL%20(UK)%20Training%20Modules/Chapter%208%20-%20Carbon%20Current%20Collectors.pdfhttps://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Forms/AllItems.aspx?RootFolder=%2Fmgamasia%2Feltools%2FShared%20Documents%2FElectrical%20Training%20Presentations%2FPowerpoint%20Presentationshttps://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Forms/AllItems.aspx?RootFolder=%2Fmgamasia%2Feltools%2FShared%20Documents%2FElectrical%20Training%20Presentations%2FPowerpoint%20Presentationshttps://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Forms/AllItems.aspx?RootFolder=%2Fmgamasia%2Feltools%2FShared%20Documents%2FElectrical%20Training%20Presentations%2FPowerpoint%20Presentationshttps://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Forms/AllItems.aspx?RootFolder=%2Fmgamasia%2Feltools%2FShared%20Documents%2FMorgan%20Advanced%20Materials%20Documentation&FolderCTID=0x0120008E9062CB2853A04BA44E165FF3D4B442&View=%7bEBB073DB-9579-4F48-AF63-6406AE7D1D0C%7dhttps://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Forms/AllItems.aspx?RootFolder=%2Fmgamasia%2Feltools%2FShared%20Documents%2FMorgan%20Advanced%20Materials%20Documentation&FolderCTID=0x0120008E9062CB2853A04BA44E165FF3D4B442&View=%7bEBB073DB-9579-4F48-AF63-6406AE7D1D0C%7dhttps://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Forms/AllItems.aspx?RootFolder=%2Fmgamasia%2Feltools%2FShared%20Documents%2FMorgan%20Advanced%20Materials%20Documentation&FolderCTID=0x0120008E9062CB2853A04BA44E165FF3D4B442&View=%7bEBB073DB-9579-4F48-AF63-6406AE7D1D0C%7dhttps://morganet.morganplc.net/mgamasia/eltools/Shared%20Documents/Forms/AllItems.aspx?RootFolder=%2Fmgamasia%2Feltools%2FShared%20Documents%2FMorgan%20Advanced%20Materials%20Documentation&FolderCTID=0x0120008E9062CB2853A04BA44E165FF3D4B442&View=%7bEBB073DB-9579-4F48-AF63-6406AE7D1D0C%7d

Silicon ADD System Copper ADD System Bonded Collector Design Trolley Pole Components

The ADD or Auto Drop Device can be built into most of our designs and should be coordinated with our UK design team. We have the options of utilising a silicon rupture or copper rupture tube as the air carrier within the strip. The advantage of the silicone tube is that it will fail under impact generally quicker than the copper tube version providing a higher level of safety for the pantograph assembly and overhead infrastructure. Schunk have standardised on the use of the copper rupture technology within their product range, whilst we can offer either solution as required. Environmental awareness in recent years has seen carbon collector materials move to “Lead Free” compositions. Morgan Advanced Materials have a wide range of lead free materials to suit overhead and third rail applications. Below are tables showing common grades for Overhead, 3rd Rail, and trolley pole applications


As previously stated as a “General” rule plain carbons such as CY280 have been successfully used on 25KV systems, whereas grades such as MY258A2 and MY7A2, both lead free have been very successful on lower voltage high current applications. Our premium “Leaded” material historically has been grade MY7D. As with all applications wher carbon is the interface between moving parts, issues will appear which are often blamed on the carbon material. It is important the sales engineer takes a wholistic approach to the application in understanding both mechanical, electrical and environmental factors which may affect performance. Collector performance especially in Wet Weather conditions can be drastically different to Dry weather conditions as in wet conditions the protective patina produced by the carbon can be compromised, generating accelerated carbon wear. Below is a fault finding chart which will be of assistance in fault analysis on collector products aimed at improving both reliability and product-overhead life cycles.


Traction Motor Brushes There are numerous manufacturers of DC traction motors which are employed globally including products from companies such as ABB, Bombardier,AEG, Siemens, Brush, GEC, Hitachi, Mitsubishi, Dong Feng to name a few, with each application with respect to brush and brush holder configuration and number of motors employed differing People moving Metro or Tram systems generally employ carbon materials which are treated grades to cater for “lighter” loadings, however in some parts of the world such as Australia, Grade DE7000 has become the standard widely long life high performance material on GEC and ABB machines. Film or Patina formation and maintenance is key to providing excellent brush performance and many of our materials are also treated to cater for both low humidity environments, whilst the combination of treatments controls the patina thickness levels under all operating conditions.

