NORME INTERNATIONALE CEI IEC INTERNATIONAL STANDARD 61377 2 Première édition First edition 2002 06 Applications ferroviaires – Matériel roulant – Essais combinés – Partie 2 Moteurs de traction à coura[.]
Interfaces spécifiées
Les interfaces extérieures spécifiées d’un système combiné avec hacheur sont
• les interfaces avec la ligne d'alimentation
• les interfaces avec la puissance mécanique de sortie
• les interfaces avec le système de régulation du véhicule
• les interfaces entre le hacheur et le moteur
• les interfaces entre le hacheur et la régulation
• les interfaces entre le moteur et la régulation
• les interfaces avec le système de refroidissement du véhicule
Caractéristiques spécifiées
The specification of a combined system should generally include characteristic curves, which are defined as the specified characteristics These curves must be plotted up to the operating limits for each variable Typically, they should be drawn for the input values on the direct current side imposed by the regulation, especially if there is a regulated intermediate circuit on the direct current side, along with the supply voltage.
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The short-time rating, such as 1 hour, indicates the mechanical output that the combined system can achieve on the test bed at a specified speed for the designated duration, while adhering to the temperature rise limits outlined in Table 2 of IEC 60349-1 and IEC 61287-1 This assessment begins with a cold combined system, ensuring that all other standard requirements are met.
The short-time overload rating of mechanical output indicates the maximum performance that the combined system can achieve on the test bed at a specified speed for a defined duration This test is conducted in accordance with section 8.1.5 of IEC 60349-1, ensuring that the temperature rise remains within the limits outlined in table 3 of IEC 60349-1 and IEC 61287-1.
Short-time overload ratings are essential for assessing the compatibility of combined systems in applications that experience extended durations of operation below the continuous rating, followed by brief periods of exceeding it, particularly in locomotive scenarios However, these ratings are not applicable for repeated short-load cycles typical in rapid transit and similar operations, and should not be used for such purposes.
The combined system can operate under a 3.14 intermittent duty rating duty cycle without exceeding the temperature rise limits specified in Table 2 of IEC 60349-1 and IEC 61287-1.
The periodic duty rating of 3.15 allows the combined system to operate without exceeding the temperature rise limits specified in Table 2 of IEC 60349-1 and IEC 61287-1.
4 Combined system interfaces and characteristics
The specified external interfaces of a chopper combined system are
• interfaces with vehicle control system
• interfaces between chopper and motor
• interfaces between chopper and control
• interfaces between motor and control
• interfaces with vehicle cooling system
Combined system specifications typically include characteristic curves, referred to as "specified characteristics." These curves should be plotted within the designed operating limits of each variable and are generally based on the specified d.c input values set by the control, particularly when a controlled d.c link is present, as well as the supply voltage of the traction system.
The traction network operates at its specified nominal voltage If there is no regulated intermediate circuit on the direct current side, the direct input corresponds to the voltage level of the traction network when it is at its nominal value Additionally, characteristics can be plotted for both the highest and lowest voltage levels of the traction network if an agreement is made between the operator and the manufacturer These characteristics should be plotted at a reference temperature of 150 °C for the motor windings and for the temperatures of the chopper converter components as specified by the supplier.
In addition to torque and speed, the characteristics can represent the traction effort at the wheels and the vehicle's speed In this context, it is essential to specify the gear ratio, wheel diameter, and transmission losses If conventional values are used for these parameters, they must comply with Figure B.10.
Les caractéristiques spécifiées doivent être soumises à l’exploitant avant que la commande du système combiné ne soit enregistrée, sauf spécification contraire.
The supply voltage values for the traction network must be specified by the operator It is advisable to select these values preferably from the standardized options outlined in IEC 60850.
Caractéristiques de base
Courbes caractéristiques obtenues à partir des résultats des essais de type effectués conformément à 6.5.
Caractéristiques et valeurs d’un système combiné
The specified and fundamental characteristics and values of the combined system are represented in relation to speed across the entire operating range These include external characteristics and values such as
– les valeurs moyennes des grandeurs d’entrée côté courant continu: tension, courant
(y compris les harmoniques) et puissance du système combiné,
– le couple mécanique moyen; b) les caractéristiques et valeurs internes telles que
− la valeur efficace du courant de sortie du hacheur,
− la valeur d’ondulation crête à crête du courant de sortie du hacheur,
− la valeur efficace du courant de champ pour les moteurs en série ou excités séparément,
− les formes d’onde de tension et les transitoires de commutation, qui sont les valeurs de tension de crête maximale point-à-point ou point-à-terre du hacheur,
NOTE Les transitoires de commutation internes servent à vérifier la tension d’essai diélectrique des constituants.
When considering performance, it is crucial to request and represent this characteristic effectively Efficiency is especially significant for combined systems utilized in thermal/electric rolling stock or battery-powered vehicles.
Les caractéristiques de rendement du système combiné doivent prendre en compte le moteur, le hacheur, la résistance en parallèle de champ, les câbles et les autres composants appropriés.
The system operates at its specified nominal value, with the d.c input reflecting the traction system's supply voltage at this nominal level Additionally, characteristics may be provided for both lower and higher supply voltages if mutually agreed upon by the user and manufacturer These characteristics are determined at a reference winding temperature of 150 °C, along with the expected temperature of the chopper converter components as specified by the supplier.
An alternative to torque and speed is to analyze the tractive effort at the wheels and the vehicle speed In this context, it is essential to specify the gear ratio, wheel diameter, and transmission losses If conventional values are applied, they must align with figure B.10 of IEC 60349-1.
The specified characteristics shall be submitted to the user before the order for the combined system is placed, unless otherwise specified.
The values of the supply voltage of the traction system shall be specified by the user They should preferably be the standard values according to IEC 60850.
Characteristic curves obtained from the results of type tests carried out in accordance with 6.5.
4.4 Combined system characteristics and values
The specified and declared characteristics and values of the combined system shown as a function of speed, over the whole application range are a) external characteristics and values such as
– the mean values of the d.c input: voltage, current (including harmonics) and power of the combined system,
– the mean mechanical torque); b) internal characteristics and values such as
− the root-mean-square value of the output current of the chopper,
− the peak-to-peak ripple value of the output current of the chopper,
− the root-mean-square value of the field current for series or separately excited motors,
− voltage waveforms and switching transients, which are the maximum peak voltage point-to-point or point-to-earth of the chopper,
NOTE Internal switching transients are of use to check the dielectric test voltage of the constituents.
