ge ohv drive systems technology update 06082006 wmea

Thursday, June 8, 2006

Allen RandolphOHV Engineering Manager

GE OHV Drive Systems Technology Update

WMEA Conference

GE OHV Drive Systems Technology UpdateJune 8, 20062

A company with a history of innovation

1879 First carbon-filament incandescent lamp

1913 First commercially practical X-ray device

1942 Aircraft jet engine

1963 First electric drive for haul trucks

1983 Magnetic resonance imaging

1995 Worlds most powerful jet engine

2002 The most environmentally friendlylocomotive ever designed


A company with a history of innovationin Mining

1960s First DC electric drive system for mininghaul trucks

1970s StatexTM DC control technology

1980s Trolley technology 400+ systems delivered

1990s First InvertexTM AC electric drive systemfor mining haul trucks

2000s Air cooled IGBT power electronicsHybrid Technology

9,000+ systems delivered world-wide

5,000+ systems in operation in 37 countries

The ability to lead innovation will be the primary management focus for this decade.

Jeff Immelt


GE continues to invest in technology

Develop

GE320ACTM

GE150ACTM

Develop

GE240ACTM

Develop

GE360ACTM

Develop

Global Haul Truck Deliveries

GE200ACTM

The more demanding the environment outside, the more you need a capable drive system inside


Dynamic Retarding Group- Dynamic Retarding Grids- Grid Blowers

Alternator- Traction Alternator Technology Motorized AC Wheels

- AC Induction Motors

AC Control Group- Microprocessor Cards / Algorithms- Air Cooled IGBT Power Electronics

Leveraging heavy haul locomotive technology to meet mining requirements

Advantages:9Performance9Reliability9Robust Components9Cost9Speed to Market


GTA39 WM FAN CURVES @ 1900 RPM AND CG FLOW (3V / 5H HOLES OPEN)TESTED 5/7/01 - 40 in diameter impeller - 0.075 lb/ft^3

Sp = -4E-08cfm2 - 0.0011cfm + 25.566

HP = 5E-08cfm2 + 0.0024cfm + 72.557

0

5

10

15

20

25

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000

Flow (cfm)

S

p

(

i

n

W

g

)

0

50

100

150

200

2501000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000

P

o

w

e

r

(

s

h

p

)

SpCG FlowAlt. FlowKsys=.215Ksys=.1692ksys=.3137Power

Integrated Drive System Development ProcessRequirements Definition /

System DesignComponent Design

Development

Advanced SimulationsSystem and Component Validation

GTA41 Airflow Scheme

Air In Air to Control Group

Air to Wheel Motors

Air to Alternator

Plenum Chamber Validation (Performance)

FEA Structural Analysis (Reliability)

System Airflow = Sum of Component Airflows

Device Existing airflow (cfm) Required Airflow @ 1700 rpm (cfm)

Wheel Motor (2) #### ##### Control Group #### #####

Alternator ##### #####


Insulated Gate Bipolar Transistor (IGBT)

Locomotive based design ~20,000 IGBT

Inverters in service

Smaller and lighter component

designed for maintainability

Reduced complexity

Fewer control components

Simpler control and diagnostics

Robust air-cooled design

Five fold inverter reliability improvement

1,000,000 hours of OHV field experience

Single Inverter Stack up to 2000 HP

Dual Inverter Stack up to 4000 HP

Delivering the latest innovations


GTO and IGBT Inverter Comparison

Gate-Turn-Off Thyristor (GTO) Can be switched between:

High impedance low current Off state Low impedance high current On state

Gate switching at any circuit current: Turned on with forward gate voltage Turned off with reverse gate voltage

Insulated Gate Bipolar Transistor (IGBT) Can be switched between:

High impedance low current Off state Low impedance high current On state

Snubberless Power Circuit fewer components IGBTs in parallel for higher current capacity


GTO Control System

GATEDRIVER

PHASE MODULE

DC-

DC+

GATE DRIVEPOWERCONTROLLER

FL320PANEL

CMA

CMBDIT

GATE DRIVEPOWERSUPPLY


IGBT Control System

GATEDRIVER

PHASE MODULE

DC-

DC+

GATE DRIVEPOWERCONVERTER

FL375PANEL

CMA

CMB


Industry Leader in Heavy Haul Traction Drives

Easy to Use Diagnostics 2 line full text DID panel >300 fault codes PTU (laptop) interface

