transportationconverter solutions - reo · the clearance and creepage distances are realized...
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TransportationConverter SolutionsEfficient components from REO
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Content:
•Fromdevelopmenttofinalproduct...............................................................S.7
•Factors-pollution,humidity,acoustics,position,fire,overvoltagecategory....S.8
•Materialselection...........................................................................................S.9
•Analysistechniques,normsandstandards....................................................S.10
•Fullprototype...............................................................................................S.12
•Typetest......................................................................................................S.12
•Componentsforauxiliaryconverter..............................................................S.15
•OverviewofProducts..................................................................................S.16
•Inductiveandohmiccomponentsforauxilaryconverters..............................S.18
•OverviewofProducts...................................................................................S.20
•REOplus-globalqualityandlocalservice.....................................................S.22
•Productionsitesandsalesoffices..................................................................S.24
•Shortdescriptionofeachsite.......................................................................S.25
•Water-cooledcomponentsforrailway..........................................................S.27
•Water-cooledchokes....................................................................................S.28
•Water-cooledresistors..................................................................................S.30
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TransportationConverter Solutions Efficient components from REO
Precision
Safety
Robustness
Reliability
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Rail,High-Speedtrainsormetroliners,oneofthesafestmeansoftransport,isadvancingintoevermoreremotecornersoftheEarth.Therailwaynetworkisconstantlyexpanding,helpingcountriescometogether,andisanenginedrivingeconomicgrowthandprosperity.
REOhassetitselfthetaskofcontributingtomakingtrainseversafer,todayandinthefuture.Withmainsfilters,inductorsandtransformers,weensurethatEMCproblemsareeliminateddirectlyatthesource.Theresultisthatvoltagechanges,short-circuitsandanyotherproblemsassociatedwithelectricitycannotpresentahazardtorailwaypersonnelorpassengers.Compliancewithinternationalnorms,theexploitationofthelatesttechnologiesanddecadesofexperiencemakeREOastrongpartner.
REO manufactures components for two main areas of railway technology:
A) Auxilary converters: • Transformers from 16 2/3 up to 30 kHz• Boost-/Buck converters• EMC-Filter• Sinusoidal filter• Current transformers• Charging resistors from IP 00 - IP 65, available for watercooled systems, too.
B) Main drive:• EMC HV chokes• Leakage transformers• Flow Controls• FE-chokes• Absorption circuit chokes• Onboard power supplies• Damping resistors• Current transformers• Filter chokes
InitsCentreofCompetenceinBerlin,REOtodaydevelopsrailwayengineeringcomponentstomeettherequirementsofworldwiderailwayorganizationsand,thankstopartnershipswithcompaniesintheUSA,China,IndiaandGermany,theyareabletobemanufacturedquicklyandefficientlywiththehigheststandardsofquality.Inconjunctionwithitsworldwidesalesnetwork,REOcanrespondquicklyatanytime.
Withgreatattentiontomodernproductionmethods,efficientworkflow,closecooperationwithuniversitiesandtheconstantfurtherdevelopmentandimprovementofprocesses,everydayREOprovideselectricrailwaylinebuilderswithproductsthatcontributetothesafety,functionalityandglobalgrowthofrailtechnology.
WiththeIRIScertificationofthesubsidaryinBerlin/HennigsdorfandtheISOcertificationinChinaandtheU.S.,REOdemonstratesqualityatthehighestinternationalstandards.
IRIS-Cer
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Content:
•Fromthedevelopmentstagetotheendproduct.................................P.7
•Influencingfactors-pollutiondegree,moisture,position,
firebehaviour,overvoltagecategory......................................................P.8
•Selectionofmaterials............................................................................P.9
•Analyticaltechniques,normsandstandardsapplied................... P.10,P.11
•Completeprototypeconstruction........................................................P.12
•Typetesting........................................................................................P.12
Keypoints Influence factors Material selection
Tailor-made components right up to the end product
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Key points
Allrailwaytechnologycomponents-fromtransformerstolineinductorsandfilters-aredevelopedtomeetthestandardorspecialrequirementsofourclients.Noproductcangointooperationwithoutthesefundamentallydefinedrequirements:
• Safety: Trainshavebeeninuseasameansoftransportformorethanacentury.Thedemandsplacedon materialsbecomeevergreater,inpacewithongoingtechnicaldevelopment.Toensurethatthe safetyandcomfortofpassengersarenotimpaired,everycomponentusedinatrainmustmeetthe currentnormsandstandards.Owntestsandaccreditedtestinglaboratoriesprovethesafetyofour components.