Efficiency is a crucial factor that should be explicitly requested and demonstrated, especially in combined systems utilized in thermal/electric rolling stock or battery-powered vehicles.
The efficiency characteristic of the combined system shall take into account the motor, the chopper, the field shunt resistor, the cables and other relevant components.
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Les caractéristiques doivent être tracées au moins pour la référence maximale de couple
The displayed value of the manipulator across the full operating speed range of the application, during both traction and braking, is crucial, especially if electric braking is available Additionally, these values can be plotted for 1/4, 1/2, and 3/4 of the maximum torque reference at all speeds, subject to agreement between the operator and the manufacturer.
Only the external characteristics and maximum internal switching transients are mandatory If efficiency measurement is requested, it must include excitation losses Other internal characteristics and values should be measured, but the results should not affect the acceptance of the combined system.
Les figures 2 à 5 montrent des exemples des courbes obligatoires les plus communes.
Echange d’information et responsabilité
The IEC 60349-1 and IEC 61287-1 standards emphasize the importance of information exchange between the motor supplier and the chopper supplier This collaboration ensures that the combined system meets the requirements outlined in these standards The documentation of this information exchange is a crucial component of the specifications for both the motor and the chopper.
Paragraph 3.3 defines the constructor as the entity responsible for the technical provision of the combined system Consequently, the constructor is accountable for the technical specifications of the components of the combined system to ensure compliance with the requirements of this standard.
Généralités
Il existe trois catégories d’essais:
La présente norme ne concerne pas directement les essais de série Chaque composant du système subit les essais de série suivant la norme qui lui est propre.
Essais de type
Type tests are designed to validate the assigned regimes, characteristics, and performance of a new combined system These tests must be conducted on each newly designed combined system.
If design or manufacturing process changes are made to the components after the combined system has undergone type testing, the impact of these changes on the system's performance must be assessed Subsequently, an agreement may be reached between the operator and the manufacturer to either forgo retesting or to conduct only specific tests.
Subject to an agreement between the operator and the manufacturer, a type test is not required if the manufacturer provides a comprehensive type test report conducted on a combined system with similar design and power specifications.
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The characteristics should be outlined for the maximum torque reference across the entire speed range of the application, including both motoring and braking if electric braking is utilized Additionally, characteristics may be specified for 1/4, 1/2, and 3/4 of the maximum torque reference at any speed, subject to agreement between the user and the manufacturer.
The mandatory requirements include only external characteristics and the maximum internal switching transients If efficiency measurement is requested, it must account for excitation losses While other internal characteristics and values should be measured, their results will not affect the acceptance of the combined system.
Figures 2 to 5 show examples of the most common mandatory curves.
4.5 Exchange of information and responsibility
IEC 60349-1 and IEC 61287-1 emphasize the importance of information exchange between motor and chopper suppliers to ensure compliance with the relevant standards This communication is essential for the combined system to meet specified requirements, and the documentation of this exchange is a crucial component of the motor and chopper specifications.
Subclause 3.3 identifies the manufacturer as the entity responsible for the technical aspects of the combined system's supply Consequently, the manufacturer must ensure that the technical specifications of the system's components comply with the requirements outlined in this standard.
There are three categories of tests:
This standard is not directly concerned with routine tests Each component of the system is routine tested according to its relevant standard.
Type tests are intended to prove the ratings, characteristics and performances of a new combined system They shall be carried out on one combined system of every new design.
Any design or manufacturing process modifications made after the type testing of the combined system must be assessed for their impact on performance Subsequently, the user and manufacturer may agree to forgo retesting or to conduct only specific tests.
A type test may be waived if the manufacturer provides a comprehensive type-test report for a combined system that shares a similar design and power, contingent upon an agreement between the user and the manufacturer.
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Essais d’investigation
The purpose of the investigation tests is to gather additional information about the chopper when it powers the motor, the motor when it is powered by the chopper, or the regulation of the combined system These tests should only be conducted if a prior agreement has been established between the operator and the manufacturer The results of these tests should not affect the acceptance of the system unless there is an agreement between the operator and the manufacturer.
Généralités
The combined test allows for the operation of the components within the combined system using real parameters, similar to actual service conditions During this process, the motor torque, the direct current of the intermediate circuit, and, if applicable, the output current and voltage of the chopper are generated in service.
The manufacturer must provide the operator with a testing specification before the commencement of trials, outlining the key tests to be conducted in accordance with the current standards to meet contract requirements Following the completion of these tests, the manufacturer is required to deliver a comprehensive test report to the operator.
Conditions d’essais
Refroidissement pendant les essais
The combined system must be tested with its cooling system installed as it would be in service, including the pipes and filters considered part of the vehicle, or under conditions that provide equivalent scenarios Measurements of relevant parameters such as flow rate, pressure, and temperatures can be taken to demonstrate that the cooling conditions are comparable to those achieved on the vehicle.
Le refroidissement qui correspond au déplacement du véhicule peut être simulé pour les parties de l’équipement pour lesquelles le refroidissement naturel a de l’importance.
Toutes les simulations de refroidissement doivent faire l’objet d’un accord.
Les détails relatifs au refroidissement de chaque composant sont donnés dans les normes qui les régissent.
Câbles de puissance
Il est recommandé que les câbles de puissance soient disposés pour donner, du point de vue thermique et électromagnétique, des conditions pratiquement équivalentes à celles spécifiées.
It is advisable to use power cables that are specifically designed for the vehicle, although equivalent power cables may also be utilized Any information regarding these cables and their arrangement should be provided by the manufacturer upon request.
It is not essential to replicate the exact cable layout of the vehicle, as long as the most unfavorable local conditions are simulated on the test bench For instance, if it is reasonable to expect that the highest heating occurs in a 2-meter section of the cable path, it is advisable to simulate this section on the test bench, while other parts of the cable routing can be omitted from a thermal perspective.
Alimentation de puissance
Power supply can be drawn from the vehicle's DC power source or another available source at the test bench Whenever applicable, the system's inductances, capacitances, and resistances must be considered.
