A design method for a simplified traction converter for locomotives

Abstract

The present invention relates to a design method for a traction inverter scheme, and specifically to a design method for a simplified traction inverter for a locomotive. The present invention provides a simplified traction inverter design method, that is, the components of the traction inverter are reasonably arranged according to the modular concept, and the box is designed according to the frame structure. When designing the traction inverter, the heat generated by each component is calculated, and its heat dissipation method, the sealing level of the box, the wiring method, the electromagnetic interference, and the reliability, operability, and maintainability of the components are reasonably designed; at the same time, the traction inverter is subjected to strength, modal and thermal simulation to ensure the rationality of its design. The simplified structure can be used for the design base model of the locomotive traction inverter, which greatly reduces the inverter design time and improves the inverter design cycle. Since the strength and modal of the base model structure have been verified, the reliability of the traction inverter box is improved.

Description

Technical Field

[0001] The invention relates to a design method for a traction converter scheme, in particular to a design method for a simplified traction converter for a locomotive. Background Art

[0002] The traction inverter is one of the key components of the locomotive. The locomotive traction inverter is generally installed in the mechanical room of the train. It is mainly composed of an input unit, a rectifier power module, an inverter power module, an intermediate DC detection unit, a grounding detection unit, supporting capacitors, resistors, a TCU control unit and a low-voltage detection unit. It mainly realizes the AC-DC-AC power electronic conversion from the traction transformer to the traction motor, completes the drive and control of the traction motor, and thus controls the operation of the locomotive.

[0003] In order to shorten the design cycle of the traction converter and improve the operational reliability, operability and maintainability of the locomotive traction converter, the locomotive converter is laid out in an overall structural layout according to the idea of ​​simplification, modularization and functional unitization, and then the traction converter box is designed to form a unified platform for the locomotive traction converter, which provides a basic model for the design of locomotive traction converters in the future and facilitates the design. At present, the locomotive traction converter has not formed a unified model. The layout of the traction converter cabinets and devices designed by different designers is very different. When designing new products, not only is the design cycle long, but the strength and mode of the converter cabinet need to be re-verified, which increases the difficulty and time of converter design.

[0004] When designing a general traction converter, the key components in the traction converter are selected according to the main circuit topology and the technical parameters provided by the user; at the same time, the traction converter is designed according to the external dimensions provided by the user. Due to the limitation of space size, the simplicity of copper bar layout and the beauty of the cabinet, the selection of key components is usually customized to facilitate the design of the traction converter. Its disadvantages are: the components of the locomotive traction converter have not been simplified, so the suppliers and structures of the components in different converters are different, the components in the converter component library are diverse, and the reliability verification data of mature application components is lacking when designing new products. The design of the locomotive traction converter also realizes the layout of all components in the converter box according to the main circuit topology provided by the user; when laying out the traction converter scheme, it mainly follows the principle of high and low voltage partitioning, considers the operability and maintainability of the components, and finally realizes its electrical function. Its disadvantages are: the component layout of the locomotive traction converter has not been modularized, so the component layout in the converter is relatively scattered, especially the location of the low-voltage detection component is scattered, the wiring is messy, and the appearance is affected. The box design of the locomotive traction inverter must also meet the impact vibration requirements and modal requirements in GB / T21563. However, the box of the locomotive traction inverter does not adopt a frame structure design, and does not form a basic structure of the inverter box. The inverter box structures designed by different designers are different. Not only is the design cycle long, but the strength and modal of the box must be repeatedly verified, and the design efficiency is low. The sealing level of the traction inverter is designed according to user requirements. However, users have low requirements for the sealing level of the traction inverter. After the inverter has been running for a long time, dust and other pollutants accumulate in the box, affecting the repair and maintenance of the inverter. Summary of the invention

[0005] The present invention provides a simplified traction converter design method, that is, the components of the traction converter are reasonably arranged according to the modular concept, and the box is designed according to the frame structure. When designing the traction converter, the heat generation of each component is calculated, and its heat dissipation method, the sealing level of the box, the wiring method, the electromagnetic interference, and the reliability, operability, and maintainability of the components are reasonably designed; at the same time, the strength, modal and thermal simulation of the traction converter are performed to ensure the rationality of its design. The simplified structure can be used for the design base model of the locomotive traction converter, which greatly reduces the converter design time and improves the converter design cycle. Since the strength and modal of the base model structure have been verified, the reliability of the traction converter box is improved.

