IGBT-based inverter system
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GE OHV Drive Systems Technology Update WMEA Conference Thursday, June 8, 2006 Allen Randolph OHV Engineering Manager A company with a history of innovation 1879 First carbon-filament incandescent lamp 1913 First commercially practical X-ray device 1942 Aircraft jet engine 1963 First electric drive for haul trucks 1983 Magnetic resonance imaging 1995 World’s most powerful jet engine 2002 The most environmentally friendly locomotive ever designed 2 GE OHV Drive Systems Technology Update June 8, 2006 A company with a history of innovation in Mining 1960’s First DC electric drive system for mining haul trucks 1970’s StatexTM DC control technology 1980’s Trolley technology – 400+ systems delivered 1990’s First InvertexTM AC electric drive system for mining haul trucks 2000’s Air cooled IGBT power electronics Hybrid Technology … 9,000+ systems delivered world-wide 5,000+ systems in operation in 37 countries 3 GE OHV Drive Systems Technology Update June 8, 2006 “The ability to lead innovation will be the primary management focus for this decade.” Jeff Immelt GE continues to invest in technology Global Haul Truck Deliveries GE320ACTM Develop GE150ACTM Develop GE240ACTM GE200ACTM Develop GE360ACTM Develop 5 GE OHV Drive Systems Technology Update June 8, 2006 The more demanding the environment outside, the more you need a capable drive system inside… Leveraging heavy haul locomotive technology to meet mining requirements AC Control Group - Microprocessor Cards / Algorithms - Air Cooled IGBT Power Electronics Dynamic Retarding Group - Dynamic Retarding Grids - Grid Blowers Advantages: 9Performance 9Reliability 9Robust Components 9Cost 9Speed to Market Alternator - Traction Alternator Technology Motorized AC Wheels - AC Induction Motors 7 GE OHV Drive Systems Technology Update June 8, 2006 Integrated Drive System Development Process… Requirements Definition / System Design Component Design Development GTA41 Airflow Scheme Wheel Motor (2) Existing airflow (cfm) #### Required Airflow @ 1700 rpm (cfm) ##### Control Group #### ##### Alternator ##### ##### Device Air In Air to Alternator System and Component Validation Air to Control Group Air to Wheel Motors Advanced Simulations GTA39 WM FAN CURVES @ 1900 RPM AND CG FLOW (3V / 5H HOLES OPEN) TESTED 5/7/01 - 40 in diameter impeller - 0.075 lb/ft^3 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 25 14000 250 Sp = -4E-08cfm 2 - 0.0011cfm + 25.566 2 200 15 150 10 100 5 50 Power (shp) Sp (inWg) HP = 5E-08cfm + 0.0024cfm + 72.557 20 Sp CG Flow Alt. Flow Ksys=.215 Ksys=.1692 0 1000 2000 3000 4000 5000 6000 7000 8000 Flow (cfm) 9000 10000 11000 12000 13000 0 14000 ksys=.3137 Power •Plenum Chamber Validation (Performance) System Airflow = Sum of Component Airflows •FEA Structural Analysis (Reliability) 8 GE OHV Drive Systems Technology Update June 8, 2006 Delivering the latest innovations Insulated Gate Bipolar Transistor (IGBT) • Locomotive based design – ~20,000 IGBT Inverters in service • Smaller and lighter component – Single Inverter Stack – up to 2000 HP designed for maintainability • Reduced complexity – Fewer control components – Simpler control and diagnostics – Robust air-cooled design • Five fold inverter reliability improvement • 1,000,000 hours of OHV field experience 9 Dual Inverter Stack – up to 4000 HP GE OHV Drive Systems Technology Update June 8, 2006 GTO and IGBT Inverter Comparison Gate-Turn-Off Thyristor (GTO) • Can be switched between: • High impedance low current ‘Off’ state • Low impedance high current ‘On’ state • Gate switching at any circuit current: • Turned on with forward gate voltage • Turned off with reverse gate voltage Insulated Gate Bipolar Transistor (IGBT) • Can be switched between: • High impedance low current ‘Off’ state • Low impedance high current ‘On’ state • “Snubberless” Power Circuit – fewer components • IGBT’s in parallel for higher current capacity 10 GE OHV Drive Systems Technology Update June 8, 2006 GTO Control System DC+ CMA GATE DRIVE POWER SUPPLY GATE DRIVE POWER CONTROLLER DIT CMB PHASE MODULE FL320 PANEL GATE DRIVER DC- 11 GE OHV Drive Systems Technology Update June 8, 2006 IGBT Control System DC+ CMA GATE DRIVE POWER CONVERTER CMB PHASE MODULE FL375 PANEL GATE DRIVER DC- 12 GE OHV Drive Systems Technology Update June 8, 2006 Industry Leader in Heavy Haul Traction Drives Easy to Use Diagnostics Advanced Traction Control • 2 line full text DID panel • >300 fault codes • PTU (laptop) interface • Independent Wheel