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The purpose of investigation tests is to gather further insights about the chopper's performance when supplying the motor, the motor's behavior when powered by the chopper, or the control of the integrated system These tests will only proceed with prior agreement between the user and the manufacturer Additionally, the outcomes of these tests will not affect the system's acceptance unless mutually agreed upon by both parties.
Combined testing allows for the evaluation of system components under real operational conditions, utilizing actual parameters such as motor torque, d.c link voltage, and the output current and voltage of the chopper, as they would occur in service.
Before testing begins, the manufacturer must provide the user with a test specification detailing the tests to be conducted according to the standard to fulfill contract requirements After testing is completed, the manufacturer is required to deliver a comprehensive test report to the user.
The combined system shall be tested with its cooling arranged as in service, including ducting and filters regarded as part of the vehicle, or with arrangements giving equivalent conditions.
Measurements of relevant parameters (flow, pressure, temperatures, etc.) may be performed in order to show that the cooling conditions are equivalent to those encountered on the vehicle.
Cooling corresponding to that produced by the motion of the vehicle may be simulated for parts of the equipment for which natural cooling is of importance.
All simulations of cooling shall be subject to agreement.
Details about the cooling of each component are given in the relevant standards.
For optimal thermal and electromagnetic performance, power cables should be arranged to ensure nearly equivalent conditions It is advisable to use the specific power cables intended for the vehicle, although equivalent alternatives may also be acceptable Manufacturers can provide detailed information regarding these cables and their arrangement upon request.
It is not essential to replicate the exact cable arrangement found in the vehicle during testing, as long as the local worst-case conditions are accurately simulated on the test bed For instance, if the maximum temperature increase is anticipated in a specific 2 m section of the cable layout, that section should be included in the test, while other parts of the layout may be excluded for thermal considerations.
The power supply for the test bed can be sourced from the vehicle's direct current (d.c.) supply or another available source It is essential to consider system inductance, capacitance, and resistance when applicable.
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Mesure de la puissance mécanique de sortie
The output mechanical power must be measured directly using a torque meter or indirectly with a calibrated machine on the shafts of the motors The accuracy of the measurements should adhere to the specifications outlined in the relevant articles of this standard.
Alternatively, with an agreement between the operator and the manufacturer, mechanical power can be obtained by summing the losses or through a recovery method if two combined systems are available; these methods are currently being validated Figure 7 illustrates an example of a test bench layout for a recovery testing method.
NOTE La méthode par la somme des pertes inclut l’évaluation des pertes
− du moteur, à partir des mesures sur l’entrée en courant continu du moteur (méthode d’essai spécifiée dans la CEI 60349-1);
− du hacheur, généralement déduites à partir des mesures sur l’entrée en courant continu;
− des câbles, et, le cas échéant, des résistances et inductances nécessaires pour faire fonctionner le système combiné.
Essais d’échauffement
Généralités
Les essais doivent être réalisés aux régimes du système pour lesquels il existe un accord.
In the case of a continuous assigned test, the time required to reach a stable temperature can be shortened by starting the test at a higher load or with reduced ventilation of certain system components, provided that the assigned conditions are maintained for at least 2 hours or until it is demonstrated by appropriate means that stabilized temperatures have been achieved.
In the case of a test under a periodic service regime, the time required to reach a stable temperature can be reduced by starting the test at a calculated equivalent regime and continuing with repetitive cycles.
Le paragraphe 4.4 établit la responsabilité technique du constructeur du système combiné.
Consequently, it is not necessary for the supplier to conduct a heating test on a component according to the governing standard The component can be deemed to have passed the heating test as long as the temperature increases during the combined test do not exceed the specified values in the component standards If no values are specified in the component's standard, the values may be subject to agreement This remains applicable even if the electrical parameters do not precisely match those agreed upon between the supplier and the manufacturer.
Mesure des températures
La mesure de la température des parties du système combiné est décrite dans les normes appropriées.
Essai de commutation
L’essai de commutation sur les moteurs en courant continu doit être réalisé conformément à la CEI 60349-1.
The test outlined in sections 8.3.2 and 8.3.3, point 1 (Com 1) of IEC 60349-1 must be conducted under both traction and braking conditions, at maximum speed and maximum current, using a supply voltage that creates the worst ripple conditions.
L’essai défini dans les mêmes articles, point 3 (Com 3), doit être réalisé à la plus mauvaise condition d’ondulation.
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The mechanical output will be measured either directly using a torquemeter or indirectly through a calibrated machine at the motor shaft(s) The measurement accuracy must adhere to the specifications outlined in the relevant clauses of this standard.
The mechanical output can be determined through the summation of losses or the back-to-back method, provided there is mutual agreement between the user and the manufacturer This approach is applicable when two combined systems are available, as illustrated in Figure 7, which depicts a test-bed arrangement for the back-to-back testing method.
NOTE The summation of losses method includes the evaluation of the losses of
− the motor, derived from measurements on the d.c input of the motor (test method as specified in IEC 60349-1);
− the chopper, generally derived from the d.c input measurements;
− the cables, and, if any, the resistors, and inductances necessary to run the combined system.
The tests shall be carried out at the agreed ratings of the system.
To expedite the time required to achieve a steady temperature during a continuous rating test, the test can begin with an increased load or reduced ventilation in certain system elements However, it is essential to maintain the rated conditions for a minimum of 2 hours or until it is confirmed through appropriate methods that steady temperatures have been attained.
To expedite the steady temperature achievement during a periodic duty rating test, it is effective to start the test at a calculated equivalent rating and proceed with repeated cycles.
Subclause 4.4 states the technical responsibility of the manufacturer of the combined system.
The supplier is not required to perform the temperature-rise test for a constituent as per its relevant standard A constituent can be considered to have passed this test if the temperature increases during combined testing do not surpass the limits outlined in the constituent standards In cases where no specific values are provided in the standards, alternative values can be mutually agreed upon This agreement holds true even if the electrical parameters differ from those established between the supplier and the manufacturer.
The measurement of the temperature of the parts of the combined system is described in the relevant standards.
The commutation test on d.c motors shall be carried out in accordance with IEC 60349-1.
The tests outlined in sections 8.3.2 and 8.3.3, point 1 (Com 1) of IEC 60349-1 must be conducted in both motoring and braking modes These tests should be performed at maximum speed and current, using a supply voltage that creates the most severe ripple conditions.
The test defined in the same clauses, point 3 (Com 3), shall be carried out at the worst ripple condition.