[0006] The present invention is implemented by adopting the following technical scheme: a design method for a simplified traction converter for locomotives, which is functionally divided from the electrical structure according to the main circuit topology, and is divided into: a traction shaft, an auxiliary converter area, a chopper resistor functional unit area, a cooling system area, an input functional unit area, a high-voltage input and output interface area and a low-voltage interface area. The chopper resistor functional unit area is located in the upper left corner of the box body, and the chopper resistor module unit is arranged in this area. The input functional unit area is located in the lower left corner of the box body, and the input module unit is installed; between the chopper resistor functional unit area and the input functional unit area is a cooling system area, and the cooling system area is arranged with a resistor water cooling plate and a slow discharge module unit The high-voltage input and output interface area is located at the bottom of the box, and the high-voltage terminals are arranged in the high-voltage input and output interface area. The low-voltage interface area is located in front of the chopper resistor functional unit area in the upper left corner of the box, and the low-voltage interface area is arranged with low-voltage interfaces. The remaining areas are traction shafts and auxiliary converter areas. One traction shaft is a separate area, which consists of a low-voltage control area, a power module area, and a capacitor area. The low-voltage control area, the power module area, and the capacitor area are arranged from top to bottom. The low-voltage control area is arranged with a grounding detection module unit, a low-voltage electrical unit, and a TCU. The power module area is arranged with traction power modules, and the capacitor area is arranged with capacitors; the auxiliary converter area is arranged with auxiliary power modules and ACU.

[0007] The above-mentioned design method of a simplified traction converter for a locomotive is further divided into a sealed area and an open area, the chopper resistor functional unit area is the open area, and the remaining area is the sealed area.

[0008] In the above-mentioned design method of a simplified traction converter for a locomotive, the input module unit includes a main contactor, a pre-charging contactor and a pre-charging resistor.

[0009] In the above-mentioned design method of a simplified traction converter for a locomotive, the auxiliary converter area is integrated in a traction shaft.

[0010] In the above-mentioned design method of a simplified traction converter for a locomotive, a water pump installation position is reserved in the cooling system area.

[0011] The above-mentioned design method of a simplified traction converter for locomotives, the converter box adopts a frame structure, the box frame is welded by a bottom frame, a top frame, a left frame, a right frame and three partition frames; the three partition frames are fixed between the bottom frame and the top frame from left to right, and the partition frames are fixed with a non-load-bearing area mounting plate, two layers of load-bearing area mounting plates and a layer of high-voltage input and output interface mounting plates from top to bottom, and the top layer of the non-load-bearing area mounting plate is installed with a ground detection module unit, a low-voltage electrical unit, a TCU and an A CU, the middle load-bearing area mounting plate is used to install the traction power module, the bottom load-bearing area mounting plate is used to install the capacitor and auxiliary power module, and the high-voltage input and output interface mounting plate is used to install the high-voltage terminal; the load-bearing area mounting plates on both sides are arranged from top to bottom between the left partition frame and the left frame, the chopper resistor module unit and the low-voltage interface are installed on the top load-bearing area mounting plate, the area between the two load-bearing area mounting plates is the cooling system area, where the resistor water-cooling plate, slow discharge module unit and water pump are installed, and the input module unit is installed on the bottom frame below the cooling system area.

[0012] The above-mentioned method for designing a simplified traction inverter for a locomotive can change and adjust the distance between the left and right frames and the three partition frames according to different devices used so as to be used in the design of traction inverters for different voltage platforms.

[0013] In the above-mentioned design method of a simplified traction inverter for a locomotive, the box is divided into a load-bearing area and a non-load-bearing area according to the above-mentioned load-bearing plate and the non-load-bearing plate. The load-bearing beam of the fixed load-bearing plate in the load-bearing area is made of 4mm carbon steel plate bent into a U shape and overlapped and welded; the load-bearing beam of the fixed non-load-bearing plate in the non-load-bearing area is made of 3mm carbon steel bent plate, which is overlapped and welded.

[0014] Beneficial effects brought by the technical solution of the present invention:

[0015] 1) The present invention realizes the functional modular structure design of the locomotive traction converter and adopts simplified components to ensure the high reliability and low failure rate of the traction converter;

[0016] 2) The present invention realizes the frame structure of the locomotive traction converter box, which is designed according to the functional modular layout and can be used as the base type of the locomotive converter box, shortening the traction converter design cycle; at the same time, the strength and modal simulation of the traction converter box of the present invention have been verified, reducing the verification time;

[0017] 3) The box structure of the converter designed in the present invention can be used as a design reference for converters of different voltage levels and provide a reference for the design of other converters. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 Schematic diagram of the division into functional units.

[0019] Figure 2 This is a diagram illustrating the converter layout.

[0020] Figure 3 This is the functional unit module layout diagram.

[0021] Figure 4 It is a schematic diagram of the box frame structure.

[0022] Figure 5 This is the overall layout diagram of the traction converter.