•Weight: Trainsarebeingusedevermorerapidlyandevermoreextensively,insufficientlyoptimized equipmentmeansstressonthetrain,fewerpersonscanbetransportedandspeedandeconomy isreduced.IntelligentmethodsinmaterialsselectionandFEM-calculationmeanthatREO componentsareofparticularlylowweight. • Space requirements: Manycomponentshavetobedevelopedinsuchawaythat,togetherwithotherproducts,theyfit intotheavailablespace.Theoptimaluseofspace,andcompliancewithspecifiedmechanicaland electricalrequirements,formthebasisofourdevelopmentwork.
• Costs: Theoptimizationofoperatingcostsplaysaparticularlyimportantroleinrailwayengineering.To remaincompetitive,trainmakershavetorationalizecostsbutwithoutendangeringpassenger safetyintheprocess. Withthelatestsoftware,simulationandtestingtechniques,weensurethatthenecessary developmentworkisalreadyoptimallyusedinadvance.
Tests/Analyses technologies Full prototype Type test Final product
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Influencing factors
Besidesunitsizeandweight,therearemanyotherfactorsthatinfluenceacomponent,suchas:
Environmental conditionsIfacomponentisusedontheoutsideofthetrain,thedegreeofpollutionitisexposedtoisanimportantfactor.Dirtcangetintocomponents,impairingtheirfunctionalityandshorteningtheirusefullifetime.REOcomponentscanbedesignedforapollutiondegreeofuptoPD4andatemperatureof-50°Corworse.TheclearanceandcreepagedistancesarerealizedaccordingtoDINEN50124-1.
MoistureWetnessandmoisture,inconjunctionwithtypicalrailwaycontaminationandhightemperatures,canimpairfunction.Ifmoisturegetsintoelectricalwindingsorcablingsystems,short-circuitsandthermaloverloadingmayoccur.Withtheaidofaspecialcoatingandvarioussealingtechniques,REOproductsachieveahighprotectionclassandareparticularlyresistanttodirt,moistureandotherenvironmentaleffects.
AcousticsEspeciallyinthefieldofrailwaytechnologyacousticsplaysagrowingrole.REOdevelopsandusestechnologies,processesandmaterialsthatallowtomeetandexceedtheacousticrequirementsandstandards(DINEN60076-10).Thus,evenlevelsbelow85dBsoundpressurelevelcanberealized.Asstandard,theairbornesoundismeasured,andifdesiredastructure-bornenoisecanbedone,too.
Position of equipmentThepositionofrailwaycomponentsplaysanequallyimportantroleintheirdesigncalculation.Factorslikeweightmanagementandtrainconstructionareimportantissues.
Preventive fire safetyThebehaviourofmaterialsinafireplaysacrucialroleinpassengersafety.Allmaterialsusedarepreparedincompliancewiththeapplicablenormsandaretestedbyaccreditedtestlaboratoriesfortheirbehaviourwhensubjecttoafireanditssideeffects.Thetestreportsandthecorrespondingdocumentationaremadeavailabletoclients.StandardssuchasEN45545,DIN5510andNFF16101areself-evident.
Protection grades:IP00 - IP65 Pollution level:PD1 - PD4
Fire protection standards: EN 45545, DIN 5510, NF F 16-101 / NF F 16-102
Tailor-made components
Choke,developedaccordingtocustomerspecificationsandusedunderthefloor.
Specialsiliconecoating
Forasinusoidalcurrent,andimprovedacoustics
Keypoints Influencefactors Materialselection
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Selection of materials
Theoptimizationofunitsizeandweightisdependentontheselectionofthecorematerialsandwindingmaterials.REOhasmanyyearsofexperienceinthemanufactureofinductorsandtransformersandcanselecttheoptimalmaterialsforaspecificproject.Directandfocussedanalysisoftherequiredmaterialpropertieshelpsminimizethecosts.