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Relevé des caractéristiques et des tolérances
Caractéristiques de couple
Testing is essential to demonstrate that the system meets the specified torque characteristics by operating the motors at a given speed The torque reference (displayed value from the controller) must be provided to the regulation element to assess the combined system's characteristics Subsequently, it is necessary to measure the average output torque of the motor, along with the average voltage, average current, and power.
(moyenne), du côté continu du hacheur.
NOTE Le paragraphe 4.4 indique que "les caractéristiques de couple doivent être tracées pour la référence maximale de couple".
Les valeurs limites d’erreur de l’appareil de mesure ne doivent pas être supérieures à
– ±2 % du maximum du couple mécanique de référence à la vitesse considérée;
– ±1 % pour les valeurs moyennes de la tension, du courant et de la puissance en courant continu.
Similarly, for the warm-up test, the motor(s) can be deemed to have met the torque characteristics requirements of IEC 60349-1, provided that the torque characteristics measured during the combined system test comply with the specifications of this standard This remains applicable even if the electrical parameters do not precisely match those agreed upon between the supplier and the manufacturer.
Tolerances: The base torque at any specified speed must not be less than 95% of the specified value, between the values corresponding to the maximum torque and 90% of the maximum speed.
6.5.1.2 Essai de balayage de la vitesse à couple maximal
The torque characteristic should be assessed by varying the speed range both upward and downward, with the torque reference set at its maximum value during both acceleration and braking when applicable No system interruptions should be observed, and the rate of speed variation must be suitable for each specific application.
6.5.1.3 Caractéristiques de rendement du système combiné (caractéristiques de perte)
If loss measurements are required, they should be conducted at the end of the heating test outlined in section 6.3 These measurements must be subtracted from the direct current input power and the mechanical output power Typically, a small number of data points is sufficient.
The measurement error limits for the input power device in direct current should not exceed ±1% The torque measurement device must have an accuracy of ±0.5% of the maximum reference torque at the specified speed, while the speed measurement device should maintain an accuracy of ±0.1% These tolerances may vary if an agreement is reached between the operator and the manufacturer The error limits utilized, along with the resulting tolerance on efficiency, should be represented on the efficiency characteristic.
Les méthodes de récupération ou d’addition mentionnées en 6.2.4 peuvent être utilisées si un accord a été conclu entre l’exploitant et le constructeur.
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Compliance with specified torque characteristics is verified by operating the motor(s) at a designated speed The control unit receives the torque reference from the main controller to assess the combined system's performance Measurements of the mean motor output torque, voltage, current, and power on the d.c side of the chopper are then conducted.
NOTE Subclause 4.4 states that "the torque characteristics shall be drawn for the maximum torque reference".
The limits of error of the measurements instrument shall not be greater than
– ±2 % of the maximum mechanical torque reference at the speed considered;
– ±1 % for the mean values of the d.c voltage current and power.
In the temperature-rise test, motors can be considered to have successfully passed the torque characteristics tests of IEC 60349-1 if the torque characteristics observed during the combined system test align with the standard's requirements This holds true even if the electrical parameters differ slightly from those previously agreed upon by the supplier and manufacturer.
Tolerances dictate that the declared torque at any speed must fall within the specified characteristic, ensuring it is no less than 95% of the specified value between the maximum torque and 90% of the maximum speed.
6.5.1.2 Sweeping speed test at full torque
The torque characteristics must be tested across the entire speed range, with the torque reference set at its maximum value during both motoring and braking, if applicable It is essential that there are no instances of tripping or system shutdowns Additionally, the speed change rate should be suitable for each specific application.
6.5.1.3 Efficiency characteristics of the combined system (loss characteristics)
Loss measurements must be conducted after the temperature-rise test as outlined in section 6.3 These measurements should be based on the d.c power input and mechanical output, with a limited number of data points typically being sufficient.
The measurement instruments for d.c power input must have error limits not exceeding ±1%, while torque measurement instruments should maintain an accuracy of ±0.5% of the maximum torque reference at the specified speed Additionally, speed measurement instruments are required to be accurate within ±0.1% These tolerances can be adjusted through mutual agreement between the user and the manufacturer It is essential to display the error limits and the corresponding efficiency tolerance on the efficiency characteristic.
The summation of losses and back-to-back methods mentioned in 6.2.4 may be used if agreed between the user and the manufacturer.
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Essais des systèmes de protection
Alimentation de l’équipement de régulation du système combiné
The combined system must operate seamlessly with any variation of the power supply within the specified range, without system interruption or fault indication The loss of one or more power supplies should lead to the immediate shutdown of the chopper, ensuring no failures or defective operation of the combined system Additionally, the system must be capable of controlled restart once the regulating power supplies are restored.
Alimentation en courant continu
It is essential to verify the operation of the regulation system by varying the DC voltage source from the minimum to the maximum specified operating range This ensures that the combined system functions correctly and that its output is regulated and inhibited according to the accepted curve.
Interruption de courte durée de l’alimentation en courant continu (essai de type facultatif)
Cet essai peut être réalisé en faisant fonctionner deux contacteurs l’un après l’autre de manière à générer une interruption de courte durée de l’alimentation avec une durée spécifiée.
La figure 8 donne un exemple de circuit d’essai possible.
Variation soudaine de la tension d’alimentation (essai de type facultatif)
Cet essai peut être réalisé en utilisant un contacteur en parallèle d’une résistance connectée comme à la figure 9, qui donne un exemple de configuration possible de circuit.
L’essai est effectué à la fois en traction et en freinage.
Harmoniques du courant d’entrée du hacheur (essai de type facultatif)
The chopper can disrupt railway signaling systems, power supply systems, or other fixed or onboard equipment due to the generation of harmonic currents on the direct current power line Therefore, it is crucial to measure the alternating currents present at the direct current input of the chopper under various voltage and current conditions of the motors.
L’exploitant doit spécifier le contenu harmonique maximal, en fonction de la fréquence et du courant continu d’entrée du système combiné.
Measurement results can be utilized to enhance the calculation of the total harmonic disturbance level of the vehicle, taking into account the total number of choppers, the design of the line filter, and other factors.
NOTE 1 Pour les mesures, il est recommandé d’utiliser un capteur de courant de haute précision, ainsi qu’un analyseur de fréquences.
