Indian Patents. 259985:DEVELOPMENT OF A COMMON, 315 KW, LIGHT WEIGHT DC TRACTION MOTOR FOR BOTH BROAD GAUGE & STANDARD GAUGE DIESEL ELECTRIC LOCOMOTIVE APPLICATION WITH HIGHER POWER TO WEIGHT RATIO

Title of Invention	DEVELOPMENT OF A COMMON, 315 KW, LIGHT WEIGHT DC TRACTION MOTOR FOR BOTH BROAD GAUGE & STANDARD GAUGE DIESEL ELECTRIC LOCOMOTIVE APPLICATION WITH HIGHER POWER TO WEIGHT RATIO
Abstract	A DC Series wound, four pole, forced Ventilated traction motor for axle mounting on taper roller Suspension bearing, characterized by, Maximum Voltage : 1100 Volt DC Maximum Current : 1350 Amps DC Class of Insulation : Class "H" Gear ratio : 4.94 Weight : 2950+50 kg Ventilation : 2300 CFM

Full Text	2 FIELD OF INVENTION The present invention relates to development of a common 315 kw, light weight dc traction motor for both broad gauge & standard gauge diesel electric locomotive application with higher power to weight ratio. BACKGROUND OF INVENTION BHEL has undertaken this challenging development job to cater to long pending requirement of the customer M/s Indian Railway for an ultra lightweight DC traction motor common, for both Broad gauge & Standard gauge diesel electric locomotives. This development will also add another industry competitive product for the export market of BHEL as well as for Indian Railways. These motors shall be used in locomotives, which shall be based on the proven & advanced DC - DC drives Technology. In these locomotives, the hauling is done with 6 DC series motors. In the present invention power to weight ratio of contemporary machines have significantly been improved form a range of (0.085- 0.097) to 0.107. Also the magnet frame has been modified to accommodate the bearing housing of suspension tube within the outer geometry of frame. The fabrication of air inlet and inspection openings of magnet frame have been done from inner periphery of magnet frame tube to suit standard gauge constraint as well as to reduce weight. 3 In the invention the ratio of core diameter to commutator diameter has also been improved to 1.382 from 1.148 in the prior art to reduce the overall weight of the motor. The brush holder has been designed with less wall thickness to optimize the brush holder component with respect to requirement of less weight and increased heat dissipation on account of increased power of the machine. Since in the prior art there was no common traction motor for both standard and Broad gauge applications an effort has been made to develop a common traction motor suitable for fitment in the standard gauge as well as Broad gauge applications. OBJECTS OF THE INVENTION - The object of the invention is to develop a light weight 315 Kw DC series traction motor for diesel electric locomotives. - Another object of the invention is to provide a common DC traction motor for both Broad gauge and standard gauge diesel electric locomotives. - Further object of the invention is to provide an improved DC traction motor having comparatively higher power to weight ratio. 4 - Also the object of the invention is to provide lighter axle load of the locomotives. - Yet other object of the invention is to accommodate the bearing housing of suspension tube within the outer geometry of the magnetic frame to suit standard gauge constraint as well as to reduce weight. - Still another object of the invention is to improve the ratio of core dia to commutator dia to reduce the overall weight of the motor. - Again the object of the invention is to design the wall thickness of the brush holder to optimize brush holder component with respect to requirement of less weight and increased heat dissipation on account of increased power of the machine. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Traction motor type TM4701AZ is especially designed for broad gauge diesels electric locomotive for goods mixed traffic version and standard gauge passenger traffic. It is a DC series wound, four pole, and forced ventilated traction motor suitable for axle mounting on taper roller suspension bearings. It is supported on the nose by a resilient suspension unit. It complies with IEC-60349:2001 / IEE-11:1882. Rating Maximum voltage : 1100 Volt DC Maximum current : 1350 AMPS DC Class of Insulation : Class 'H' Gear ratio : 4.94 Weight of traction motor : 2950+50 Kg. With pinion gear wheel, gear case and taper roller bearing arrangement. Ventilation : 2300 CFM The embodiment of the outstanding features of the motor are out lined as under. A. It is a 315 Kw DC Traction motor weighing 2950+50Kg approx. B. This motor is designed to fit in diesel electric locomoitives of both broad gauge as well as standard gauge applciations. C. This traction motor ca be used in goods, mixed and passenger traffic applications. D. This motor has been designed to suit the ventialation provided by the existing traction motor blower used by M/s DLW Varanasi. E. Higher power to weight ratio with respect to the existing machines for the similar application. F. Center distance between and centerline and armature centerline retained to use the existing bogie of IR. 6 G. Weight reduction (Light weight) is one of the major goals in this development. Lighter vehicles perform better and cost less to operate because they are more energy efficient and also can attain very high speeds. On the other hand they can accelerate at a much higher rate. This opens the opportunity for Diesel Engines Drives to compete with Electric engine drives for suburban commuter traffic route. CONSTURCTIONAL FEATURES OF TM4701 AZ AS INCORPORATED IN THE PRESENT EMBODIMENT ARE DESCRIBED AS UNDER I. Magnet Frame The high permeability steel magnet frame (FIG 3 - ITEM 1 ) is machined to ensure alignment of the end shields, pole bores (FIG 1 - ITEM 2 ) and axle ways (FIG 1 - ITEM 3 ). The nose of the motor is resiliently supported in the bogie. The end shields are spigotted into frame with slight interference fit and held in position by means of bolts (FIG 1 - ITEM 4) suitably locked. This method of mounting ensures that the fit between the end shield and the frame remains tight in service. Roller bearings (FIG 1 - ITEM 5) are provided and labyrinths are formed to prevent the escape of lubricating grease or the entry of dirt or moisture. Greasing vents (FIG 1 - ITEM 6) are provided on topside of both bearing housings (FIG 1 - ITEM 7) with grease nipples. Overall length optimized to meet the requirement of standard gauge fitment. 7 II. Armature The armature core (FIG I - ITEM 8) is built from electrical quality low loss sheet steel laminations insulated from each other assembled on the shaft (FIG 2 - ITEM 9) with interference fit and consolidated under pressure. The laminations are held together between endplates, (FIG 1 - ITEM 10) fitted on the shaft machined form nickel-chromium- molybdenum steel bar hardened and tempered. The armature is lap wound. The armature conductors (FIG 1 - ITEM 11) are insulated with Kapton and mica based Class "H" Insulation system. The coils (FIG 2 - ITEM 12) are held down in the core slots with epoxy glass laminated slot wedges, ( FIG 6 - ITEM 38) and Res-I-glass bands (FIG 2 - ITEM 31) retain in the end portions of the coil. The wound armature is finally vacuum pressure impregnated in solvent less polyesterimide varnish . Armature end plate is redesigned with straight ribs (FIG 1 - ITEM 10) instead of Y shaped ribs for better strength. Epoxy glass slot wages are provided for extra strength. Special commuter hub (FIG 5B - ITEM 13) designed for increased ventilation. III. Commutator The commutator (FIG 5B - ITEM 14) is of arch bound construction. The copper segments (FIG 5B - ITEM 15) are made from hard drawn silver bearing copper and risers (FIG 5B - ITEM 16) integral with segments are slotted to receive the armature coil leads (FIG 5B -ITEM 24). The armature coil leads are finally TIG welded to commutator risers. The copper segments which are insulated from each other with the micanite segments, (FIG 6 -ITEM 39 )are held together with the Steel "V" rings,( FIG 5B - ITEM 17) insulated with the moulded micanite V-rings.