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1Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
The Merits of AC vs DC Locomotives
November 13, 2008
2Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
The Merits of AC vs DC Tractiom
1. EMD Historical Perspective
2. Development of AC Traction
3. Performance and Maintenance Benefits of AC Traction
4. The Market- What are Railways Purchasing
5. Summary
3Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
• Market, Design, Sell and Manufacture diesel-electric locomotives, component sets and aftermarket products
EMD
4Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
• Providing value to our marketsby continuously developing our core competencies
Locomotive DesignLocomotive Systems IntegrationMarketing and SellingFinancingManufacturingProduct Support Services
• Developing and supporting global partners
Fully Integrated Locomotive Supplier
5Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Electro-Motive Engineering Corporation
• “The successful application of internal combustion engines to rail service”– Over 500 railcars produced by 1930
• Incorporated in August of 1922
6Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
1st Diesel-Electric Locomotive
1930 1940 19601950 19801970 1990 20001934
EMD Significant Milestones
7Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
0
10,000
20,000
30,000
40,000
50,000
60,000
1930
1935
1940
1945
1950
1955
1960
Dieselization of the American Railroads
Steam
Diesel
Locomotives in Service
In 1939, EMD introduced the FT103
8Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
1st Overseas Manufacturing Associate
1930 1940 19601950 19801970 1990 20001948
EMD Significant Events
9Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Fully Integrated Locomotive Supplier
• Locomotive Assembly Affiliates
– EDI Rail - Australia– Rotem – South Korea– Vossloh - Spain– Tulomsas - Turkey– Indian Railways - India– ETP – Egypt– ELMOTEC – Argentina– D-LOCO - China
10Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Global Presence with Broad International Customer Base
EMD has delivered approximately 11,300 locomotives in 71 countries outside North America
North America48,750
South America1,800
Western Europe1,650
Eastern Europe500
Middle East1,000
Africa2,650
Australia1,500
Asia1,400
11Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
EMD Development of AC Traction SD70MACSD60MAC
SD90MACSD80MAC
12Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Development of AC Traction in North America
• In the 1980s, EMD invested in developing AC traction for the special requirements of heavy haul– High axle loads of 32 metric tonnes – Sustained high tractive effort levels for pulling long,
heavy freight trains - up to 18,000 metric tonnes• Many declared that AC was not the right
technology for North America– EMD went ahead with development and tests– EMD was the first North American supplier to market
AC traction locomotives
13Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Evolution of Inverter Control
• 1987 - EMD tested the first AC locomotive in North America with six powered axles– one inverter per axle
• 1989 - EMD built the first new locomotive design in North America with AC traction (F69PH)– one inverter per two axles
• 1991 - EMD built the first heavy haul locomotives in North America with AC traction (SD60MAC)– one inverter per three axles
14Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
SD60MAC - 1st heavy haul AC prototype
• The SD60MAC added a new page to the book of locomotive technology history
• Previously, dispatchable adhesion was typically less than 30%
• With the SD60MAC, dispatchable adhesion was raised to 35% and higher
• The SD60MAC demonstrated unprecedented adhesion levels of 45% for starting trains
• This set the stage for Unit reduction on Heavy Haul Trains
15Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
1st North American Order for AC Technology Freight Locomotives(Burlington Northern orders 350 SD70MACs)
1930 1940 19601950 19801970 1990 20001993
EMD Significant Events
16Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Productivity Improvement
3 SD70MAC locomotives replaced 5 SD40-2 DC locomotives in heavy haul service
17Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
SD70MAC - 1st Series of AC Production
• Today, over 900 SD70MAC locomotives are in service
• This is a highly successful Systems Integration of – AC traction– Advanced computer systems– High traction bogie design
• SD70MAC’s reputation has been established for high locomotive reliability
• SD70MAC locomotives are typically dispatched at 35 to 38% adhesion
18Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
EMD AC Traction in India and Australia
• Examples of modern EMD AC traction technology in other regions of the world– India:
21 mt axle load, broad gage, 4000 HP– Australia:
Narrow and Standard gage, 3000 and 4300HP20mt to 32mt axle load
– Mexico and Venezuela : 32mt axle load, standard gage 4300 HP
• All locomotive designs have demonstrated very high adhesion– 35 - 40% dispatchable adhesion– 43 - 50% starting adhesion
19Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Queensland Rail, Australia
GT42C-AC Locomotive3000 thp, Cape gage (1067mm), 20 tonne axle load
20Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
SD70ACe/LCIIn operation on BHP in Australia
• 4300 Traction Horsepower.
21Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Why is the Adhesion so High?
• Speed-torque characteristic of AC motor promotes higher utilization of adhesion
• High speed computer and sophisticated wheel creep control have been developed
• Diesel engine with fast response is needed to optimize adhesion
• Where radial steering bogies are used, transverse wheel slippage in curves is virtually eliminated
22Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Wheel Creep Control
• 1970s - EMD was the first locomotive builder to establish and use the wheel creep control concept
• 1980s-1990s - EMD optimized use of adhesion-creep concept on modern AC and DC traction systems
Wheel-RailAdhesion Wheel Slip Systems operate
at lower adhesion levels
EMD’s Creep ControlSystem operates at peak
of Adhesion-Creepcurve
Wheel Creep
23Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Tractive Effort-Wheel Creep Curves
Typical 3-Axle Truck Tractive Effort – Wheel Creep Curve Characteristics AC Motor Truck Control AC Motor Axle Control DC Motor Axle Tractive Effort Axle #3 Axle #2 Axle #1 Wheel Creep – Per Cent
AC traction motor loading is dependent upon the friction-creep load line for a given axle.
AC traction motors load at a higher tractive effort than DC traction motors based on their torque-speed characteristic and individual axle friction – wheel creep curve.
24Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Inverter InverterInverterInverter
Bogie Control Axle Control
Connected in parallel within a truck and controlled by a common high power traction inverter (truck control),
Individually connected to a low power traction inverter (axle control).
On a high adhesion AC Traction Locomotive, the AC traction motors are either:
AC Systems Design- AC Traction Motor Loading
25Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
SD70ACe Inverter Truck Control
EMD Systems Design Approach To Inverter Truck Control:
• Maximize System Reliability with Lower Parts Count• Automatic Load Sharing between Traction Motors within a Truck • Wheel Diameters wear together and maximize tread life• Radial Truck Design provides higher Tractive Effort and Power
in curves• Fast Wheel Slip Control System with Rapid Inverter Torque
Control • Quick 2-Cycle Engine Load Control Response• Proven High Voltage, High Tractive Effort, and High Power
Inverter • Design with minimal EMI concerns
26Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Inverter InverterInverterInverter
Wheel Mismatch In ServiceBogie Control Axle Control
WheelMismatch
WheelMismatch
Mileage Mileage
Wheel DiametersAlways Converge
Wheel DiametersDiverge Unless Bogie Control is Emulated
Wheel Diameter Wear Mismatch
27Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
SD70ACe/LCI OverviewTraction System Reliability
• Inverter– Utilizes proven IGBT inverter
technology. Phase Modules are air cooled.
– Inverter control system is integrated into EM2000 locomotive computer.
Eliminates two additional computer systems (more than 25 cards in each).Improves reliability and diagnostic capability.
28Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
AC Inverter Phase Module Maintenance
• Projected life expectancy of the Inverter Phase Modules- Greater than 15 years
• Maintenance - No preventive replacement- Replace only when failure occurs
• AC Inverters are Repairable
29Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
• Performance Advantages of AC Traction
– Higher wheel-rail adhesion 40% advantage
– Higher tractive effort20 to 40% advantage on starting TE Greater than 40% advantage on Continuous TE
– Improved mission reliability Traction Motors
– Lower traction motor maintenance
– Train Handling AdvantagesFlat Top Low Speed Dynamic BrakeRoll Back and Opposite Direction BrakingNo issues for Dead in Consist Towing
Creating Value For The Railways
30Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
AC Traction Motor Reliability and Maintenance Less Time in Shop Compared to DC Motor
• Less Maintenance
– No Brushes to Change
– No Commutator to Inspect
• Fewer Failures than DC
– No Stall Burns
– No armature ground relays,
– No flashovers
AC Traction Motors have Less Maintenance and Fewer Failures
31Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
AC Motor Overhaul
• Overhaul Interval
– At overhaul, AC motors generally
require only stator and rotor
bearing attention
32Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
AC vs. DC Locomotive Market -Historical Deliveries in USA & Canada 1993 to 2005
• When AC Traction was introduced, there was a rapid traction technology conversion for heavy haul freight
• However, DC traction has comprised 40 to 50% of the new locomotive market
0%
20%
40%
60%
80%
100%
90 93 96 99 02 05
Traction Technology Conversion
AC Traction
DC Traction
33Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Largest Single International Order for Locomotives(EW&S orders 250 Class 66 diesel-electric locomotives)
1930 1940 19601950 19801970 1990 20001996
EMD Significant Events
34Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Largest Single Locomotive Order in History – 1000 SD70Ms
1930 1940 19601950 19801970 1990 20001999
EMD Significant Events
35Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
AC62%
DC38%
AC and DC Locomotive Deliveries
• Recent EMD Delivery Experience is approximately a 60/40 Spilt of AC to DC in the Marketplace
US and Canadian Rail MarketAC vs. DC deliveries Since 2005
36Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Comparison of Key Buying Factors
Key Buying Factors AdvantageAC Traction
▲▲▲
Traction (kW) = =TE at Moderate to High Speed = =Purchase Cost ▲Ease of Maintenance/ Skill Set / Training ▲
TE Starting and at Minimum Continuous Speed
DC Traction
Train Handling
Adhesion
37Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
What Factors drive The DC or AC Purchase Decision?
Service Heavy HaulHigh Speed
RequiredPerformance
Life Cycle Cost
Analysis
Business Plan Growth
Fleet Planning &Logistics
Railway Procurement Decision Model
Maintenance Planning
Capital Cost and ROI
Duty Cycle and Asset Utilization
?
Training&
Facilities
Financing
38Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
When is DC Traction Preferred?DC Traction is the preferred lower cost solution for:
– Moderate to higher train speeds– Passenger service – light tonnage General Freight service– Inter-modal freight service
Different solutions for different needs
39Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Perspectives From the North American Rail Market
Canadian National feel the added tractive effort benefits of AC can not be fully utilized on their system to justify the premium for AC locomotives over DC. Canadian National continue to purchase 100% DC Locomotives.
Canadian Pacific - 100% of CP's purchases since 1998 have been AC. They believe AC traction provides much greater reliability and provides unit reduction as they cross challenging grades in the Rocky Mountains.
40Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Perspectives From the North American Rail Market
BNSF continues to purchase both AC and DC as they have operations and fleet sizes that can separately utilize the advantages of each. AC for the Powder River basin heavy haul coal operations and DC for their higher speed intermodal operations. BNSF are able to keep their fleets focused on specific operations.
UP has standardized on a building block philosophy utilizing units that can run reliably in any corridor of service. The 4300-4400 hp block with AC technology has become that standard. UP has only purchased AC freight locomotives since 2005. The SD70ACe is utilized primarily in high speed intermodal service. UP Mechanical Dept believes the added cost of AC is more than offset by the lower maintenance costs, longer component life to overhaul, and higher reliabilityof the AC system for a standardized fleet.
41Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Perspectives From the North American Rail Market
CSX has been purchasing AC locomotives exclusively since 2006. They have concluded that AC Traction is a more universal locomotive for them. Premium for AC is justified based on the perfromanceand life cycle cost.
NS has historically purchased only DC locomotives. They have recently purchased some AC locomotives but report that the purchase was driven by special incentives rather than a desire to switch to AC locomotives. They also maintain the perspective that they can maintain their DC fleet to a higher standard at a cheaper cost than their competition.
42Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
EMD AC Traction Summary
• Since 1993, EMD has delivered over 1500 AC traction locomotives
• The market shifted from DC to AC for most heavy haul operations in North America
• EMD is building AC traction locomotives for international railways predominantly for Heavy Haul applications
• Many railroads continue to purchase DC traction for non-heavy haul General and Intermodal freight operations
• Current EMD Market Split is approximately 60% AC and 40% DC
43Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
AC vs. DC Traction Conclusions• EMD has successfully introduced both AC and DC
locomotives designs with higher horsepower diesel engines, advanced computer technology, and high traction bogies
• AC traction has generally been the choice for heavy haul freight where the number of locomotives can be reduced
• DC traction is generally the choice where unit reduction cannot be achieved e.g. General Freight Operations and for medium to high speed operation.
• The weighting on the many decision variables used lead to different procurement conclusions for different customers.
44Contains proprietary Electro-Motive information that shall not be disclosed to third parties.
Question Time