Thefollowingoptionsareavailable: • aluminium • copper • iron • amorphousandnanocrystallinematerials • carbonfibre-reinforcedplasticsandinsulatingmaterials
Inaddition,theselectedproductdesignhasasubstantialinfluenceonmechanicalandelectricalcharacteristics:
• cylindricalair-coreinductors • iron-coreinductors • toroidalair-coreinductors
Thetypeofcoolingshouldalsobedecidedinadvance.REOoffersvarioustypesofcooling:
• AN,AFaircooling • watercooling
Protection grades:IP00 - IP65 Pollution level:PD1 - PD4
Fire protection standards: EN 45545, DIN 5510, NF F 16-101 / NF F 16-102
Specialsiliconecoating
Tests/Analyses technologies Full prototype Type test Final product
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Tests/analytical techniques
Tests/analyticaltechniquesAfterelectricaldesigncalculation,andduringmechanicaldesign,thecomponentsundergovarioustestswiththeassistanceofsimulationtoolsandanalyticaltoolsbeforetheygointoprototyping.
SuchsimulationtechniquesasFEManalysisbasedonsolid3Dmodelsgiveinformationaboutphysicalmagnitudes.Thesearefurtheranalysedasaconsequenceofdesigncalculation,andproductoptimizationmeasuresareundertaken,ifrequired.
Thesevarioussimulationtechniquespermitworkingwiththeoptimizationoftimeandcost,sincethefindingsaccumulatedinthesimulationprocesscansubsequentlybeimplementedintheprototyping.Thisprocedureenablesthoseproblemsthatmaycrop
Here is an overview of some of the main types of analysis:
3D magnetic-field simulationComprehensiveelectromagneticandthermalcalculationscanbeperformedbasedonthethree-dimensionalfinite-elementmethod(3DFEM).
FEM thermal simulationBesidestheelectromagneticthree-dimensionalfieldcalculation,thermaldesigncalculationbasedonFEMisalsoofgreatsignificanceforREO,becauseitpermitsalookinsideanactualproductandsubsequentlysuppliesimportantfindingshereaboutlocalhotspotsthatcouldendangertheexpectedusefullifetimeofaproductinthemediumterm.
Thismakesitpossibletodesignproductsthermallyinthedevelopmentphasebeforeproductionbegins.Thisensuresthatthefinishedproducthasalonglifespan.
FEM analysis of structural mechanicsPhysicalfactorsinfluencingthecomponentaresimulatedusingtheFEManalysis,basedon3DCADmodeldesignedusingSolidWorks.
Thisenablesthefollowingcalculationstobemade:
• staticanddynamiclinearandnonlinearstressanalysis • frequencyanalysis • analysisoflifetime • designcalculationofscrewstrength • weldingseamcalculation
Tailor-made components
Keypoints Influence factors Material selection
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Norms and standards used by REO: - IRIScertified(Rev02,V2.2) - EN15085CL1 - DINEN60310/VDE0115Part420/IEC60310:Railwayapplications-Traction transformersandinductorsonboardrollingstock - EN12663-1:Railwayapplications-structuralrequirementsofrailwayvehiclebodies - EN15085-1bis-5:Weldingofrailwayvehiclesandcomponents - IEC61373:Rollingstockequipment–Shockandvibrationtests. - EN50125-1:Railwayapplications–environmentalconditionsforequipment - DINEN60076-10:Determinationofthenoiselevel - EN50124Railwayapplications-insulationcoordination(basicrequirements -clearancesandcreepagedistancesforallelectricalandelectronicequipment) - IEC60085:Electricalinsulation-thermalevaluationanddesignation - DINEN61378and60076:Convertortransformersandpowertransformers - UnderwritersLaboratoriesInc.(UL)certificationforREOsystemsofinsulatingmaterials inthermalclassesF(155°C)andH(180°C)inaccordancewiththeUL1446standard. - ULandTÜVcertificationforREOEMCfilters,inductorsandbrakingresistors - Fireprotectionstandard:EN45545,DIN5510,NFF16-101/NFF16-102,BS6853
Tests/Analyses technologies Full prototype Type test Final product
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Construction of prototypesAftertheanalysisandtestingphaseissatisfactorilyconcluded,theproductismanufacturedasasampleusingtheresultsderivedfromtheFEManalysis.Thisisacompletein-houseprototype.AllprototypescanbecompletelymanufacturedintheproductionfacilitiesinHennigsdorfandKyritzutilizingin-housemetalwork,CNCmachiningcentre,insulatingmaterialsworkshopandweldingbays.