NOTE 2 Il convient de prendre en compte les harmoniques générées par l’alimentation en courant continu pour la mesure du contenu harmonique total.
Essai de perturbation (essai de type facultatif)
Cet essai doit être effectué conformément à 2.4.6.23 de la CEI 61287-1.
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6.6.1 Power supply for control equipment of the combined system
The combined system is designed to function seamlessly across a range of supply variations, ensuring uninterrupted operation without fault indications In the event of one or more power supply losses, the chopper will enter an off-state without causing any failures or malfunctions in the overall system Additionally, the system is capable of restarting in a controlled manner once the control supplies are restored.
A thorough check will be conducted by adjusting the d.c supply voltage from the maximum to the minimum within the specified operating range to ensure the control system functions correctly Additionally, it will be verified that the output of the combined system is regulated and inhibited according to the established curve.
6.6.3 Short-time d.c power supply interruption (optional type test)
The test may be performed by operating two contactors in sequence in such a way as to generate a short-time interruption of the power supply with a specified duration.
Figure 8 gives an example of a possible test circuit.
6.6.4 Sudden variation of the supply voltage (optional type test)
The test may be performed by using a contactor in parallel to a resistor connected as in figure 9, which gives an example of possible circuit configuration.
The test is carried out in both motoring and braking.
6.6.5 Harmonics in the input current of the chopper (optional type test)
The chopper can disrupt the railway signalling system, power supply, and other equipment due to harmonic current generation on the d.c supply line Therefore, it is crucial to measure the a.c currents on the d.c input of the chopper under various voltage and current conditions of the motors.
The user shall specify the maximum harmonic content, as a function of frequency, of the d.c. input current of the combined system.
The measurement results can enhance the calculation of the total harmonic interference level from a vehicle by factoring in the total number of choppers and the design of line filters.
NOTE 1 For the measurements, a high-precision current sensor, together with a frequency analyser, should be used.
NOTE 2 The harmonics generated by the d.c power supply should be considered when measuring the total harmonic content.
6.6.6 Interference test (optional type test)
The test shall be carried out in accordance with 2.4.6.23 of IEC 61287-1.
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Specified interfaces
The specified external interfaces of a chopper combined system are
• interfaces with vehicle control system
• interfaces between chopper and motor
• interfaces between chopper and control
• interfaces between motor and control
• interfaces with vehicle cooling system
Specified characteristics
Combined system specifications typically include characteristic curves, referred to as "specified characteristics." These curves should be plotted according to the designed operating limits of each variable and are generally based on the specified d.c input values set by the control, particularly when a controlled d.c link is present, as well as the supply voltage of the traction system.
The traction network operates at its specified nominal voltage If there is no regulated intermediate circuit on the direct current side, the direct input corresponds to the traction network's nominal supply voltage Additionally, characteristics can be plotted for both the highest and lowest supply voltages if an agreement is reached between the operator and the manufacturer These characteristics should be plotted at a reference temperature of 150 °C for the motor windings and for the temperatures of the components of the chopper converter as specified by the supplier.
In addition to torque and speed, the characteristics can represent the traction effort at the wheels and the vehicle's speed In this context, it is essential to specify the gear ratio, wheel diameter, and transmission losses If conventional values are used for these parameters, they must comply with Figure B.10.
Les caractéristiques spécifiées doivent être soumises à l’exploitant avant que la commande du système combiné ne soit enregistrée, sauf spécification contraire.
The supply voltage values for the traction network must be specified by the operator It is advisable to select these values from the standardized options provided in IEC 60850.
Courbes caractéristiques obtenues à partir des résultats des essais de type effectués conformément à 6.5.
4.4 Caractéristiques et valeurs d’un système combiné
The specified and fundamental characteristics and values of the combined system are represented in relation to speed across the entire operating range These include external characteristics and values such as
– les valeurs moyennes des grandeurs d’entrée côté courant continu: tension, courant
(y compris les harmoniques) et puissance du système combiné,
– le couple mécanique moyen; b) les caractéristiques et valeurs internes telles que
− la valeur efficace du courant de sortie du hacheur,
− la valeur d’ondulation crête à crête du courant de sortie du hacheur,
− la valeur efficace du courant de champ pour les moteurs en série ou excités séparément,
− les formes d’onde de tension et les transitoires de commutation, qui sont les valeurs de tension de crête maximale point-à-point ou point-à-terre du hacheur,
NOTE Les transitoires de commutation internes servent à vérifier la tension d’essai diélectrique des constituants.
When considering performance, it is crucial to request and represent this parameter effectively Efficiency plays a significant role, especially in combined systems utilized in thermal/electric rolling stock or battery-powered vehicles.
Les caractéristiques de rendement du système combiné doivent prendre en compte le moteur, le hacheur, la résistance en parallèle de champ, les câbles et les autres composants appropriés.
The system operates at its specified nominal value, with the d.c input reflecting the traction system's supply voltage at this nominal level Additionally, characteristics may be provided for both lower and higher supply voltages if mutually agreed upon by the user and manufacturer These characteristics are based on a reference winding temperature of 150 °C and the expected temperature of the chopper converter components as specified by the supplier.
An alternative to torque and speed is to represent the characteristics in terms of tractive effort at the wheels and vehicle speed In this context, it is essential to specify the gear ratio, wheel diameter, and transmission losses If conventional values are applied for these parameters, they must align with figure B.10 of IEC 60349-1.
The specified characteristics shall be submitted to the user before the order for the combined system is placed, unless otherwise specified.
The values of the supply voltage of the traction system shall be specified by the user They should preferably be the standard values according to IEC 60850.
Declared characteristics
Characteristic curves obtained from the results of type tests carried out in accordance with 6.5.
Combined system characteristics and values
The specified and declared characteristics and values of the combined system shown as a function of speed, over the whole application range are a) external characteristics and values such as
– the mean values of the d.c input: voltage, current (including harmonics) and power of the combined system,
– the mean mechanical torque); b) internal characteristics and values such as
− the root-mean-square value of the output current of the chopper,
− the peak-to-peak ripple value of the output current of the chopper,
− the root-mean-square value of the field current for series or separately excited motors,
− voltage waveforms and switching transients, which are the maximum peak voltage point-to-point or point-to-earth of the chopper,
NOTE Internal switching transients are of use to check the dielectric test voltage of the constituents.
