Stationary and mobile test rig applications

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n For asynchronous and synchronous drives

n For a variety of high performance test applications such as trains,

transformers and special motors

n Individually customized with scalable, modular performance levels

n Low-level electromagnetic emissions for sensitive test rig applications

n User-friendly service software and interface design

n Unmatched infrastructure including full laboratory to pretest multiple test

systems prior to commissioning

n Over 600 systems in operation worldwide

References: AVL LIST, Deutsche Bahn, HIGHVOLT

POWER CONVERTER AT A GLANCE

PowerTech is THE specialist in high performance converter technology for high performance test rigs. With over 600 installations worldwide, PowerTech offers unmatched product performance, know how, service experience and testing infrastructure. PowerTech converters for test rig applications are used for:

n Product development and end of line testingn Combustion motors, gears and hybrid drive trainsn High voltage transformer testingn Rail testing of pantographs, propulsion and braking n Electric motor and generator testingn Component testing of diverse industriesn Testing of industrial machines, compressors and

special motors

HIGHLY DYNAMIC TEST BENCHES FORM THE BACKBONE OF INDUSTRIAL DEVELOPMENT: To ensure that systems work reliably and meet performance requirements

PowerTech converters enable the turnkey simulation of technological processes. This contributes to lower product development costs and faster development cycles. The use of intelligent power modules, compact design, minimal number of components and forced air and water cooling define PowerTech’s state of the art technology. This is why almost all Formula 1 racing teams now use the PowerTech family for their development.

TECHNICAL FEATURESn IGBT-based four-quadrant technologyn With voltage link and pulsed mains convertern AFE - active front end functionalityn Active harmonic compensation for best possible grid qualityn Reactive power management with adjustable cos phin Maximum output frequency of up to 2 500 Hzn Maximum IGBT pulse frequency of up to 15 kHzn Excellent field-oriented control propertiesn Low losses and high immunity to electromagnetic interferencen Minimal electromagnetic emissionsn Single-phase/multi-phase solutionsn Modular, flexible design and constructionn Optimised air or water-coolingn Support of common field bus systems and binary interfacesn User-friendly service software and interface design

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1 Control electronics2 Power module with air cooling, water cooling as an option

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Knorr-Bremse Powertech GmbH

Am Borsigturm 10013507 Berlin, GermanyTel.: +49 30 297725 0info.berlin@kb-powertech.com

Knorr-Bremse Powertech GmbH & Co. KG

Ohmstraße 183607 Holzkirchen, GermanyTel.: +49 8024 990 0info.holzkirchen@kb-powertech.com

Knorr-Bremse Powertech Corp. USA

300 International Drive, Suite 2Mount Olive, New Jersey 07828, USATel.: +1 973 527 6060info.usa@kb-powertech.com

Knorr-Bremse Powertech China

Building 4, Jingxi Industry Park2 Jingui Road, Hudai Town, Binhu District214161 Wuxi, Jiangsu Province, PR ChinaTel.: +86 510 6888 0513info.china@kb-powertech.com

sales@kb-powertech.comW W W . K B - P O W E R T E C H . C O MW W W . K N O R R - B R E M S E . C O M

This publication may be subject to alteration without prior notice. A printed copy of this document may not be the latest revision. Please contact your local Knorr-Bremse representative or check our website www.knorr-bremse.com for the latest update. The figurative mark „K” and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG. Copyright 2016 © Knorr-Bremse AG. All rights reserved. Including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.

TESTING FEATURES

Load tests with air- and liquid-cooled equipment and machinery n Test beds for in-house coupling of motor/converter

drive setsn Testing capabilities for determining vibration, velocities,

torques and speedsn Motors can be run with dynamic as well as stationary tests

e.g. for thermal testsn Workshop is capable of adapting customized

shaft connections

In-house facilities for testing of grid faults Realization of simulated grids for product tests n Adjustable grid voltage 0 - 830 V n Adjustable grid frequency 0 - 200 Hzn 700 A continuous reactive current possiblen 2000 A peak current for LVRT tests possiblen Simulation of flicker effects, LVRT, HVRT, harmonics

FACILITY FEATURES

Feed-in possibilities n Terminal areas with 400 V and a capacity of 1.3 MVA n Terminal areas with 690 V and a capacity of 2.0 MVA n Variable source 0 - 200 Hz, 0 - 690V

DC voltage source n 0 - 1000 V DC 350A recovery-capable

Loading devices n Dynamometer with 300 kW, 0 - 7 000 U/minn Transformer / inductor combination for loop operation

up to 2.0 MVA

Internal test rigsn Air-suspended prestressed bed for motor testingn Unsuspended prestressed bed for motor testing

Cooling equipmentn Water / water heat exchanger n Additional equipment according to customer requirement

EXTENSIVE TESTING FACILITIES IN-HOUSE

PowerTech has years of experience in testing with high power applications. Before delivery to the customer, each converter is tested with the original motor – only a fully tested package of power converter and motor is delivered to our customer. New motor types are “identified” with special load tests. That ensures a high accurate control of the torques – and in the end, best quality.

