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ADVANCES IN DIESEL LOCOS

MICROPROCESSORS IN DIESEL
LOCO - TOPICS

Micro controller based governor(MCBG) - MEG 601


Microprocessor based control system - MEP 660
Computer control of EMD loco EM2000
Automatic Engine Shutdown (AES) with Auxiliary
Power Unit (APU)
Distributed Power (LOCOTROL)
ACD & EOTT
Remote monitoring of loco on train (REMLOT)

Basic functions of Governor

Help to crank the engine when operator


demands.
Increase / Decrease engine RPM as per the
notch selection.
Maintain the engine RPM from no load to
full load.
Provide load control signal to reduce over
load on the engine to maintain constant
engine RPM.
Shuts down the engine on demand by
operator or any safety device is operated.

Micro Controller Based Governor


(MCBG)
In addition the fuel oil Pressure
signal is also taken as an input in
MCBG

The MCBG has been


divided in to two parts
Actuator Unit
Control Unit

BAP
FOP

LOP

MCBG
Governor
Notch

Control
Desk

Turbo

Diesel Tr.
Engine Alt.
Fuel
Rack

Eng.RPM

HP

Excitation
Control

Micro Controller Based Governor


CONTROL UNIT

ACTUATOR UNIT

Block diagram of
Micro Controller Based Governor

CONTROL UNIT
Display &
72V Power Supply
Card

The control unitACTUATOR


is again functionally
UNIT
divided into 6 modules.
The governor works on 72V DC.
The power supply module derive low
voltages required for other modules.
Display loco parameters.

Load & Clutch


Control Card

Stepper Motor
Cards (2)

Input
Card

Provides supply for the clutch coil in the


actuator unit.
Provides load control signal to excitation.

There are two stepper motor control cards.

Provides drive signal to the stepper motor.

Receive notch signals from the


locomotive.
Receive pressure signals from actuator
unit.
Transmits these signals to control card

Block diagram of
Micro Controller Based Governor

CONTROL UNIT
Display &
72V Power Supply
Card

Load & Clutch


Control Card

Control
Card

Stepper Motor
Cards (2)

Input
Card

ACTUATOR UNIT

The Control Card consists a Micro


Controller with its peripherals.

It receives various input signals like


Notch, Engine Speed, Fuel Rack
position and pressure signals etc.,
from the input card.
It communicate these parameters to
display unit.

Block diagram of
Micro Controller Based Governor

CONTROL UNIT

The driver sitting at control desk opens


the notch to the required position.
The notch signal is communicated to the
input card.

Display &
72V Power Supply
Card

Load & Clutch


Control Card

Control
Card

Stepper Motor
Cards (2)

Input
Card

Eng. RPM

Tacho /
ESS

Notch

Control
Desk

The control card decides the


engine RPM for the selected
notch.
Existing RPM is compared with
new RPM level.
The control card computes the
stepper motor direction and the
angular movement required for
new fuel rack position.
It gives signal to the stepper
motor cards to drive the motor.

Block diagram of
Micro Controller Based Governor

CONTROL UNIT

ACTUATOR UNIT

Display &
72V Power Supply
Card

Stepper Motor
signal

Load & Clutch


Control Card

Control
Card

Stepper motor

Stepper Motor
Cards (2)

Input
Card

Eng. RPM

Tacho /
ESS

Notch

Control
Desk

The stepper motor cards communicate


this drive signal to the stepper motor in
the actuator unit.

Block diagram of
Micro Controller Based Governor

CONTROL UNIT

ACTUATOR UNIT

Display &
72V Power Supply
Card

Stepper Motor
signal

Load & Clutch


Control Card

Control
Card

Stepper motor
Gear Box

Stepper Motor
Cards (2)

Input
Card

Eng. RPM

Tacho /
ESS

Notch

Control
Desk

The stepper motor slowly rotates in steps


as controlled by the control card.
The motor torque is amplified through gear
box.

Block diagram of
Micro Controller Based Governor

CONTROL UNIT

ACTUATOR UNIT

Display &
72V Power Supply
Card

Stepper Motor
signal

Load & Clutch


Control Card

Control
Card

Stepper motor
Gear Box
EM -Clutch

Stepper Motor
Cards (2)

Rack & Pinion

Input
Card

Eng. RPM

Tacho /
ESS

Notch

Control
Desk

The torque is transmitted to the rack and


pinion through an electro magnetic clutch.

Block diagram of
Micro Controller Based Governor

CONTROL UNIT

ACTUATOR UNIT

Display &
72V Power Supply
Card

Stepper Motor
signal

Load & Clutch


Control Card

Control
Card

Stepper Motor
Cards (2)

Clutch signal

Stepper motor
Gear Box
EM -Clutch
Rack & Pinion

Input
Card

Eng. RPM

Tacho /
ESS

Notch

Control
Desk

The clutch coil gets supply from the load &


clutch control card soon after the MCBG is
powered up.

Block diagram of
Micro Controller Based Governor

CONTROL UNIT

ACTUATOR UNIT

Display &
72V Power Supply
Card

Stepper Motor
signal

Load & Clutch


Control Card

Control
Card

Stepper Motor
Cards (2)

Input
Card

Eng. RPM

Tacho /
ESS

Notch

Control
Desk

Clutch signal

Stepper motor
Gear Box
EM -Clutch
Rack & Pinion

Output
shaft

To Fuel
Rack

The rack & pinion converts this rotary motion


into vertical motion.
The output shaft moves the fuel rack to the
new position against over travel spring.

Block diagram of
Micro Controller Based Governor

CONTROL UNIT

ACTUATOR UNIT

Display &
72V Power Supply
Card

Stepper Motor
signal

Load & Clutch


Control Card

Control
Card

Stepper Motor
Cards (2)

Input
Card

Eng. RPM

Tacho /
ESS

Notch

Control
Desk

Clutch signal

Fuel Rack
Position sensor

Stepper motor
Gear Box
EM -Clutch
Rack & Pinion
Fuel Rack Position
sensor

Output
shaft

To Fuel
Rack

The fuel rack position sensor provide a


feed back signal to the input card and
from there it is communicated to the
control card. The cycle repeats till the
required RPM is reached.

Block diagram of
Micro Controller Based Governor

CONTROL UNIT

ACTUATOR UNIT

Display &
72V Power Supply
Card

Stepper Motor
signal

Load & Clutch


Control Card

Control
Card

Stepper Motor
Cards (2)

Input
Card

Eng. RPM

Tacho /
ESS

Notch

Control
Desk

Clutch signal

Fuel Rack
Position sensor

Stepper motor
Gear Box
EM -Clutch
Rack & Pinion
Fuel Rack Position
sensor

Output
shaft

To Fuel
Rack

The Control card de-energises the


clutch coil under emergency
shutdown. Due to the spring force
the output shaft returns back to 0
position.

Block diagram of
Micro Controller Based Governor

CONTROL UNIT

Excitation

Display &
72V Power Supply
Card

Stepper Motor
signal

Load & Clutch


Control Card

Control
Card

Stepper Motor
Cards (2)

Input
Card

Eng. RPM

Tacho /
ESS

Notch

Control
Desk

Clutch signal

Fuel Rack
Position sensor

ACTUATOR UNIT
Stepper motor
Gear Box
EM -Clutch
Rack & Pinion
Fuel Rack Position
sensor

Output
shaft

To Fuel
Rack

The control card increases the load


control voltage through Load &
clutch control card to reduce the
excitation under over load
conditions.

Block diagram of
Micro Controller Based Governor

CONTROL UNIT

Excitation

Display &
72V Power Supply
Card

Stepper Motor
signal

Load & Clutch


Control Card

Control
Card

Stepper Motor
Cards (2)

Input
Card

Eng. RPM

Tacho /
ESS

Notch

Control
Desk

Clutch signal

Fuel Rack
Position sensor

ACTUATOR UNIT
Stepper motor
Gear Box
EM -Clutch
Rack & Pinion
Position Feedback
Pressure Sensor
Module

The Actuator unit has got a subassembly called pressure sensor


module.

Output
shaft

To Fuel
Rack

Block diagram of
Micro Controller Based Governor

CONTROL UNIT

Excitation

Display &
72V Power Supply
Card

Stepper Motor
signal

Load & Clutch


Control Card

Control
Card

Stepper Motor
Cards (2)

Input
Card

Eng. RPM

Tacho /
ESS

Notch

Control
Desk

Clutch signal

Fuel Rack
Position sensor
Pressure
Sensor Signals

ACTUATOR UNIT
Stepper motor
Gear Box
EM -Clutch
Rack & Pinion
Position Feedback

Output
shaft

To Fuel
Rack

Pressure Sensor
Module

It receives pressures from loco and


convert them into electrical signals. It
communicates to the input card.

Loco
Pressures
LOP, BAP,
FOP

FUEL RACK DRIVE


RACK SHAFT WITH FRP SENSOR

CLUTCH
MOTOR
GEAR BOX

FUEL RACK DRIVE


SPRING

GREASE NIPPLE

BELLOW

OUTPUT SHAFT

PRESSURE SENSOR SUB


ASSEMBLY
FILTER

FOP
SENSOR

LOP
SENSOR

BAP
SENSOR

PRESSURE INPUTS

FRP
CONNECTOR

SENSOR
CONNECTOR

Diesel Electric Locomotive


Governor
Diesel
Engine

Traction
Alternator

Aux.Gen.

Exciter

Rectifier
Panel

Power
Contactors

Excitation
Control

Propulsion
Control

AG
Control

Engine
Control

Traction
Motors

Control
Desk
22

Diesel Electric Locomotive with MEP-660


Governor
Diesel
Engine

Traction
Alternator

Aux.Gen.

Exciter

Rectifier
Panel

Power
Contactors

Propulsion
Excitation
Control
ControlPROCESSOR
MICRO

CONTROL
SYSTEM
AG
Engine
Control

Control

Traction
Motors

Control
Desk
23

MEP block diagram

Input signals from master handle,


start/stop button etc. are directly
connected to the system through
their respective digital inputs.

Control
Desk 1
Control
Desk 2

Switches
&
Breakers

D
I
G
IT
A
L
I
N
P
U
T
S

Various output devices


like contactors, relays
etc. are directly
energized by the system
with out any sequential
interlocks.

Microcontroller

DIGITAL OUTPUTS
Power Contactors,
Relays, Solenoids

The status of the output


devices are identified
through status of their
respective auxiliary
contacts connected as
digital inputs.

24

MEP block diagram


Control
Desk 1
Control
Desk 2

Switches
&
Breakers

D
I
G
IT
A
L
I
N
P
U
T
S

The software logic for Inputs


vs output devices is stored in
the microcontroller.

Microcontroller

DIGITAL OUTPUTS
Power Contactors,
Relays, Solenoids
25

MEP block diagram


Control
Desk 1
Control
Desk 2

Switches
&
Breakers

D
I
G
IT
A
L
I
N
P
U
T
S

Voltages, Currents,
Pressures, Temperatures
Analog inputs

Microcontroller

DIGITAL OUTPUTS
Power Contactors,
Relays, Solenoids

Various parameters
like Voltages,
Currents, Pressures,
Temperatures are
measured through
different sensors and
are connected as
analog inputs to the
system.
26

MEP block diagram


Control
Desk 1
Control
Desk 2

Switches
&
Breakers

Engine RPM and


Wheel RPM signals
are measured
through sensors
and are connected
as frequency inputs
to the system.

D
I
G
IT
A
L
I
N
P
U
T
S

Voltages, Currents,
Pressures, Temperatures
Analog inputs

Microcontroller

DIGITAL OUTPUTS
Power Contactors,
Relays, Solenoids

F
R
E
Q
U
E
N
C
Y
I
N
P
U
T
S

Tr. Motor
RPMs
Engine
RPM

27

Comm. Ports

Cont.Desk

Digital
outputs

Control Panel

RDB

Digital inputs

ADB4

ADB3

ADB2

Display

ADB1

Inter connections of MEP-660 sub


assemblies
AGFI
AGAI
AGAV
BATI

BANGI
EOT
AAT
MRPR

TAAI
TAV
EXAI
EXFI

LCPV
BKCPV
TANGI
EWT

TM1AI TM5AI
TM2AI TM6AI
TM3AI BATV
TM4AI
APR

BPP
BCP
LOP
BAP

Current sensor

Voltage sensor

Air Temp. sensor

FOP
Pressure Sensors
B.Tmp.
Spare
Spare

WRPM1 WRPM5
WRPM2 WRPM6
WRPM3 ESS
WRPM4 Spare

TM
Speed
sensor

28

EM2000 Block Diagram with AC Traction

Arrangement / Location of EM2000


Module Cabinet
1. DIO300 DIGITAL
INPUT/OUTPUT MODULE
3 Nos
2. CPU302 CENTRAL
PROCESSING UNIT
3. COM301 EM2000/TCC
/KNORR COMMUNICATIONS
INTERFACE
4. ADA305 ANALOG TO
DIGITAL TO ANALOG
MODULE
5. MEM MEMORY MODULE

PANEL MOUNTED MODULES

FCD300 FIRING
CIRCUIT DRIVER
MODULE
FCF301 FIRING
CIRCUIT
FEEDBACK
MODULE
ASC300 ANALOG
SIGNAL
CONDITIONER
MODULES
TLF301 TRAINLINE
FILTER MODULE
DVR300 DIGITAL
VOLTAGE
REGULATOR

Power Circuit

BLOCK DIAGRAM OF TRACTION


COMPUTER

TM Current

TM Voltage
TM Temp

DSP receives the torque


requirement from LCC

Analog Input
Interface

Heat Sink, DC Link


The gateTemp
pulse signals are
Capacitor
communicated through OFC to
concerned IGBTs.
The DC voltageSpeed
is converted into 3
Sensor
phase AC voltage
of required
TMfrequency.
Speed
Interface

DSP

Computes the analog data of


Traction motors and decide
the Frequency of the
Gate drive
OFC
invertor to produceOfthe
IGBTs
Interface
required torque. In Invertor

Dual Redundant
OFC
Interface

LCC

Distributed Power control

Distributed Locomotives - higher Aggregate HP


with lesser peak coupler forces
Longer Trains imply higher traffic throughput
Continuous Brake Pipe with multiple braking
locomotives Shorter Braking Distances

LOCOTROL & EOTT

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