Type testing
AtREO,everyrailwaycomponentundergoescompletetypetestinginaccordancewithEN60310.Thisincludesthecompleteverificationandvalidationofthedesign,partiallybyexternalaccreditedcompanies.Testing in accordance with EN 60310 includes the following tests, among others:
• acoustics measurement • temperature test • partial discharge measurement • high potential test and high-current test • shock and vibration testing (external) • salt and mist testing (external) • EMC testing
Componentssubmittedbyaclient,suchasfrequencyconvertersetc.,canbeintegratedwithourspeciallyfittedtestingstationswiththeirmodularunits.
Safetyhasabsolutepriorityinrailtravel:faultsinthisexactingfieldofengineeringcanhavecatastrophicconsequences.Sorailwaysaresubjecttospecialadditionalnormsdealingwithmechanicalstability,shockadvibration,andresistancetoEMC.
Millionsofpeopleusetrainsastheirmeansoftransporteveryday.Forthisreason,countlessinternationalstandardsandnormsareapplicabletorailwaystoensurepassengerssafety.Ourengineersdevelopreliablerailwaycomponentsbasedonthesenormsandthosedemandedbyclients.
Thedifferentstages:Constructionphase,3-Dmodel,finalproduct.
Tailor-made components
Keypoints Influence factors Material selection
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Thedifferentstages:Constructionphase,3-Dmodel,finalproduct.
Tests/Analyses technologies Fullprototype Typetest Final product
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Content:•Componentsforauxilaryconverters................ p.15
•Overviewofproducts...................................... p.16
Our product range Components for auxiliary converter
Keypoints Influence factors Material selection
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Components for auxiliary converter
Electricrailwayshaveanextraordinaryenergydemand,e.g.forheating,airconditioning,lightingorcookinginthebistrocar.Alloftheseperipheralapplicationsnormallyrequireasupplythatisdifferentfromtheavailableelectricitysource.Inadditiontoprovidingoptimumpowertothesefacilitiesthereisalsoanimportantrequirementtoensureelectromagneticcompatibilityfortheprotectionofpassengers.Theseauxiliaryconvertersmustmeetthetoughrequirementsofrailwaytechnology:shockandvibrationresistance,highprotectionlevelsandalonglifearejustafewexamplesofthesedemands
REOdevelopsandmanufacturescomponentsforthispurpose,oftenavailableasstandardproductsbutalsoprovidingfastturnaroundofspecialdesigns-foreveryapplicationtherightsolution!
©Urbanhearts-Fotolia.com
Tests/Analyses technologies Full prototype Type test Finalproduct
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REOChargingresistors(upto3kW)*
–highpowerdensity,widevarietyofconnectionoptionsandpossiblecombinationsof
severalresistorsinoneprofile(typeofprotectionuptoIP67)
REOmainschokes750V-1500V*
–incastdesignforingressprotectionuptoIP65;Usedforreducingcommutation
lossesandharmonics;veryrobustandgoodheattransfer
REOEMC-Filter*
withhighattenuation(upto100dBfromsimpletobroadspectra)inapracticalprofile
housingforvariableinstallationandwithlowheatingguaranteed
Many REO components are also available in a liquid-cooled design (direct cooling).Alternatively, a water-cooled sub-element can be used (indirect cooling), which is combined with the REO-component.
In this simple way, a liquid-cooled system can be easily achieved with all the benefits of a modern water cooling.For more information on water cooling in rail technology, see page 26
1
1
2
DC
3AC 230V
ConverterInput filter HF- transformers
3-Phase-Converter
Sinusoidalfilter
Vorladewiderstand
Precharging resistor
3
4
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6
Input
or
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Our product range Multitude of applications
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REOdv/dt-filter(690V/to150A)*
–forlimitingthevoltageriseattheoutputfromtheconverterwithhighinductance,
lowtotallossesandminimalleakagefield(typeofprotectionuptoIP65)
REOSinusoidalfilter(690V/1200A)*
–forgivingsinusoidalformtocurrentandvoltage.Forexample,usedinairconditioning
systemsagainstnoise(protectionuptoIP65)
REOCurrenttransformers(0-1000A)*
–insuitabledesignforAC/DCmeasurementsupto150kHzinrailwayapplications,
distinguishedbyshortresponsetimesandexcellentlinearity.
*higherperformancesonrequest
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6
Output
DC-link
or
or
or
REOBoost/Buckconverter
ThechokeisusedinapplicationswhereDCvoltagesareconvertedintoanother
(higherorlower)DCvoltageinavehiclepowersupplyandisoperatedatavoltageof
500V..1100.
Chokesaremanufacturedwithcopperwindingsandamorphouscore.
REOHF-Transformer
TheHFtransformerisusedforexampleatavoltagesupplyasanisolating
transformer.Asafeseparationandlowpartialdischargevoltagesare
characteristic.
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Content:
•Componentsforsafetyinrailway....................... S.19
•Overviewofproductsforauxiliaryconverters..... S.20
Our product range for auxiliary converter Inductive and resistive components for railway engineering
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Excellent components for safety in railway technology
Withtheuseofmoderninverterengineeringinelectrictrains,techniquessuchaspulse-widthmodulationareused,generatingvoltagepulseswithashortrise-timetoachievehighpowerratings.Howeverthistechniquehasseveralissueswhichcancauseundesirableeffects,suchasthelossofmotorpower.Someoftheseproblemsare:
•EMCissues •Harmonicdistortion •dv/dtproblems •Voltagesurges •Short-circuitcurrents •Interferencecurrents
Inadditiontothesephenomenathereisalsotheneedtoabsorbexcessiveenergysuchasswitch-onortransientcurrentsurges,causedbystarting-upandslowing-downatrain,toprovidethemostefficientmotorperformance.
Solutions from REO
Sincemostoftheseproblemsoccursimultaneously,itismostimportantforREOtoatakeaholisticviewofthesystem.REOprovidesclosely-matchingsolutionsforinductiveandresistivecomponentsusedaroundthetrain’sdrivemotorsystemandforauxiliaryapplications;fromasinglesource–thisensuresthatthemostefficientdesignfortheapplicationandan
overallawarenessduringtheearlystagesofthedevelopmentphase,areavailable.AsaleadingsupplierofcompleteinductiveandresistivesolutionsREOoffersawiderangeofcomponentsfortheenhancedperformanceofrailwaydrivesandtrainelectricalequipment.
•AC-chokes •Dampingresistors •Filterresistors
•Short-circuitResistors •Groundingresistors •Interferencechokes
•Invertertransformers •Chopper-Chokes •Absorptioncircuitchokes
•AC-Transformers •Powertransformers •Auxilarytransformers
•Combinations •Brakingresistors
•Assembliesofspecialcomponentsforenergyregeneration
REOdemonstratesaparticularstrengthacquiredthroughlongexperiencewithinductors.Thebroadbaseofcompletedprojectsinrailwaytechnology,guaranteesagoodresult,particularlyforcustomizedsolutions.
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REOthree-phasetransformer
–iscompletelyimpregnatedandmountedinarobustcasing
toprotectofthewindingagainstexternalinfluencingfactors.
Thistransformerisusedforsupplyingvoltagetokitchen
appliancesinahigh-speedtrain.
REOdampingresistor
TheNTTR159resistorisusedasadampingresistorinserieswithafilter
capacitorinatractionpowerconverteronthe3-kVDCmains.
Customer-specific components
Besidesthestandardcomponentsforuseintheconverter,REOofferscustomer-specificproducts-asindividualcomponentsorasacompletesolutioninacontainer.
Theoverridingcriteriainrailwayengineeringareavailabilityforoperationandpassengersafety.Here,REOofferscustomizedsolutionsthatwedevelopstepbystepinclosecooperationwithourclient.
ThisguaranteesthatREOlineinductorsandtransformersareoptimallysuitedtoyourapplication.Ourdevelopmentmethodsemphasizemaximumusefullifetime,cost/benefitoptimizationandsafety.
REOthree-phaseconvertertransformer
–isemployedinauxiliaryconvertersforthe
galvanicseparationoflinkDCvoltageup
to2000VDC.Specialimpregnationserves
toprotectthetransformeragainstexternal
influencingfactors.