Efficiency is a crucial factor that should be explicitly requested and demonstrated, especially in combined systems utilized in thermal/electric rolling stock or battery-powered vehicles.
The efficiency characteristic of the combined system shall take into account the motor, the chopper, the field shunt resistor, the cables and other relevant components.
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Les caractéristiques doivent être tracées au moins pour la référence maximale de couple
The displayed value of the manipulator across the full operating speed range of the application, during both traction and braking, is crucial, especially if electric braking is available Additionally, these values can be plotted for 1/4, 1/2, and 3/4 of the maximum torque reference at all speeds, subject to agreement between the operator and the manufacturer.
Only the external characteristics and maximum internal switching transients are mandatory If efficiency measurement is requested, it must include excitation losses Other internal characteristics and values should be measured, but the results should not affect the acceptance of the combined system.
Les figures 2 à 5 montrent des exemples des courbes obligatoires les plus communes.
The IEC 60349-1 and IEC 61287-1 standards emphasize the importance of information exchange between the motor supplier and the chopper supplier This collaboration ensures that the combined system meets the requirements outlined in these standards, with the documentation of this information exchange being a crucial part of the specifications for both the motor and the chopper.
Paragraph 3.3 defines the constructor as the entity responsible for the technical provision of the combined system Consequently, the constructor is accountable for the technical specifications of the components of the combined system to ensure compliance with the requirements of this standard.
Il existe trois catégories d’essais:
La présente norme ne concerne pas directement les essais de série Chaque composant du système subit les essais de série suivant la norme qui lui est propre.
Type testing is essential for validating the assigned regimes, characteristics, and performance of a new combined system It is necessary to conduct these tests on every newly designed combined system.
If design or manufacturing process changes are made to the components after the combined system has undergone type testing, the impact of these changes on the system's performance must be assessed Subsequently, an agreement may be reached between the operator and the manufacturer to either forgo retesting or to only conduct specific tests.
Subject to an agreement between the operator and the manufacturer, a type test is not required if the manufacturer provides a comprehensive type test report conducted on a combined system with similar design and power specifications.
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The characteristics should be established for the maximum torque reference across the entire speed range of the application, including both motoring and braking modes if electric braking is utilized Additionally, characteristics may be defined for 1/4, 1/2, and 3/4 of the maximum torque reference at any speed, subject to agreement between the user and the manufacturer.
Only the external characteristics and maximum internal switching transients are required If efficiency measurement is requested, it must account for excitation losses While other internal characteristics and values should be measured, their results will not affect the acceptance of the combined system.
Figures 2 to 5 show examples of the most common mandatory curves.
Exchange of information and responsibility
IEC 60349-1 and IEC 61287-1 emphasize the importance of communication between motor and chopper suppliers to ensure compliance with the relevant standards This exchange of information is crucial, and the documentation resulting from it is essential for the specifications of both the motor and the chopper.
Subclause 3.3 identifies the manufacturer as the entity responsible for the technical aspects of the combined system's supply Consequently, the manufacturer must ensure that the technical specifications of the system's components align with the requirements set forth by this standard.
General
There are three categories of tests:
This standard is not directly concerned with routine tests Each component of the system is routine tested according to its relevant standard.
Type tests
Type tests are intended to prove the ratings, characteristics and performances of a new combined system They shall be carried out on one combined system of every new design.
Any design or manufacturing process modifications made after the type testing of a combined system must be assessed for their impact on the system's performance Subsequently, the user and manufacturer may agree to forgo retesting or to conduct only specific tests.
A type test may be waived if the manufacturer provides a comprehensive type-test report for a combined system that shares a similar design and power, contingent upon an agreement between the user and the manufacturer.
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The purpose of the investigation tests is to gather additional information about the chopper when it powers the motor, the motor when it is powered by the chopper, or the regulation of the combined system These tests should only be conducted if prior agreement has been reached between the operator and the manufacturer The results of these tests should not affect the acceptance of the system unless there is an agreement between the operator and the manufacturer.
The combined test allows for the operation of the components within the combined system under real service parameters During this process, the motor torque, the direct current of the intermediate circuit, and, if applicable, the output current and voltage of the chopper are generated in service conditions.
The manufacturer must provide the operator with a testing specification before the commencement of trials, outlining the key aspects of the tests to be conducted in accordance with the current standards to meet contract requirements Following the completion of these tests, the manufacturer is required to deliver a comprehensive test report to the operator.
The combined system must be tested with its cooling system installed as it would be in service, including the pipes and filters considered part of the vehicle, or under conditions that provide equivalent scenarios Measurements of relevant parameters such as flow rate, pressure, and temperatures can be taken to demonstrate that the cooling conditions are equivalent to those achieved on the vehicle.
Le refroidissement qui correspond au déplacement du véhicule peut être simulé pour les parties de l’équipement pour lesquelles le refroidissement naturel a de l’importance.
Toutes les simulations de refroidissement doivent faire l’objet d’un accord.
Les détails relatifs au refroidissement de chaque composant sont donnés dans les normes qui les régissent.
Il est recommandé que les câbles de puissance soient disposés pour donner, du point de vue thermique et électromagnétique, des conditions pratiquement équivalentes à celles spécifiées.
It is advisable to use power cables that are specifically designed for the vehicle, although equivalent power cables may also be utilized Any information regarding these cables and their arrangement should be provided by the manufacturer upon request.
It is not essential to replicate the exact cable layout of the vehicle, as long as the most unfavorable local conditions are simulated on the test bench For instance, if it is reasonable to expect that the highest heating occurs in a 2-meter section of the cable path, it is advisable to simulate this section on the test bench, while other parts of the cable routing can be excluded from thermal considerations.
Power supply can be drawn from the vehicle's DC power source or another available source at the test bench It is essential to consider the inductances, capacitances, and resistances of the system whenever applicable.
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Investigation tests
The purpose of investigation tests is to gather further insights about the chopper's performance while supplying the motor, the motor's behavior when powered by the chopper, or the control of the integrated system These tests will only proceed with prior agreement between the user and the manufacturer Additionally, the outcomes of these tests will not affect the system's acceptance unless mutually agreed upon by both parties.
General
Combined testing allows for the evaluation of system components under real operational parameters, including motor torque, d.c link voltage, and the output current and voltage of the chopper, reflecting actual service conditions.
Before testing begins, the manufacturer must provide the user with a test specification detailing the tests to be conducted according to the standard to fulfill contract requirements After testing is completed, the manufacturer is required to deliver a comprehensive test report to the user.
Test conditions
Cooling during the tests
The combined system shall be tested with its cooling arranged as in service, including ducting and filters regarded as part of the vehicle, or with arrangements giving equivalent conditions.
Measurements of relevant parameters (flow, pressure, temperatures, etc.) may be performed in order to show that the cooling conditions are equivalent to those encountered on the vehicle.
Cooling corresponding to that produced by the motion of the vehicle may be simulated for parts of the equipment for which natural cooling is of importance.
All simulations of cooling shall be subject to agreement.
Details about the cooling of each component are given in the relevant standards.
Power cables
For optimal thermal and electromagnetic performance, power cables should be arranged to ensure nearly equivalent conditions It is advisable to use the specific power cables intended for the vehicle, although equivalent alternatives may also be acceptable Manufacturers can provide detailed information regarding these cables and their arrangement upon request.
It is not essential to replicate the exact cable arrangement found in the vehicle during testing Instead, the focus should be on simulating the local worst-case conditions on the test bed For instance, if the maximum temperature increase is anticipated in a specific 2 m section of the cable layout, that section should be included in the test, while other parts may be excluded for thermal considerations.
Power supply
The power supply for the test bed can be sourced from the vehicle's direct current (D.C.) supply or another available source It is essential to consider system inductance, capacitance, and resistance when applicable.
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6.2.4 Mesure de la puissance mécanique de sortie
The output mechanical power must be measured directly using a torque meter or indirectly through a calibrated machine on the shafts of the motors The accuracy of the measurements should align with the specifications outlined in the relevant articles of this standard.
Alternatively, with an agreement between the operator and the manufacturer, mechanical power can be obtained by summing the losses or through a recovery method if two combined systems are available; these methods are currently being validated An example of a test bench layout for a recovery testing method is illustrated in Figure 7.
NOTE La méthode par la somme des pertes inclut l’évaluation des pertes
− du moteur, à partir des mesures sur l’entrée en courant continu du moteur (méthode d’essai spécifiée dans la CEI 60349-1);
− du hacheur, généralement déduites à partir des mesures sur l’entrée en courant continu;
− des câbles, et, le cas échéant, des résistances et inductances nécessaires pour faire fonctionner le système combiné.
Les essais doivent être réalisés aux régimes du système pour lesquels il existe un accord.
In a continuous assigned test, the time required to reach a stable temperature can be shortened by starting the test at a higher load or with reduced ventilation for certain system components, provided that the assigned conditions are maintained for at least 2 hours or until it is appropriately demonstrated that stabilized temperatures have been achieved.
In the case of testing under a periodic service regime, the time required to reach a stable temperature can be reduced by starting the test at a calculated equivalent regime and continuing with repetitive cycles.
Le paragraphe 4.4 établit la responsabilité technique du constructeur du système combiné.
Consequently, it is not necessary for the supplier to conduct a heating test on a component according to the governing standard The component can be deemed to have passed the heating test as long as the temperature increases during the combined test do not exceed the specified values in the component standards If no values are specified in the component standard, the values can be subject to agreement This remains valid even if the electrical parameters do not exactly match those agreed upon between the supplier and the manufacturer.
La mesure de la température des parties du système combiné est décrite dans les normes appropriées.
L’essai de commutation sur les moteurs en courant continu doit être réalisé conformément à la CEI 60349-1.
The test outlined in sections 8.3.2 and 8.3.3, point 1 (Com 1) of IEC 60349-1 must be conducted under both traction and braking conditions, at maximum speed and maximum current, using a supply voltage that creates the most unfavorable ripple conditions.
L’essai défini dans les mêmes articles, point 3 (Com 3), doit être réalisé à la plus mauvaise condition d’ondulation.
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Mechanical output measurement
The mechanical output will be measured either directly using a torquemeter or indirectly through a calibrated machine at the motor shaft(s) The measurement accuracy must adhere to the specifications outlined in the relevant clauses of this standard.
The mechanical output can be determined through the summation of losses or the back-to-back method, provided there is mutual agreement between the user and the manufacturer This approach is applicable when two combined systems are available, as illustrated in Figure 7, which depicts a test-bed arrangement for the back-to-back testing method.
NOTE The summation of losses method includes the evaluation of the losses of
− the motor, derived from measurements on the d.c input of the motor (test method as specified in IEC 60349-1);
− the chopper, generally derived from the d.c input measurements;
− the cables, and, if any, the resistors, and inductances necessary to run the combined system.
Temperature-rise tests
General
The tests shall be carried out at the agreed ratings of the system.
To expedite the time required to achieve a steady temperature during a continuous rating test, the test can begin with an increased load or reduced ventilation in certain system elements However, it is essential to maintain the rated conditions for a minimum of 2 hours or until it is confirmed through appropriate methods that steady temperatures have been attained.
To optimize the periodic duty rating test, initiating the test at a calculated equivalent rating can significantly reduce the time required to achieve a steady temperature, allowing for efficient execution of repeated cycles.
Subclause 4.4 states the technical responsibility of the manufacturer of the combined system.
The supplier is not required to perform the temperature-rise test for a constituent according to its standard, as long as the temperature increases during combined testing do not surpass the limits set in the constituent standards If no specific values are outlined in the constituent standard, alternative values can be mutually agreed upon This agreement holds true even if the electrical parameters differ from those initially established between the supplier and the manufacturer.
Measurement of temperatures
The measurement of the temperature of the parts of the combined system is described in the relevant standards.
Commutation test
The commutation test on d.c motors shall be carried out in accordance with IEC 60349-1.
The tests outlined in sections 8.3.2 and 8.3.3, point 1 (Com 1) of IEC 60349-1 must be conducted in both motoring and braking modes These tests should be performed at maximum speed and maximum current, using a supply voltage that creates the most severe ripple conditions.
The test defined in the same clauses, point 3 (Com 3), shall be carried out at the worst ripple condition.
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6.5 Relevé des caractéristiques et des tolérances
Testing is essential to demonstrate that the system meets the specified torque characteristics by operating the motors at a given speed The torque reference (displayed value from the controller) must be provided to the regulation element to assess the combined system's characteristics Subsequently, it is necessary to measure the average output torque of the motor, as well as the average voltage, current, and power.
