Rail
Figure 1: Advanced Energy’s Artesyn ERM series of fully encapsulated DC-DC Converters are designed to address the challenges of modern railway applications
standard sets limits for the DC-DC module for the emissions from and susceptibility to electromagnetic interference (EMI) and mandates that it does not propagate electromagnetic energy that may affect other systems on the train. Numerous performance examinations and tests are used to determine reliability of operation plus design and construction from both an electrical and mechanical perspective. In terms of DC-DC converters, there are several areas where adherence to the standard must be achieved. Due to the demands of multiple onboard systems and the tough electrical environment, input voltages may fluctuate by as much as 0.7 to 1.25 of their nominal value. As such, local DC-DC conversion modules must be flexible and robust enough to handle this fluctuation – and sometimes even wider, short duration transients of 0.6 to 1.4 nominal. To address this, Advanced Energy has developed DC-DC converters that offer a wide degree of flexibility. AE’s new Artesyn ERM150 (150 W continuous power module), for example, has an input voltage range that spans 36 to 160 VDC. Isolation voltages are also essential, and the standard defines tests for insulation resistance measurement and voltage withstand that any equipment must pass. This means adequate electrical insulation and component spacing must be part of the design.
Clearly any type of transportation will be subject to vibration, though modern rolling stock is designed to mitigate that as much as possible. When it comes to a DC-DC converter a fully encapsulated module with mounting points provided for mechanical attachment to the application largely renders the modules immune to the vibration that they are likely to see in rolling stock.
Thermal management For power electronics housed in encapsulated packages operating
www.cieonline.co.uk.
in an environment with high ambient temperatures, thermal management is another vital consideration. Failure to address cooling can cause components to operate outside of recommended parameters, and in the worst case, completely fail. What’s more, runaway heat also presents serious safety risks. Wherever possible, avoiding the need for active cooling is preferable; fans are effective, but they use precious power, may need maintenance and can fail.
When considering power modules such as DC-DC converters, the higher the efficiency the less the waste heat. Modules such as Advanced Energy’s ERM150 series with efficiency levels up to 90 per cent already negate many thermal issues at source. However, some form of heat management may still be needed. Coupling the heat generating components inside the module to an integrated baseplate spreads the heat and allows the module to be thermally bonded to the train’s metal chassis or an external heatsink to draw the heat from the module and maintain an appropriate operating temperature throughout its service life.
Summary
As rail travel becomes increasingly important, there is significant focus on train technology which is leading to an increase in electronics to support a wide range of comfort, convenience and safety functionality. DC-DC converters are needed throughout the train to power these features. Small, fully integrated modules that comply with the specific and stringent standard for rail such as Advanced Energy’s Artesyn ERM series are a good example of what is needed for these challenging applications, where resilience and robustness coupled with performance can help achieve a ‘fit-and-forget’ approach for designers in the industry.
www.advancedenergy.com Components in Electronics June 2023 17
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