Our product range for auxiliary converter Inductive and resistive components for railway engineering
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REOaircorelinechokes
–isdesignedforuseinelectricrailways
operatedonDCnetworks.
Thespecialconfigurationoftheinductor
permitsfullfunctionalityevenunderextreme
conditions.
REODCfilterchoke
–asacomplete,ready-to-useunitconsistingofchoke,
cooling-airduct,suspensionandconnections.
REOREOLeakagetransformer
TheREOleakagetransformerensuresharmonizedcurrentandvoltage
outputs,filteringharmonics,andlimitingtheripplecurrent.Withthe
spatialseparationoftheprimaryandsecondarywindingsandthe
resultingintentionalincreaseinthemagneticleakagefield,theREO
leakagetransformerachievesaloosemagneticcoupling.
REOTransformerwithsupportframe:
Arrangementformountingonthevehiclerooforunderthefloorto
supplyvariouskitchenappliances.
REOabsorptioncircuitchoke:
Absorptioncircuitinductorforamulti-systemvehicle(25kV,50HzAC
mains,5kV,16.7HzACmains,3kVDCmains,1.5kVDCmains)
Theinductorisemployedincombinationwithacapacitorinthecooling
systemoftheconvertercontainertocreatearesonantcircuitfora
specificresonantfrequency.
Therobustconstructionisdesignedforsecureassembly,withspecial
dampingelementsabsorbingvibrations.
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• REO Unity • REO at your side• REO Service
Inhalt:
•REOplus-globalqualityandlocalservice.................. S.22
•Productionsitesandsalesoffices............................... S.24
•Briefdescriptionofeachsite..................................... S.25
REOplus Global quality and local service
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• From the simulation model to mature end product
• Taking into account international certifications and standards
• Verification of all technical parameters, long-term measurements
• Documentations and tests with all products
REO at your side• Certified production processes
• 1:1 production transfer• Same test and production
equipment
REO Unity• All from one single source :
Components in and around the frequency converter - as stand-alone
products or designed as a complete system (including housing, fan, etc.)
• Customized solutions
REO Service
Worldwide sales network
Withaworldwidesalesnetworkandaverycomprehensiveproductportfolio,REOcanreactrapidlytoyourwishesanywhereintheworld-nomatterwhatlanguageyouspeak.Besidesourwideselectionofstandardproducts,wecanofcourseofferyoutailor-madesolutions,developedspeciallytomeetyourwishes.
OurproductionfacilitiesinChina,IndiaandtheUSAareequippedinexactlythesamewayasthoseinGermany,andcanmakeeveryproduct1:1.
Evenafterthe1000thproductionrun,aREOproductalwayshasthesamequality,everywhereintheworld.Usingthesamesoftware,withdevelopmentanddesigninGermanyandintensivecommunicationsbetweenourlocations,weensurethatREOproductsarealwaysuptothelateststateoftheart.
TheREOgroupismadeupofcompanieswithmanyyearsofexperienceasmanufacturersofinductivewindings,locatedallaroundtheworld.BasedinGermanyandwithitstechnicalengineeringknow-howhousedinitsCentreofCompetenceinBerlin,theREOGroupprovidesitsrailwayengineeringclientswithalltheadvantagesofacompanyproducinglocally.
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WithproductionlocationsintheUSA,China,IndiaandGermany,REOoffersdecisiveadvantagesworldwide.
Technology: REOisareliablesourceofmaturetechnologyfortheworld.WithdevelopmentfocusedattheCentreofCompetenceinBerlin,manufacturingmeetsthesamequalitystandardsateveryproductionlocation.Productionmonitors,standardizedproductionequipmentandtheuseofthesamesoftwareworldwideensure1:1manufactureeverywhereintheworld.
Finance: Asagroupofcompaniesoperatingworldwide,REOhasastrongfinancialbackgroundthatmakeslong-termcooperationsecure.
Cost-efficiency: REObenefitsfromlocalsiteconditions,whichenableittofunctionsubstantiallymoreefficientlyandflexiblyasregardsthepricing.
Speed: Localproductioneliminateslongtransportationroutes.SoREOcanalsomeetshort-termdeliverydeadlines.