3 ~

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3 2 =

3 ~

APPLICATION EXAMPLES

STATIONARY HIGH-VOLTAGE TRANSFORMER TEST FACILITY

Train component testing (e.g. train transformers, propulsion inverters and motors) used in different voltage levels.

Solutionn Modular designed frequency converter with DC bus and active front end n Motor inverter as load for the unit under testn Supply of the auxiliary voltages n Control cabinet for the internal power supply and protectionn Advanced control functions, including safety circuit for safe stop n Different I/O’s, including interface for different field bus versions (Profibus,

Profinet, CAN)

TEST RIGS FOR RAILWAY INDUSTRY

L

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S Antriebsstrang-belastung

S

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PowerTech converters are used as a voltage supply for test facilities that test transformers according to IEC. These facilities are used for insulation tests and endurance tests.

Solutionn Very high output power and parallel converter operation are possiblen High level of EMC experience is required as test routines with partial

discharge measurements during converter operation occurn Short-circuit-proof, three-phase or single-phase operation, harmonics

stabilization of THD and DC offsetn Also suitable for mobile high-voltage transformer testing facilities

TEST RIGS FOR MOTORS, GEARS AND HYBRID DRIVE TRAINS

E Engine

P Primemover

W Wheels

T Transmission output

D Drive

PowerTech converters are deployed in test rigs for motors, gears and hybrid drive trains. Any configuration is possible: from a compact, reliable test bench for combustion engines to a test rig with maximum dynamics.

Solutionn Control of asynchronous and synchronous motors with up to 24 000 rpmn High dynamic speed and torque control with a step response of < 1 msn Frequency limit of the drive system at 2500 Hz with an IGBT pulse

frequency of up to 15 kHz with large test systemsn Speed change gradient of the drive system: 100 000 rpm/sn For Formula One applications with up to 1000 000 rpm/sn Battery simulation of 50 kW to 1 000 kW

The system of electric motor and PowerTech converter replace each of the mentioned components for simulating technological processes:

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TP

E

D

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Load of propulsion

External AC/DC auxiliary power supply

Simulation of AC- or DC catenary voltage

1100 V DC

Sine wave filter

Step up trafo

0 - 170 kV5 MVA

Static frequency converter

690 V AC2.5 MW

Transformer under test

WORLD LEADER FOR HIGH DYNAMIC POWER CONVERTERS IN THE AUTOMOTIVE TESTING AREA

About 600 power converters delivered worldwide for n Motor test benches for testing combustion engines,

universal drives, electric drivesn Gear test benches as the most complex in the automotive

testing industryn Combustion shock simulation with power converter

and electric motorn Motorsport applications for highest dynamics, as required

by Formula 1, IndyCarn Hybrid drive test benches, AC and DC converters provide

variable energy source, for e.g. battery simulationn High voltage transformers test rigs, e.g. insulation tests,

lifetime testsn Train component test rigs for testing of train transformers,

propulsion inverters and motors

QUALIFIED SYSTEM PARTNER

System solutions for converters and motorsn PowerTech closely works together with well-known,

qualified motor suppliers like VEM, Schorch, Krebs und Aulich, LDW, Faurndau

n Coordinated solutions in electrical parameters, interpretation of the encoders and protection functions

n Preconfigured, proven and therefore reliable compilations of components of the electric drive train

333 3 AC 3* 3*

3 AC

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This publication may be subject to alteration without prior notice. A printed copy of this document may not be the latest revision. Please contact your local Knorr-Bremse representative or check our website www.knorr-bremse.com for the latest update. The figurative mark „K” and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG. Copyright 2016 © Knorr-Bremse AG. All rights reserved. Including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.

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TECHNICAL DATAConverters for test rig applications

Line voltage

Rated voltage 380 - 480 V, 380 - 690 V

Grid frequency 50 / 60 Hz

AC output

Nominal power 50 - 6 000 kW, expandable to 12 MW with parallel connection

Maximum frequency 2 500 Hz

Rated voltage 0 - 500 V AC, 0 - 700 V AC3 phase or single phase

DC output

Rated voltage 0 - 800 V DC, 0 - 1 200 V DC

Nominal power up to 4 MW expandable through parallel connections

ELECTRICS MECHANICS

Fieldbus systems CAN, Profibus, Ethercat

Housing Standard industrial cabinets

Cooling Air or water cooling

Protection IP23, IP54

Temperature range 0 to +45 °C

BLOCK DIAGRAM

Synchronous or asynchronous motors

Motor 1

Motor 2

Motor nLine-side converter

Line

Line filter

Circuit breaker

*Single-phase or DC/DC solutions also available

2. Motor-side converter

n Motor-side converter

1. Motor-side converter

I/O statusFieldbus

Converter control

Output inductor

DC link

PowerTech Converter GmbH

Am Borsigturm 10013507 BerlinGermanyPhone: +49 30 297725-0Fax: +49 30 297725-102

S A L E S @ K B - P O W E R T E C H . C O MW W W . K B - P O W E R T E C H . C O M Copyright 2020 © PowerTech Converter GmbH