[0023] In the figure: 1-bottom frame, 2-top frame, 3-left frame, 4-right frame, 5-partition frame, 6-non-load-bearing area mounting plate, 7-load-bearing area mounting plate, 8-high voltage input and output interface mounting plate. DETAILED DESCRIPTION

[0024] The present invention provides a design method for a simplified traction converter for locomotives. Functions are divided from the electrical structure according to the main circuit topology, and then arranged according to the functional unit modules when designing the traction converter scheme, thereby realizing the functional modular design of the traction converter, which is convenient for installation and maintenance. The traction converter box adopts a frame structure design, and carbon steel plates of different thicknesses are used for the load-bearing area and the non-load-bearing area, which are realized by lap welding.

[0025] The present invention divides the functional units according to the main circuit topology from the electrical structure, and realizes the modular design of the converter functional units according to the functional unit division (see Figure 1 ), mainly including input module unit, power module unit (including traction power module and auxiliary power module), ground detection module unit, slow discharge module unit, chopper resistor module unit, low-voltage electrical unit, control unit (including TCU and ACU (auxiliary control system)), capacitor, etc.

[0026] The present invention arranges the overall solution of the converter according to the principle of high and low voltage zoning and the functional unit module design from a structural perspective. Figure 2The traction converter is divided into a sealed area and an open area. The chopper resistor module unit is arranged in the open area, which is located in the upper left corner of the box, and the rest are arranged in the sealed area. In the sealed area, a complete traction shaft is a separate area, which is composed of a low-voltage control area, a power module area, and a capacitor area. The low-voltage control area, the power module area, and the capacitor area are arranged from top to bottom. The low-voltage control area is arranged with a grounding detection module unit, a low-voltage electrical unit, and a TCU. The power module area is arranged with a traction power module, and the capacitor area is arranged with a capacitor. The input module unit is located in the lower left area of ​​the box, and consists of a main contactor and a pre-charge contactor. The auxiliary converter area is composed of a converter and a pre-charging resistor. The auxiliary power module and ACU are arranged in the auxiliary converter area. The cooling system area is arranged with a resistor water cooling plate and a slow discharge module unit. The area is reserved for the installation of a water pump to facilitate the design of traction converters on different platforms. The high-voltage input and output interface area is reserved for the outside and is located at the bottom of the box. The high-voltage interface area is arranged with high-voltage terminals. The low-voltage interface area is located in the front side of the open area in the upper left corner of the box. The low-voltage interface in this area is integrated into the connector for easy wiring. All devices realize functional unit modularization, and the functional unit modules are highly integrated, which is easy to install and maintain. Figure 3 .

[0027] The box body of the present invention adopts a frame structure design, and the box body frame is formed by welding a bottom frame 1, a top frame 2, a left frame 3, a right frame 4 and three partition frames 5; according to different devices used, the distance between the left and right frames and the three partition frames can be changed and adjusted so as to be used for the design of traction inverters with different voltage platforms. Three partition frames 5 are fixed between the bottom frame and the top frame from left to right, and non-load-bearing area mounting plates 6, two layers of load-bearing area mounting plates 7 and a layer of high-voltage input and output interface mounting plates 8 (load-bearing plates) are fixed on the partition frames from top to bottom. The top non-load-bearing area mounting plate is used to install the grounding detection module unit, the low-voltage electrical unit, TCU and ACU, the middle load-bearing area mounting plate is used to install the traction power module, the bottom load-bearing area mounting plate is used to install the capacitor and the auxiliary power module, and the high-voltage input and output interface mounting plate is used to install the high-voltage terminal; two layers of load-bearing area mounting plates are arranged from top to bottom between the partition frame on the left and the left frame, the top load-bearing area mounting plate is used to install the chopper resistor module unit and the low-voltage interface, the area between the two load-bearing area mounting plates is the cooling system area, where the resistor water-cooling plate, the slow discharge module unit and the water pump are installed, and the input module unit is installed on the bottom frame below the cooling system area.

[0028] The box body is divided into a load-bearing area and a non-load-bearing area according to the above-mentioned load-bearing plates and non-load-bearing plates. The load-bearing beams of the fixed load-bearing plates in the load-bearing area are made of 4mm carbon steel plates bent into a "U" shape and overlapped and welded; the load-bearing beams of the fixed non-load-bearing plates in the non-load-bearing area are made of 3mm carbon steel bent plates and overlapped and welded; the frame structure has been verified by strength and modal simulation, and the area can be reduced and expanded according to the different external dimensions of the device, and can be used as the basic type of locomotive traction inverter box.