( FIG 5B - ITEM 32) The exposed surface of the commutator front micanite V- ring (FIG 5B - ITEM 32 ) is covered with PTFE bush (FIG 5B - ITEM 33) to obtain high creepage and for ease in maintenance. Arcing horns ( FIG 2- ITEM 37 are provided to minimize the damage to the commutator and brush gear in the event of flashover. IV Poles and Field Coils The poles (FIG 2 - ITEM 25) are built up from steel laminations riveted together. The main field coils (FIG 2 - ITEM 26) are made of copper strap wound on flat, whereas the compole coil (FIG 2 - ITEM 27) are edge wound. The coils are insulted with Class "H" insulating materials and vacuum pressure impregnated in solventless polyesterimide varnish. V Brush Gear There are four brush arms, (FIG 1 - ITEM 28) each carrying a brush holder (FIG 4A - ITEM 29 ) with two carbon brushes, (FIG 4B- ITEM 30) Twin-stud insulators (FIG 1 - ITEM 35) secure brush holders. PTFE bushes (FIG 5A - ITEM 34) are mounted on the stud insulators in between each portion and the brush holder provides a creepage (FIG 5A - ITEM 36) surface for ease in cleaning. 9 VI Gears and Gearcase Gear case (FIG 3 - ITEM 18) has top mounted bolting (FIG 3 - ITEM 22) arrangement to reduce vibration VII Axle Suspension Bearings Locomotive axle (FIG 2 - ITEM 19) is supported on an axle suspension- bearing unit(FIG 2 - ITEM 21) consisting of taper roller bearings (FIG 2 - ITEM 20) at the ends housed in a tube, which is bolted (FIG 3 - ITEM 23 ) to the traction motor magnet frame, ( FIG 3 - ITEM 1) which require less maintenance during service. VIII Armature Bearings The bearing assemblies (FIG 1 - ITEM 5) are of sealed type provided with adequate labyrinths to avoid the contamination of the lubricating grease with dirt, moisture and cardium compound. WE Claim 1 A DC Series wound, four pole, forced Ventilated traction motor for axle mounting on taper roller Suspension bearing, characterized by, 10 Maximum Voltage : 1100 Volt DC Maximum Current : 1350 Amps DC Class of Insulation : Class "H" Gear ratio : 4.94 Weight : 2950+50 kg Ventilation : 2300 CFM 2 The motor as claimed under claim 1 is characterized by its applicability both for broad gauge as well as Standard gauge track with over all length reduced to 1284 mm. 3 The motor as claimed under claim 1 and 2 is characterized by power to weight ratio of 0.107. 4 The motor as claimed under claim 1, 2.and 3 is characterized by the magnet frame to accommodate the bearing housing of Suspension tube within the outer geometry of frame with fabrication of air inlet and inspection openings of the said magnet frame done from inner periphery of the magnet frame tube to suit standard gauge constraint and reduce the weight. 5 The motor as claimed under claim 1,2,3 and 4 is characterized by the core diameter to commutator diameter ratio of 1.382 resulting reduction in weight. 11 6 The motor as claimed under claim 1,2,3,4,and 5 is characterized by the brush holder with lesser wall thickness to optimize the brush holder component for lesser weight and increased heat dissipation on account of increased power of the machine. A DC Series wound, four pole, forced Ventilated traction motor for axle mounting on taper roller Suspension bearing, characterized by, Maximum Voltage : 1100 Volt DC Maximum Current : 1350 Amps DC Class of Insulation : Class "H" Gear ratio : 4.94 Weight : 2950+50 kg Ventilation : 2300 CFM