As Metro and Tram systems slowly move toward AC traction systems, most of the applications encountered will be well established with long standing material approvals, with customers hesitant to change grades. As opportunities arise a focus on reliability and asset utilisation should be employed in the sales process to promote a “Total Cost of Ownership” uniques selling point. For Metro systems in the table to the right we have listed grade DE7000 as a premium material for EMU Metro Systems, Whilst grade N2000 has been nominated for

Traction Grade Recommendations

GRADEDC x x xRectified AC x x xThyristor x x xChopper x x xDC x xRectified AC x xThyristor x xChopper x xDC xRectified AC xThyristor xChopper xDC xRectified AC xThyristor xChopper xDC xRectified AC xThyristor xChopper x

AC Tractionx

xxx

xx

x

T900

N20

00

R31

8

DE9

000

D37

4B

Earthing

R78

3

Alternators

CM

1S /

M26

88

DE8

Auxi

liarie

s

Generators/ExcitersCompressorsBlowers - Vent FansPumps

MA Sets

Suburban EMU (Passenger)

Metro / Rapid Transit

Trolley Bus - Tram

DC

Tra

ctio

n M

otor

s

DE7

000

AC Commutator Drive

Freight

Passenger Loco (high speed)


lighter loaded tram systems. These recommendations are based on experience, and although we have many other carbon grades which could be employed, the nominated grades provide an excellent start point for technical differentiation. Seeking guidance from In-house technical resource should be used as part of both the grade selection combined with brush design, as both will have a marked effect on performance. Auxiliary & Earthing Brushes Metro (EMU) and tram systems generally employ small auxiliary drives for applications such as Air provision via compressors for door opening and closing, MA – Motor Alternator sets, pumps, air conditioners and blower fans. For simplicity in this document we have nominated our Resin based graphite material R783 for these applications. This grade works well at low current densities providing low friction performance combined with excellent film forming capabilities. Consultation with internal technical resource is recommended for difficult applications, and it will be important for these applications that information such as the currently fitted material, brush force and machine rated and running currents are understood for grade selection. Earthing Brushes Axle Hung Earthing Unit Earthing brush patterns are used on both Metro (EMU) and tram systems in order to provide a path of low resistance for both leakage and fault currents for both equipment and personal protection. Two types of systems are generally employed either “Frame” mounted as per the lower picture or “axle” hung as per the top picture. Frame hung earthing brushes are generally found on EMU systems, whereas Axle hung can be found on both EMU and Tram based machines. Frame Hung Earthing Unit Copper Graphite materials are employed for earthing applications and from experience our grade of choice for earthing applications especially “Frame hung” is grade CM1S or alternatively grade M2688, which have a copper content in the region of 88%. Axle hung units depending on the manufacture can employ one to three brushes and in most cases use copper graphite materials with an approximate copper content of 75%-88%. Common axle earthing units experienced in the field will be Ferraz, Frost and Stemmen.

Axle hung Single Brush Design


Flange Lubrication Wheel Flange Lubrication (WFL) systems are employed on rail systems in order to reduce friction on track curves which often generate a high pitched screech as the moving train progresses around a bend. Graphite materials possess excellent lubrication properties, hence reducing friction and can be utilised for WFL systems. The WFL brush holder mounts on the bogie frame, and provides lubrication to the train wheel flange via a series of interlocking graphite inserts which can be replaced as necessary during maintenance periods. A key player in this market are Canadian based company Kelsan, who have been bought out by L.B Foster. The Kelsan inserts utilise Molybdenum which provide the lubrication for WFL applications. WFL products are available via our UK team, who should be consulted in relation to product suitability for any identified application. Coupler Contacts

Coupler contact tips are utilised on both Diesel and Electric multiple unit sets for the transfer of power and signal data from one carriage to another. The Contacts are embedded onto a large pad which is mounted to the end of the carriage, usually underneath the door frame.

Silver Contact tip assemblies are used to transfer power and signal data, and need to be replaced as a replaceable maintenance item. Our UK team have developed a range of couple contacts which are now widely used in the European market.


Aegis (Non-Group) Product – SGR - Shaft Grounding Rings

Aegis SGR – Shaft Grounding Rings have been available in many global regions on an exclusive distributor agreement for many years. The product utilises conductive microfibers which “Earth” shaft leakage currents which if not earthed will generally cause machine failure via “bearing fluting”. The conductive fibres compared to carbon brush earthing solutions assist in the earthing of HIGH Frequency switching currents, whilst

carbon brush solutions primarily excel and handling higher current earthing applications, and by default absorb or earth LOW frequency switching currents. Ideally a combined solution of the utilisation of BOTH Aegis SGR product combined with traditional Axle or frame hung earthing solutions provides maximum machine protection. With respect to rail applications the Aegis SGR product has been used successfully on traction motor applications on ABB Bombardier motors and has applications on both AC & DC Traction motors and Auxiliary drive products.


Resources within group for Rail Products – Initial Point of Contact • Global Electrical Portal

o https://morganet.morganplc.net/mgamasia/eltools/SitePages/Home.aspx

• Rail Product Carbon Brush Selection – Roly Roberge [email protected] • Rail Market Europe – James Dun – [email protected] • Rail Market South Africa – Jacques Visser – [email protected] • Rail Market USA – Paul Kling [email protected] • Rail Market China –Mark Yu [email protected] • Brush Holders – Jon Ford [email protected] • Coupler Contacts – Jon Ford [email protected] • Flange Lubrication – Tony Morgan – [email protected]

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