[0029] The simplified traction converter design method of the present invention proposes a layout and a box structure prototype, which can realize the design of locomotive converters of different voltage levels, shorten the traction converter design cycle, and improve the design efficiency. Specific embodiments

[0030] The traction converter in the present invention is based on the 1800V platform of a wide-gauge six-axle electric locomotive. All components in the traction converter are simplified components; the traction converter adopts a modular structure design, specifically including input unit components, chopper resistor unit components, water-cooled resistor components, low-voltage electrical detection components, grounding detection components, etc.; see Figure 5 Each traction shaft is a separate area, and three traction shafts use three traction control units to ensure the independence of the system; according to the topological diagram, the auxiliary unit is arranged on the second traction shaft to facilitate power supply. The traction converter box in the present invention adopts a frame structure, which is convenient for modification and borrowing when designing other traction converter boxes; see Figure 4 .

Claims

1. A design method for a simplified traction converter for locomotives. Features: According to the main circuit topology, the electrical structure is functionally divided into: traction shaft, auxiliary converter area, chopper resistor functional unit area, cooling system area, input functional unit area, high-voltage input and output interface area and low-voltage interface area. The chopper resistor functional unit area is located in the upper left corner of the box, where the chopper resistor module unit is arranged. The input functional unit area is located in the lower left corner of the box, where the input module unit is installed. The cooling system area is between the chopper resistor functional unit area and the input functional unit area, where the resistor water cooling plate and slow discharge module unit are arranged. The high-voltage input and output interface area is located at the lower part of the box. The high-voltage input and output interface area is arranged with high-voltage terminals, the low-voltage interface area is located in the front of the chopper resistor functional unit area in the upper left corner of the box, the low-voltage interface area is arranged with low-voltage interfaces, and the remaining areas are traction shafts and auxiliary converter areas. One traction shaft is a separate area, which consists of a low-voltage control area, a power module area, and a capacitor area. The low-voltage control area, the power module area, and the capacitor area are arranged from top to bottom. The low-voltage control area is arranged with a grounding detection module unit, a low-voltage electrical unit, and a TCU. The power module area is arranged with traction power modules, and the capacitor area is arranged with capacitors; the auxiliary power modules and ACU are arranged in the auxiliary converter area.

2. The design method of a simplified traction converter for locomotive according to claim 1, Features: It is also divided into a sealed area and an open area, the chopper resistor functional unit area is the open area, and the rest of the area is the sealed area.

3. A design method for a simplified traction converter for a locomotive according to claim 1 or 2, Features: The input module unit includes a main contactor, a pre-charging contactor and a pre-charging resistor.

4. The design method of a simplified traction converter for locomotive according to claim 2, Features: The auxiliary converter area is integrated in a traction shaft.

5. The design method of a simplified traction converter for locomotive according to claim 4, Features: The cooling system area has a reserved location for water pump installation.

6. The design method of a simplified traction converter for locomotive according to claim 5, Features: The converter box adopts a frame structure, and the box frame is formed by welding a bottom frame (1), a top frame (2), a left frame (3), a right frame (4) and three partition frames (5); the three partition frames are fixed between the bottom frame and the top frame from left to right, and a non-load-bearing area mounting plate (6), two layers of load-bearing area mounting plates (7) and a layer of high-voltage input and output interface mounting plate (8) are fixed on the partition frames in sequence from top to bottom, the top layer of the non-load-bearing area mounting plate is used to mount a ground detection module unit, a low-voltage electrical unit, a TCU and an ACU, the middle layer of the load-bearing area mounting plate is used to mount a traction power module, the bottom layer of the load-bearing area mounting plate is used to mount a capacitor and an auxiliary power module, and the high-voltage input and output interface mounting plate is used to mount a high-voltage terminal; Two layers of load-bearing area mounting plates (7) are arranged from top to bottom between the left partition frame and the left frame. The top layer of the load-bearing area mounting plate is mounted with a chopper resistor module unit and a low-voltage interface. The area between the two layers of the load-bearing area mounting plates is a cooling system area, where a resistor water cooling plate, a slow discharge module unit and a water pump are mounted. The input module unit is mounted on the bottom frame below the cooling system area.

7. The design method of a simplified traction converter for locomotive according to claim 6, Features: The distances between the left and right frames and the three partition frames can be changed and adjusted according to different devices used so as to be used in the design of traction converters of different voltage platforms.

8. The design method of a simplified traction converter for locomotive according to claim 7, Features: The box body is divided into a load-bearing area and a non-load-bearing area according to the above-mentioned load-bearing plates and non-load-bearing plates. The load-bearing beams of the fixed load-bearing plates in the load-bearing area are made of 4mm carbon steel plates bent into a U shape and overlapped and welded; the load-bearing beams of the fixed non-load-bearing plates in the non-load-bearing area are made of 3mm carbon steel bent plates and overlapped and welded.

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