IGBT Technology State of Art IGBT Snubberless

Power Circuit Simple and Robust Air Cooled

Design no leakage or environmental concerns

Proven GE AC4400/EVOTMLocomotive Experience

Systems Capable of 4,100 HP Motoring / 6,000 HP Retarding

Higher Efficiency and Reliability...Low Life Cycle Cost

AdvancedTraction Control Independent Wheel

Control Wet Weather RetardTM Advanced spin/slide

control State of Art Digital

Alternator Control Hill start hold

Optimized ControlCabinet Isolated High and Low

Voltage Compartments Maximized use of solid

state electronics



wPTUTMWindows based, portable software solution for communicating with OHV drive systems;Aids in system diagnostics;Provides real-time graphic capability of system events and parameters.

Pocket PTUAll of the common capabilities of the wPTU Toolbox, in a convenient size;Supports Statex III and Invertex Drive Systems


GE320AC GDY106 Wheel Motor AC Traction Motor 5GEB16

Over 23,000,000 hours of OHV

proven service

No running maintenance

Transmission GDY106

Robust Heavy-Duty Design

1,400,000+ hours of OHV

proven service

Delivering 24,000 hr MTBO

Minimal running maintenance



GE240AC GEB25 Wheel Motor AC Traction Motor 5GEB13

Proven Locomotive AC Motor+26,000 in

service on AC4400/EVO

No running maintenance

Transmission GEB25

Robust Heavy-Duty Design based on

proven GE787 design

Designed for 24,000 hr MTBO

Minimal running maintenance




Whisper GridsTMRetarding Assemblies for applications requiring low noise emissions

Standard configuration delivers up to 25 dBA Sound Power Reduction

Strong application knowledge provides Customized Solution

Available for new production or aftermarket

TheGE150ACTM

Giving new meaning to peak performance


GE150ACTM

Alternator1,800 gHP capabilitySelf-ventilatedAdvanced excitation system -

enables faster response to power demand

AC Control GroupAir-Cooled IGBT Inverter - highest

available efficiency and reliability

Optimized package design for easy and safe access

GE InvertexTM AC control with independent wheel motor control and hillstartTM and spin/slideTM algorithms

Motorized AC Wheels Fixed ratio planetary

transmission - Industry proven GE776/791 gearing configuration.

GEB15 traction motor - Proven concept with > 1,000,000 hrs in locomotives and minimal running maintenance (brushless)

Dynamic RetardingMaximum 2,700 HP

retarding capability to 12,000 ft

Designed to incorporate GE WhisperGridTM

The GE200ACTM

A high-performance drive system for the most

dynamic mining environments


GE200ACTM

Alternator2,500 gHP capabilityCooling air for main controlsAdvanced Excitation System - enables

fast response to power demands

Motorized AC Wheels

Fixed ratio planetary transmission - Industry proven GE787 gearing configuration.

GEB13 traction motor - Proven concept with > 26,000 in locomotive serice

Minimal running maintenance (brushless)

Dynamic Retarding

Maximum 3,700 HP retarding capability

Single blowerDesigned to incorporate

GE WhisperGridTMpackages



Two high-capacity retard contactors less maintenance

GE InvertexTM system control -independent wheel motor control and spin/slide, hillstart and thermal self protection algorithms

The GE240ACTM

A high-performance drive inside for a demanding

environment outside


GE240ACTM

Alternator2,700 gHP capabilityCooling air for main controls and wheel

motors

Advanced Excitation System - enables fast response to power demands

Motorized AC Wheels

Fixed ratio planetary transmission - Industry proven GE787 gearing configuration.

GEB13 traction motor - Proven concept with > 26,000 in locomotive service

Minimal running maintenance (brushless)

Dynamic Retarding

Maximum 4,300 HP retarding capability

Designed to incorporate GE WhisperGridTMpackages



Only two high-capacity retard contactors less maintenance

GE InvertexTM system control -independent wheel motor control and spin/slide, hillstart and thermal self protection algorithms

The GE320ACTM

Over 11 million hours of experience


GE320ACTM

Motorized AC WheelsDelivering 24,000 MTBO

at nominal 1,112,000 lbs with over 1,400,000 hours of OHV service

Industry proven GEB16 Traction Motor with over 23,000,000 hours in OHV service

Removable inboard thrust washer

Increased continuous retard capability

Sea level to 12,000 ft capability without derating


Dynamic Retarding

2,700 or 3,500 gHP capabilityCooling air for main controls and wheel

motors aux blower elimination

Advanced Excitation System - enables fast response to power demands

Alternator

Air-Cooled IGBT Inverter - highest efficiency and 5x reliability improvement

High-capacity rectifier up to 3500 HP applications

GE InvertexTM AC control - with spin/slide, hillstart and thermal self protection algorithms

AC Control Group

The GE360ACTMAll innovations coming

together, full circle


GE360ACTM

AC Control Group Dual IGBT inverter highest

available reliability

Continuous motoring capability up to 12% equivalent grade

GE InvertexTM AC control with spin-slide, hill start and thermal self-protection algorithms

Motorized AC Wheels

Designed for 24,000 hours MTBO at nominal 1,250,000 GVW based on GDY106 Wheelmotor

High HP Traction Motor delivers 6,000 HP continuous retarding capability

Redundant brake/transmission fluid sealing arrangement increased reliability

AlternatorRated for upto 3,500 ghpProvides cooling air for main controls and

wheel motors

Advanced excitation system enables fast response to power demands

Dynamic Retarding

Continuous 6,000 hp retarding capability to 12,000 feet



Corporate Research & Development

Niskayuna, NY

JFW Technology CenterBangalore, India

GE continues to Invest in technology

China Technology CenterShanghai, China

Global Research EuropeMunich, Germany


Traditional Electric Truck Power Flow

Propulsion power

Retarding power

Dissipated heat

Engine power

Fuel


Fuel

Power Flow with Hybrid Technology

Energy Storage System

Hybrid power

Fuel ReductionHP Boost

Engine power

Propulsion power

Retarding power

Dissipated heatDissipated heat


Komatsu 830E Battery Placement(Demo Only)

8x RF Deck

Hybrid Development Program

US DOE Awarded GE Proof of Concept Demo

9Power Circuit Design9Define Battery Technology9Mission Analysis Tool Developed9GE Global Research Sub-scale testing9GE Erie Power Lab Full-scale SimulationTruck Integration: Komatsu 240TACBattery & Control PackagingKomatsu PG Demo and design tool

validation - 2006

2x 2mH inductors

Hybrid ControlGroup

4x BumperExtension

2002 2006 2007

Prototype Integration ProductionDesign

2010

Phase IIProof of Concept


Extreme Safety and Environmentally friendly- no hazardous chemical disposal

High energy and power density (weight)

High-energy efficiency

Maintenance-free construction

Long useful life

High reliability

Properties independent of ambient conditions

OHV Energy Storage CTQs


GE Erie Simulation Lab Testing

Full Power SystemValidation

12 batteries 17KG535:

D-IGBT Control Group Hybrid Control Group Inductors

17KG535 Group

BatteriesInductors

Hybrid Control Group


GE Technology Focused on Driving LCC

TonAvailabilityMaximize fleet up-time

MaintenanceRobust-simple design maximizes MTBO, AC delivers minimal running maintenance

$

Fuel SavingsHybrid system utilizes stored energy

to offset Engine HP, offers extended Engine OH

cycle, Reduced fleet

PerformanceHigh retard HP limits mechanical brake wear, Traction controls optimizes tire life

ProductivityHybrid system utilizes stored energy

as supplement to engine HP toincrease speed on grade

PerformanceAC provides top speed on-grade, top vehicle speed and broad retard envelope


Innovation continues

Future1996 2006

7

777

7GE200ACGE200ACGE360ACGE360AC

GE240ACGE240AC

GE150ACGE150AC

GE320ACGE320AC

7

1996

7GE791GE791

GE776GE776

7GE772GE772

7GE787GE787

1966

7GE788GE788

ge ohv drive systems technology update 06082006 wmea

Documents