Service: Anengineerwhocansolveaclient‘sproblemsinthelocallanguageandonsite,ismuchmoreefficientthanonewhooperatesacrossgeographicalandculturaldivides.REO‘sbranchesworldwideenableittodojusticetothisrequirement.
Manufacturing Sales office
REOplus Production locations and field sales offices
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REO-GPDInductiveComponentsPVT.LTD.isajointventurebetweenREOandGUJARATPLUG-INDEVICESPVT.LTD.GUJARATPLUG-INDEVICEShasbeenoperatingontheIndianmarketsince1985andisanactiveproducerofwindingsthere.
REO USA, inc: REOhasbeenrepresentedbyafieldsalesofficeintheUSAsince2000;Weinvestedina2118-m²productionhallin2010.REOUSAhasalsobeenISO-certifiedsinceJuly2011.
Themainfocusatthe„CentreofCompetence“inBerlinisondevelopmentandonsalesinthedomainoftransportationconvertersolutions.DevelopmentworkisdoneforinternationalmanufacturinginAmerica,China,IndiaandGermany(Hennigsdorf).TheCentreofCompetenceisaffiliatedtoastrategicglobalpurchasingdepartmentfortheareaofrailwayengineering.
REOSHANGHAIINDUCTIVECOMPONENTSCO.,LTD.OurpartnerfortheChinesemarket–specializesintheproductionofrailwaycomponents,inclosecooperationwiththeCentreofCompetenceinBerlin.Componentsforrailwayengineering(chokes,filters,transformersandcomponentsinandaroundthefrequencyconverter)foruseindrivetechnologyandinthedomainofrenewableenergysourcesareproducedinChinaA1577-m2productionhallandidenticalproductionandtestingequipmentensureexcellentquality.
IRIS-Zer
ifiziert
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Content:
•DevelopmentsatREO..................................... S.27
•Watercooledchokes........................................ S.28
•Watercooledresistors...................................... S.30
Solutions of REO Watercooled components in railway technology
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Watercooling
Usingwater-cooledsystems,onecanconvertsignificantlyhighercapacitiesusingthesamesurfacearea-fromwhichincreasedcoolingefficiencyarises.
REOhaslongsincerecognizedthetrendtowardswatercoolingandhasoperateddevelopmentsinthewatercoolingareaforinductiveandresistivecomponents.ThishasenabledREOtobuildupacomprehensiveknow-howandawidespectrumofwater-cooledproducts.
Watercoolingisanexcellentsolution,especiallyfortheuseofinductiveandresistivecomponents,astemperaturebehaviorplaysamajorrolehere.Watercoolingenablesthetemperatureofthecomponentstobekeptatanoptimumlevelinauniqueway,ashighpowerlossesaredirectlytransportedoutofapplicationviathecoolinglines.Thisensuresalongerlifetimeforthecomponentsaswellasincreasedperformance.
Water cooling is a technique that pays off
WatercoolingisatechniquethatpaysoffConstructingthiskindofsystemmaybeinitiallyconnectedwithhighercoststhanwithregularforcedaircooling,however,theseinvestmentspayoffintheend.Variousbenefitscanbeachievedbywatercooling: • Highefficiencyandlownoiselevels • Minimizationofconstructionsizesupto80%withresistors • Effectivecoolingwithhighambienttemperatures • Verylowexcesssurfacetemperature • Increaseoflifetimewithnormaloperation • Constant,highperformance,astemperatureisdirectlydissipated • Onlycoolingtypeduringwhichthetemperaturemayfallbelowtheambient temperature • Verywellsuitedforindustrialapplicationsinwhichcomponentswithlowsurfacetemperaturesarerequired(woodandtextileindustriesorinexplosion-protectedenvironments,windturbines)
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ThechokesareavailableinprotectivetypesIP00toIP65.REO-canrealizevarioustypesofwatercoolingforthesecomponents.Thismeansthetargeteddischargeoflossesviathecoolingcircuit-thelossesarenotdischargedintotheenvironment.Byusingwatercooling,thetemperaturesinthecomponentscanbegreatlyreduced-thismeanslessstressontheinsulationmaterialsandalongerlifetime.
