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Next Generation Auxiliary Converter - Mechanical Design Critical Design Review (CDR) to Detailed Design Review (DDR)

Next Generation Auxiliary Converter - Mechanical Design Critical Design Review (CDR) to Detailed Design Review (DDR)

Designed with the Indian rail market in mind

Customer Challenge

We needed to assist our client in the design of an auxiliary converter which would cater for next generation products.

Requirement of a standardised design which allowed the client to reuse the component across a number of existing and upcoming projects. It also had to be compact, so that it fit in with pre-existing third rail facilities on a metro system in India.

Scope

Mechanical design of enclosure and integration of all sections with IP integrity, structural integrity and to sustain shock and vibration according to EN60529, EN 12663, EN61373
Mechanical layout of all electrical and mechanical components inside all sections
Developing a BoM with long lead item list with product data management structure
Create a cable integration solution with assembly sequence logic
Ensure mechanical and electrical interface definition with the car body as well as within the converter box
Pass all gate reviews from CDR to DDR. All mechanical deliveries are to be met.
Release all necessary drawings through virtual project modelling and product data management

Solution

We ensured a constant collaboration with the client project team to develop concept layouts of all electrical components.
Our team designed mechanical fixations, enclosures and cable integration whilst carrying out frequent reviews with the internal project teams and client operations team.
We worked with the car body team to ensure proper mechanical and electrical interface definition.
We defined the mechanical requirements — to make sure the product meets all requirements and regulations, while at the same time ensuring better component layout.
Our specialists reviewed the manufacturability and assembly sequences with the client operations team.

Features

Milestone achieved: Approved preliminary design review.
The Preliminary Finite Element Analysis (FEA) results confirmed the structural integrity of the design.
Our preliminary thermal simulation ensured acceptable results with suggestions to improve the layout.
We created a standardized solution of enclosure for contactor module section and capacitor module section and mid-frame for both the projects (1500V AC variant & 750V DC variant).

Benefits

The design is compatible with multiple projects and can be used as a platform solution across all future train projects within the Indian rail market.
The design complies with international railway standard and safety requirements.
Due to continuous collaboration with the customers operations team, future prototype building would now be much easier.
With regular interactions with the stake holders and ensuring that the gate reviews are cleared, we maintained a schedule of deliveries of Aux converter to car body within the agreed timelines.

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