Full Text

2
FIELD OF INVENTION
The present invention relates to development of a common 315 kw, light
weight dc traction motor for both broad gauge & standard gauge diesel
electric locomotive application with higher power to weight ratio.
BACKGROUND OF INVENTION
BHEL has undertaken this challenging development job to cater to long
pending requirement of the customer M/s Indian Railway for an ultra
lightweight DC traction motor common, for both Broad gauge &
Standard gauge diesel electric locomotives. This development will also
add another industry competitive product for the export market of BHEL
as well as for Indian Railways. These motors shall be used in
locomotives, which shall be based on the proven & advanced DC - DC
drives Technology. In these locomotives, the hauling is done with 6 DC
series motors.
In the present invention power to weight ratio of contemporary
machines have significantly been improved form a range of (0.085-
0.097) to 0.107.
Also the magnet frame has been modified to accommodate the bearing
housing of suspension tube within the outer geometry of frame. The
fabrication of air inlet and inspection openings of magnet frame have
been done from inner periphery of magnet frame tube to suit standard
gauge constraint as well as to reduce weight.

3
In the invention the ratio of core diameter to commutator diameter has
also been improved to 1.382 from 1.148 in the prior art to reduce the
overall weight of the motor.
The brush holder has been designed with less wall thickness to optimize
the brush holder component with respect to requirement of less weight
and increased heat dissipation on account of increased power of the
machine.
Since in the prior art there was no common traction motor for both
standard and Broad gauge applications an effort has been made to
develop a common traction motor suitable for fitment in the standard
gauge as well as Broad gauge applications.
OBJECTS OF THE INVENTION
- The object of the invention is to develop a light weight 315 Kw DC
series traction motor for diesel electric locomotives.
- Another object of the invention is to provide a common DC traction
motor for both Broad gauge and standard gauge diesel electric
locomotives.
- Further object of the invention is to provide an improved DC traction
motor having comparatively higher power to weight ratio.

4
- Also the object of the invention is to provide lighter axle load of the
locomotives.
- Yet other object of the invention is to accommodate the bearing
housing of suspension tube within the outer geometry of the
magnetic frame to suit standard gauge constraint as well as to reduce
weight.
- Still another object of the invention is to improve the ratio of core dia
to commutator dia to reduce the overall weight of the motor.
- Again the object of the invention is to design the wall thickness of the
brush holder to optimize brush holder component with respect to
requirement of less weight and increased heat dissipation on account
of increased power of the machine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Traction motor type TM4701AZ is especially designed for broad gauge
diesels electric locomotive for goods mixed traffic version and standard
gauge passenger traffic. It is a DC series wound, four pole, and forced
ventilated traction motor suitable for axle mounting on taper roller
suspension bearings. It is supported on the nose by a resilient
suspension unit. It complies with IEC-60349:2001 / IEE-11:1882.

Rating
Maximum voltage : 1100 Volt DC
Maximum current : 1350 AMPS DC
Class of Insulation : Class 'H'
Gear ratio : 4.94
Weight of traction motor : 2950+50 Kg.
With pinion gear wheel, gear case
and taper roller bearing arrangement.
Ventilation : 2300 CFM
The embodiment of the outstanding features of the motor are
out lined as under.
A. It is a 315 Kw DC Traction motor weighing 2950+50Kg approx.
B. This motor is designed to fit in diesel electric locomoitives of both
broad gauge as well as standard gauge applciations.
C. This traction motor ca be used in goods, mixed and passenger traffic
applications.
D. This motor has been designed to suit the ventialation provided by
the existing traction motor blower used by M/s DLW Varanasi.
E. Higher power to weight ratio with respect to the existing machines
for the similar application.
F. Center distance between and centerline and armature centerline
retained to use the existing bogie of IR.

6
G. Weight reduction (Light weight) is one of the major goals in this
development. Lighter vehicles perform better and cost less to
operate because they are more energy efficient and also can attain
very high speeds. On the other hand they can accelerate at a much
higher rate. This opens the opportunity for Diesel Engines Drives to
compete with Electric engine drives for suburban commuter traffic
route.
CONSTURCTIONAL FEATURES OF TM4701 AZ AS
INCORPORATED IN THE PRESENT EMBODIMENT ARE
DESCRIBED AS UNDER
I. Magnet Frame
The high permeability steel magnet frame (FIG 3 - ITEM 1 ) is machined to
ensure alignment of the end shields, pole bores (FIG 1 - ITEM 2 ) and
axle ways (FIG 1 - ITEM 3 ). The nose of the motor is resiliently
supported in the bogie.
The end shields are spigotted into frame with slight interference fit and
held in position by means of bolts (FIG 1 - ITEM 4) suitably locked. This
method of mounting ensures that the fit between the end shield and the
frame remains tight in service. Roller bearings (FIG 1 - ITEM 5) are
provided and labyrinths are formed to prevent the escape of lubricating
grease or the entry of dirt or moisture. Greasing vents (FIG 1 - ITEM 6)
are provided on topside of both bearing housings (FIG 1 - ITEM 7) with
grease nipples. Overall length optimized to meet the requirement of
standard gauge fitment.