Series CNW MC - for smaller components
•Reactorcastonametalplate,withintegratedcoolingchannels.Thiscomponentenablestargetedand optimizedcoolingforsmallerpowerlevelsandischaracterizedbyitssimpleintegrationintoexisting coolingsystems •Availablein4versions(IP00,IP20,IP20+EMVandIP64) •Current3-70A
Series CNW MD - for medium to larger power levels
•Chokeinanopendesign,forwhichthecoolingprofileisintegratedintothewinding.Withthistechnology,theheat canbedirectlytiedtoitssourceandcanberemovedeasily. •Completelyencapsulatedchokes,forwhich„waterpockets“,areconnectedtoawatercoolingsystem.Theseare constructedwithinthewindingsandencapsulatingcompounds.Thistechnologyunitestheadvantagesof encapsulationtechnologytoachieveahighprotectiveclassandtheeffectiveheatdissipationatitssource..
Open design: •Type: CNWMD •Current: 100-1200A •Protection:IP00...IP40 •Inductance: 5-147mH
Watercooled chokes A specialty of REO
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Encapsulated version with water-pockets •Type: CNWMD •Current: 100-3000A •Protection: IP00...IP65 •Inductance: 5-200mH
Advantages of water-cooled chokes
•Max.temperatureCNW953/180air-cooled: 205°C•Max.temperatureCNWD953/180water-cooled: 120°C•Max.temperatureCNWMD953/180water-cooledandpoured: 68°C
Theadvantagesofthewatercoolingmethodcanbeclearlyseenbasedonthemeasurements.All3variantsweretestedwiththesameload;whendoingso,theopenwater-cooledreactorhadatemperatureadvantageof52K.IntheCNWMDversion,thetemperatureinthereactorcouldevenbeloweredby137K.ThisadvantagewasachievedduetospecialencapsulationtechniquesandaspecialREOconstruction.Inaddition,thebehavioratdifferentinlettemperatureswasresearchedtotestthebehavioratdifferentoperatingconditions.
Water-cooled chokeThisthree-phaselinechokeutilizesasinglecastingofthecoilsandprovidesverygoodinductanceandminimalphysicaldimensions.
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Areavailablewithpowerlevelsfrom1to100kW.Coolingchannelsintroducedintotheheatsinkenableefficientcoolingandthespatialseparationoftheelectricalconductors-andcoolant-enablingsafeapplication.InadditiontothegeneraladvantagesoftheREOHMbrakingresistors,suchasmodularconstructiontoattainhigherpowerlevelsorthecompactdesign,thebrakingresistorshaveanoptimalstructureandpowerconsumption,enablingthemtoalsowithstandvibrationandshocktests.REOHMbrakingresistorsareanoptimizedcombinationofprovenandinnovativetechniques,sothatnothingstandsinthewayofitsusewithhighpowerclassesunderconditionsoflimitedspaceespeciallywhenusingwatercooling.
Series REOHM BW D158 /1600 • Brakingandloadresistanceforthedrivetechnology,industrialapplications. • Power:5–100kW • CoolingchannelsseriesBWD158:Aluminum(AlMgSi0.5)Di=10.5mm • CoolingchannelsseriesBWD160:CopperorstainlesssteelDi=10mm
Type: BW D 158 •Power: 1–100kW •Protection: IP20...IP65 •Resistancevalues: 0,2-850Ohm
Type: BW D 160 •Power: 5–100kW •Protection: IP20...IP65 •Resistancevalues: 0,2-850Ohm
Comparison of an air-cooled braking resistor with a liquid-cooled braking
BW 155/3000 BW D 158/3000 aircooled watercooledDimensions(LxWxH): 762mmx175mmx75mm 320mmx50mmx68mmSpacerequired: 0,134m² 0,05m²-60 % PlatzersparnisSurfacetemperaturewithafullload: 387°C 35°C 90 % smalle surface temperature
Water cooled resistors Ideal for railway technology
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Series REOHM BW D330
• ThisseriesBWD330isavailableasloadingordampingresistororbrakingresistorforrailway technologywithcapacitiesupto100kW. Liquidcoolingenablesspacesavingsupto88%.Asaspecialbonus,theresistorcanbeconnected easilyvianon-dripquickconnectors.
• 88%spacesavings • driplessquick-connections • Watercooling • electroniccontrol
Type: BW D 330 •Power: 10-100kW •Voltage: 900V •Resistancevalues: 0,1-30Ohm
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