Control • Wet Weather RetardTM • Advanced spin/slide control • State of Art Digital Alternator Control • Hill start hold IGBT Technology • State of Art IGBT “Snubberless” Power Circuit • Simple and Robust Air Cooled Design – no leakage or environmental concerns • Proven GE AC4400/EVOTM Locomotive Experience • Systems Capable of 4,100 HP Motoring / 6,000 HP Retarding • Higher Efficiency and Reliability...Low Life Cycle Cost Optimized Control Cabinet • Isolated High and Low Voltage Compartments • Maximized use of solid state electronics 13 GE OHV Drive Systems Technology Update June 8, 2006 Delivering the latest innovations wPTUTM Windows based, portable software solution for communicating with OHV drive systems; Aids in system diagnostics; Provides real-time graphic capability of system events and parameters. Pocket PTU All of the common capabilities of the wPTU Toolbox, in a convenient size; Supports Statex III and Invertex Drive Systems 14 GE OHV Drive Systems Technology Update June 8, 2006 Delivering the latest innovations GE320AC GDY106 Wheel Motor • AC Traction Motor – 5GEB16 – Over 23,000,000 hours of OHV proven service – No running maintenance • Transmission – GDY106 – Robust Heavy-Duty Design – 1,400,000+ hours of OHV proven service – Delivering 24,000 hr MTBO – Minimal running maintenance 15 GE OHV Drive Systems Technology Update June 8, 2006 Delivering the latest innovations GE240AC GEB25 Wheel Motor • AC Traction Motor – 5GEB13 – Proven Locomotive AC Motor…+26,000 in service on AC4400/EVO – No running maintenance • Transmission – GEB25 – Robust Heavy-Duty Design based on proven GE787 design – Designed for 24,000 hr MTBO – Minimal running maintenance 16 GE OHV Drive Systems Technology Update June 8, 2006 Delivering the latest innovations Whisper GridsTM Retarding Assemblies for applications requiring low noise emissions Standard configuration delivers up to 25 dBA Sound Power Reduction Strong application knowledge provides Customized Solution Available for new production or aftermarket 17 GE OHV Drive Systems Technology Update June 8, 2006 The TM GE150AC Giving new meaning to peak performance GE150ACTM AC Control Group Air-Cooled IGBT Inverter - highest available efficiency and reliability Dynamic Retarding Optimized package design for easy and safe access Maximum 2,700 HP retarding capability to 12,000 ft GE InvertexTM AC control with independent wheel motor control and hillstartTM and spin/slideTM algorithms Designed to incorporate GE WhisperGridTM Motorized AC Wheels Alternator Self-ventilated Fixed ratio planetary transmission - Industry proven GE776/791 gearing configuration. Advanced excitation system enables faster response to power demand GEB15 traction motor - Proven concept with > 1,000,000 hrs in locomotives and minimal running maintenance (brushless) 1,800 gHP capability 19 GE OHV Drive Systems Technology Update June 8, 2006 The TM GE200AC A high-performance drive system for the most dynamic mining environments GE200ACTM AC Control Group Air-Cooled IGBT Inverter - highest available efficiency and reliability Dynamic Retarding Two high-capacity retard contactors – less maintenance Maximum 3,700 HP retarding capability GE InvertexTM system control independent wheel motor control and spin/slide, hillstart and thermal self protection algorithms Single blower Designed to incorporate GE WhisperGridTM packages Motorized AC Wheels Alternator Cooling air for main controls Fixed ratio planetary transmission - Industry proven GE787 gearing configuration. Advanced Excitation System - enables fast response to power demands GEB13 traction motor - Proven concept with > 26,000 in locomotive serice 2,500 gHP capability Minimal running maintenance (brushless) 21 GE OHV Drive Systems Technology Update June 8, 2006 The TM GE240AC A high-performance drive inside for a demanding environment outside GE240ACTM AC Control Group Air-Cooled IGBT Inverter - highest available efficiency and reliability Dynamic Retarding Only two high-capacity retard contactors – less maintenance Maximum 4,300 HP retarding capability GE InvertexTM system control independent wheel motor control and spin/slide, hillstart and thermal self protection algorithms Designed to incorporate GE WhisperGridTM packages Motorized AC Wheels Alternator 2,700 gHP capability Cooling air for main controls and wheel motors Advanced Excitation System - enables fast response to power demands 23 Fixed ratio planetary transmission - Industry proven GE787 gearing configuration. GEB13 traction motor - Proven concept with > 26,000 in locomotive service Minimal running maintenance (brushless) GE OHV Drive Systems Technology Update June 8, 2006 The TM GE320AC Over 11 million hours of experience GE320ACTM AC Control Group Air-Cooled IGBT Inverter - highest efficiency and 5x reliability improvement Dynamic Retarding High-capacity rectifier – up to 3500 HP applications Increased continuous retard capability GE InvertexTM AC control - with spin/slide, hillstart and thermal self protection algorithms Sea level to 12,000 ft capability without derating Designed to incorporate GE WhisperGridTM Alternator Motorized AC Wheels 2,700 or 3,500 gHP capability Cooling air for main controls and wheel motors – aux blower elimination Delivering 24,000 MTBO at nominal 1,112,000 lbs with over 1,400,000 hours of OHV service Advanced Excitation System - enables fast response to power demands Industry proven GEB16 Traction Motor with over 23,000,000 hours in OHV service Removable inboard thrust washer 25 GE OHV Drive Systems Technology Update June 8, 2006 The TM GE360AC All innovations coming together, full circle GE360ACTM AC Control Group Dual IGBT inverter – highest available reliability Dynamic Retarding Continuous motoring capability up to 12% equivalent grade Continuous 6,000 hp retarding capability to 12,000 feet GE InvertexTM AC control with spin-slide, hill start and thermal self-protection algorithms Designed to incorporate GE WhisperGridTM Alternator Motorized AC Wheels Rated for upto 3,500 ghp Designed for 24,000 hours MTBO at nominal Provides cooling air for main controls and 1,250,000 GVW based on GDY106 Wheelmotor wheel motors High HP Traction Motor delivers 6,000 HP Advanced excitation system – enables continuous retarding capability fast response to power demands Redundant brake/transmission fluid sealing arrangement – increased reliability 27 GE OHV Drive Systems Technology Update June 8, 2006 GE continues to Invest in technology Corporate Research & Development China Technology Center Shanghai, China JFW Technology Center Bangalore, India Global Research – Europe Munich, Germany Niskayuna, NY 28 GE OHV Drive Systems Technology Update June 8, 2006 Traditional Electric Truck Power Flow Dissipated heat Fuel Propulsion power Engine power Retarding power 29 GE OHV Drive Systems Technology Update June 8, 2006 Power Flow with Hybrid Technology Dissipated heat Dissipated heat Fuel Reduction Fuel HP Boost Propulsion power Engine power Hybrid power Retarding power Energy Storage System 30 GE OHV Drive Systems Technology Update June 8, 2006 Hybrid Development Program “Proof of Concept” Phase II Design 2002 2006 Prototype Production Integration 2010 2007 US DOE Awarded GE Proof of Concept Demo 2x 2mH inductors 9Power Circuit Design 9Define Battery Technology 8x RF Deck 9Mission Analysis Tool Developed 9GE Global Research Sub-scale testing 9GE – Erie Power Lab Full-scale Simulation Truck Integration: Komatsu 240TAC Hybrid Control Group Battery & Control Packaging Komatsu PG Demo and design tool Komatsu 830E Battery Placement (Demo Only) validation - 2006 4x Bumper Extension 31 GE OHV Drive Systems Technology Update June 8, 2006 OHV Energy Storage CTQ’s • Extreme Safety and Environmentally friendly - no hazardous chemical disposal • High energy and power density (weight) • High-energy efficiency • Maintenance-free construction • Long useful life • High reliability • Properties independent of ambient conditions 32 GE OHV Drive Systems Technology Update June 8, 2006 GE Erie Simulation Lab Testing Full Power System Validation Hybrid Control Group • 12 batteries • 17KG535: D-IGBT Control Group • Hybrid Control Group • Inductors Batteries 33 Inductors 17KG535 Group GE OHV Drive Systems Technology Update June 8, 2006 GE Technology Focused on Driving LCC $ Maintenance Robust-simple design maximizes MTBO, AC delivers minimal running maintenance Performance High retard HP limits mechanical brake wear, Traction controls optimizes tire life Fuel Savings Ton Availability Hybrid system utilizes stored energy to offset Engine HP, offers extended Engine OH cycle, Reduced fleet Maximize fleet up-time Performance AC provides top speed on-grade, top vehicle speed and broad retard envelope Productivity Hybrid system utilizes stored energy as supplement to engine HP to increase speed on grade 34 GE OHV Drive Systems Technology Update June 8, 2006 Innovation continues… 1966 7 1996 1996 2006 Future GE772 7 GE791 GE320AC GE776 7 7 7 GE788 GE787 7 7 7 7 7 GE150AC GE240AC GE360AC GE200AC GE200AC 35 GE OHV Drive Systems Technology Update June 8, 2006