7
II. Armature
The armature core (FIG I - ITEM 8) is built from electrical quality low loss
sheet steel laminations insulated from each other assembled on the
shaft (FIG 2 - ITEM 9) with interference fit and consolidated under
pressure. The laminations are held together between endplates, (FIG 1 -
ITEM 10) fitted on the shaft machined form nickel-chromium-
molybdenum steel bar hardened and tempered.
The armature is lap wound. The armature conductors (FIG 1 - ITEM 11)
are insulated with Kapton and mica based Class "H" Insulation system.
The coils (FIG 2 - ITEM 12) are held down in the core slots with epoxy
glass laminated slot wedges, ( FIG 6 - ITEM 38) and Res-I-glass bands (FIG
2 - ITEM 31) retain in the end portions of the coil. The wound armature is
finally vacuum pressure impregnated in solvent less polyesterimide
varnish . Armature end plate is redesigned with straight ribs (FIG 1 -
ITEM 10) instead of Y shaped ribs for better strength. Epoxy glass slot
wages are provided for extra strength. Special commuter hub (FIG 5B -
ITEM 13) designed for increased ventilation.
III. Commutator
The commutator (FIG 5B - ITEM 14) is of arch bound construction. The
copper segments (FIG 5B - ITEM 15) are made from hard drawn silver
bearing copper and risers (FIG 5B - ITEM 16) integral with segments are
slotted to receive the armature coil leads (FIG 5B -ITEM 24). The
armature coil leads are finally TIG welded to commutator risers.

The copper segments which are insulated from each other with the
micanite segments, (FIG 6 -ITEM 39 )are held together with the Steel "V"
rings,( FIG 5B - ITEM 17) insulated with the moulded micanite V-rings.( FIG
5B - ITEM 32) The exposed surface of the commutator front micanite V-
ring (FIG 5B - ITEM 32 ) is covered with PTFE bush (FIG 5B - ITEM 33) to
obtain high creepage and for ease in maintenance. Arcing horns ( FIG 2-
ITEM 37 are provided to minimize the damage to the commutator and
brush gear in the event of flashover.
IV Poles and Field Coils
The poles (FIG 2 - ITEM 25) are built up from steel laminations riveted
together. The main field coils (FIG 2 - ITEM 26) are made of copper strap
wound on flat, whereas the compole coil (FIG 2 - ITEM 27) are edge
wound. The coils are insulted with Class "H" insulating materials and
vacuum pressure impregnated in solventless polyesterimide varnish.
V Brush Gear
There are four brush arms, (FIG 1 - ITEM 28) each carrying a brush holder
(FIG 4A - ITEM 29 ) with two carbon brushes, (FIG 4B- ITEM 30) Twin-stud
insulators (FIG 1 - ITEM 35) secure brush holders. PTFE bushes (FIG 5A -
ITEM 34) are mounted on the stud insulators in between each portion
and the brush holder provides a creepage (FIG 5A - ITEM 36) surface for
ease in cleaning.

9
VI Gears and Gearcase
Gear case (FIG 3 - ITEM 18) has top mounted bolting (FIG 3 - ITEM 22)
arrangement to reduce vibration
VII Axle Suspension Bearings
Locomotive axle (FIG 2 - ITEM 19) is supported on an axle suspension-
bearing unit(FIG 2 - ITEM 21) consisting of taper roller bearings (FIG 2 -
ITEM 20) at the ends housed in a tube, which is bolted (FIG 3 - ITEM 23
) to the traction motor magnet frame, ( FIG 3 - ITEM 1) which require less
maintenance during service.
VIII Armature Bearings
The bearing assemblies (FIG 1 - ITEM 5) are of sealed type provided with
adequate labyrinths to avoid the contamination of the lubricating grease
with dirt, moisture and cardium compound.
WE Claim
1 A DC Series wound, four pole, forced Ventilated traction motor
for axle mounting on taper roller Suspension bearing,
characterized by,

10
Maximum Voltage : 1100 Volt DC
Maximum Current : 1350 Amps DC
Class of Insulation : Class "H"
Gear ratio : 4.94
Weight : 2950+50 kg
Ventilation : 2300 CFM
2 The motor as claimed under claim 1 is characterized by its
applicability both for broad gauge as well as Standard gauge
track with over all length reduced to 1284 mm.
3 The motor as claimed under claim 1 and 2 is characterized by
power to weight ratio of 0.107.
4 The motor as claimed under claim 1, 2.and 3 is characterized by
the magnet frame to accommodate the bearing housing of
Suspension tube within the outer geometry of frame with
fabrication of air inlet and inspection openings of the said
magnet frame done from inner periphery of the magnet frame
tube to suit standard gauge constraint and reduce the weight.
5 The motor as claimed under claim 1,2,3 and 4 is characterized
by the core diameter to commutator diameter ratio of 1.382
resulting reduction in weight.