(moyenne), du côté continu du hacheur.
NOTE Le paragraphe 4.4 indique que "les caractéristiques de couple doivent être tracées pour la référence maximale de couple".
Les valeurs limites d’erreur de l’appareil de mesure ne doivent pas être supérieures à
– ±2 % du maximum du couple mécanique de référence à la vitesse considérée;
– ±1 % pour les valeurs moyennes de la tension, du courant et de la puissance en courant continu.
Similarly, for the warm-up test, the motor(s) can be deemed to have met the torque characteristics requirements of IEC 60349-1, provided that the torque characteristics measured during the combined system test comply with the specifications of this standard This remains applicable even if the electrical parameters do not precisely match those agreed upon between the supplier and the manufacturer.
Tolerances: The base torque at any specified speed must not be less than 95% of the specified value, between the values corresponding to the maximum torque and 90% of the maximum speed.
6.5.1.2 Essai de balayage de la vitesse à couple maximal
The torque characteristic should be assessed by varying the speed range both upward and downward, with the torque reference set at its maximum value during both acceleration and braking when applicable No system interruptions should be observed, and the rate of speed variation must be suitable for each specific application.
6.5.1.3 Caractéristiques de rendement du système combiné (caractéristiques de perte)
If loss measurements are required, they should be conducted at the end of the heating test outlined in section 6.3 These measurements must be subtracted from the direct current input power and the mechanical output power Typically, a small number of data points is sufficient.
The measurement error limits for the input power device in direct current should not exceed ±1% The torque measurement device must have an accuracy of ±0.5% of the maximum reference torque at the specified speed, while the speed measurement device should maintain an accuracy of ±0.1% These tolerances may vary if an agreement is reached between the operator and the manufacturer The error limits used, along with the resulting tolerance on efficiency, should be represented on the efficiency characteristic.
Les méthodes de récupération ou d’addition mentionnées en 6.2.4 peuvent être utilisées si un accord a été conclu entre l’exploitant et le constructeur.
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Characteristic tests and tolerances
Torque characteristics
Compliance with specified torque characteristics will be verified by operating the motor(s) at a designated speed The control unit will receive the torque reference from the main controller to assess the characteristics of the combined system Measurements will include the mean motor output torque, voltage, current, and power on the d.c side of the chopper.
NOTE Subclause 4.4 states that "the torque characteristics shall be drawn for the maximum torque reference".
The limits of error of the measurements instrument shall not be greater than
– ±2 % of the maximum mechanical torque reference at the speed considered;
– ±1 % for the mean values of the d.c voltage current and power.
In the temperature-rise test, motors can be considered to have successfully passed the torque characteristics tests of IEC 60349-1 if the torque characteristics observed during the combined system test align with the standard's requirements This holds true even if the electrical parameters differ slightly from those previously agreed upon by the supplier and manufacturer.
Tolerances dictate that the declared torque at any speed must fall within the specified characteristic, ensuring it is no less than 95% of the specified value between the maximum torque and 90% of the maximum speed.
6.5.1.2 Sweeping speed test at full torque
The torque characteristics must be thoroughly tested across the entire speed range, with the maximum torque reference applied during both motoring and braking conditions It is essential that there are no instances of tripping or system shutdowns Additionally, the speed change rate should be suitable for each specific application.
6.5.1.3 Efficiency characteristics of the combined system (loss characteristics)
Loss measurements must be conducted after the temperature-rise test as outlined in section 6.3 These measurements should be based on the d.c power input and mechanical output, with a limited number of data points typically being sufficient.
The measurement instruments for d.c power input must have error limits not exceeding ±1%, while torque measurement instruments should maintain an accuracy of ±0.5% of the maximum torque reference at the specified speed Additionally, speed measurement instruments are required to be accurate within ±0.1% These tolerances can be adjusted through mutual agreement between the user and the manufacturer It is essential to display the error limits and the corresponding efficiency tolerance on the efficiency characteristic.
The summation of losses and back-to-back methods mentioned in 6.2.4 may be used if agreed between the user and the manufacturer.
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6.6 Essais des systèmes de protection
6.6.1 Alimentation de l’équipement de régulation du système combiné
The combined system must operate seamlessly with any variation of the power supply within the specified range, without system interruption or fault indication The loss of one or more power supplies should lead to the shutdown of the chopper without any failure or malfunction of the combined system Additionally, the system must be capable of controlled restart when the regulating power supplies are restored.
It is essential to verify the operation of the regulation system by varying the DC voltage source from the minimum to the maximum specified operating range This ensures that the combined system functions correctly and that its output is regulated and inhibited according to the accepted curve.
6.6.3 Interruption de courte durée de l’alimentation en courant continu
Cet essai peut être réalisé en faisant fonctionner deux contacteurs l’un après l’autre de manière à générer une interruption de courte durée de l’alimentation avec une durée spécifiée.
La figure 8 donne un exemple de circuit d’essai possible.
6.6.4 Variation soudaine de la tension d’alimentation (essai de type facultatif)
Cet essai peut être réalisé en utilisant un contacteur en parallèle d’une résistance connectée comme à la figure 9, qui donne un exemple de configuration possible de circuit.
L’essai est effectué à la fois en traction et en freinage.
6.6.5 Harmoniques du courant d’entrée du hacheur (essai de type facultatif)
The chopper can disrupt railway signaling systems, power supply systems, or other fixed or onboard equipment due to the generation of harmonic currents on the direct current power line Therefore, it is crucial to measure the alternating currents present at the direct current input of the chopper under various voltage and current conditions of the motors.
L’exploitant doit spécifier le contenu harmonique maximal, en fonction de la fréquence et du courant continu d’entrée du système combiné.
Measurement results can be utilized to enhance the calculation of the total harmonic disturbance level of the vehicle, considering factors such as the total number of choppers and the design of the line filter.
NOTE 1 Pour les mesures, il est recommandé d’utiliser un capteur de courant de haute précision, ainsi qu’un analyseur de fréquences.
NOTE 2 Il convient de prendre en compte les harmoniques générées par l’alimentation en courant continu pour la mesure du contenu harmonique total.
6.6.6 Essai de perturbation (essai de type facultatif)
Cet essai doit être effectué conformément à 2.4.6.23 de la CEI 61287-1.
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