11
6 The motor as claimed under claim 1,2,3,4,and 5 is characterized
by the brush holder with lesser wall thickness to optimize the
brush holder component for lesser weight and increased heat
dissipation on account of increased power of the machine.

A DC Series wound, four pole, forced Ventilated traction motor
for axle mounting on taper roller Suspension bearing,
characterized by,
Maximum Voltage : 1100 Volt DC
Maximum Current : 1350 Amps DC
Class of Insulation : Class "H"
Gear ratio : 4.94
Weight : 2950+50 kg
Ventilation : 2300 CFM

Documents:

01506-kol-2007-abstract.pdf

01506-kol-2007-claims.pdf

01506-kol-2007-correspondence others.pdf

01506-kol-2007-description complete.pdf

01506-kol-2007-drawings.pdf

01506-kol-2007-form 1.pdf

01506-kol-2007-form 2.pdf

01506-kol-2007-form 3.pdf

01506-kol-2007-gpa.pdf

1506-KOL-2007-(13-12-2013)-CORRESPONDENCE.pdf

1506-KOL-2007-(19-12-2013)-CORRESPONDENCE.pdf

1506-KOL-2007-(20-12-2013)-PETITION UNDER RULE 137.pdf

1506-KOL-2007-(24-07-2013)-ABSTRACT.pdf

1506-KOL-2007-(24-07-2013)-CLAIMS.pdf

1506-KOL-2007-(24-07-2013)-CORRESPONDENCE.pdf

1506-KOL-2007-(24-07-2013)-DESCRIPTION (COMPLETE).pdf

1506-KOL-2007-(24-07-2013)-DRAWINGS.pdf

1506-KOL-2007-(24-07-2013)-FORM-1.pdf

1506-KOL-2007-(24-07-2013)-FORM-2.pdf

1506-KOL-2007-(24-07-2013)-FORM-3.pdf

1506-KOL-2007-(24-07-2013)-OTHERS.pdf

1506-KOL-2007-(24-07-2013)-PA.pdf

1506-KOL-2007-CORRESPONDENCE 1.1.pdf

1506-KOL-2007-CORRESPONDENCE OTHERS 1.1.pdf

1506-KOL-2007-FORM 18.pdf

abstract-01506-kol-2007.jpg

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Patent Number

259985

Indian Patent Application Number

1506/KOL/2007

PG Journal Number

14/2014

Publication Date

04-Apr-2014

Grant Date

30-Mar-2014

Date of Filing

02-Nov-2007

Name of Patentee

BHARAT HEAVY ELECTRICALS LIMITED

Applicant Address

REGIONAL OPERATIONS DIVISION (ROD), PLOT NO : 9/1, DJBLOCK 3RD FLOOR, KARUNAMOYEE, SALT LAKE CITY, KOLKATA-700091 HAVING ITS REGISTERED OFFICE AT BHEL HOUSE, SIRI FORT, NEW DELHI-110049, INDIA.

Inventors:

#	Inventor's Name	Inventor's Address
1	SHRI SHARMA SURYA KANT	GM/TPTN-ENGG. BHEL, BHOPAL
2	SHRI BHAKTA MANVENDRA	DGM/TME, BHEL, BHOPAL
3	SHRI MEHROTRA SHARAD	MANAGER/TME, BHEL, BHOPAL
4	SHRI DANI AKASH	MANAGER/TME, BHEL, BHOPAL
5	SHRI DAS APURBA KUMAR	SR. DGM/TME, BHEL, BHOPAL

PCT International Classification Number

H02K 5/04 ; H02K 11/00

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA