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IP1 Traction TD1 and Brakes TD5 – Phase 2

Periodic Reporting for period 1 - PINTA2 (IP1 Traction TD1 and Brakes TD5 – Phase 2)

Reporting period: 2018-09-01 to 2019-12-31

Context: the PINTA2 project is following the PINTA project implemented within Shift2Rail (S2R) Innovative Program 1.
This project has been developed as Phase 2 of the work developed within the Technical Demonstrators Traction (TD1.1) and Brakes (TD1.5) of S2R.
It takes place after PINTA project (considered as Phase 1) funded under the contract number 730668.
The main problems and issues are to improve technical performances of Traction systems, Brakes systems used under low adhesion conditions (like wet rails) and to master new technologies at affordable Life Cycle Cost (LCC) in line with general Key Performance Indicators (KPIs) of S2R.
Technical performances are covering: less energy, noise, weight, volume, more reliability and some other specific performances like reduction of braking distances under low adhesion.
It’s important for society as the Traction and Brakes sub-systems are contributing to higher performances trains, helping to achieve the agreed S2R KPIs (LCC reduction, higher reliability and punctuality, higher train or line capacities) and then stimulate passengers modal shift from road to rail.
The final main objectives, at the end of S2R are to demonstrate on trains several new technical solutions, both proving that they are technically functioning and that they bring major technical and economical benefits.

In more details,
This project is tackling the the following topics:
On Traction
1) Master technology breakthroughs applied to different railways tractions applications like driven independently rotating wheels for High Speed Train (HST) or Silicon carbide (SiC) based Traction systems;
2) Contribute to the implementation of new methodologies, tools, norms and standards of reliability, noise, virtual validation/certification and smart maintenance.
Continue and extend early work started on Traction components in the PINTA. The Traction sub-project has progressed on:
• 7 Traction KPIs progress quantification on a yearly basis, developing and testing up to TRL5-6 Traction sub-systems, paving the way for future TRL7 on trains full Traction sub-system demonstrations later in S2R.
• Continuing to improve methods and tools on noise reduction, reliability, availability, and smart maintenance for semi-conductors; virtual validation and certification methods and Tools.
• Extending pre-standardization work on different fields by interfacing with Standardisation Cross Cutting Activities (CCA) of S2R and normalisation bodies.

On Adhesion
The wheel rail contact is a great source of uncertainty in the prediction of braking distances. This affects a large number of rail traffic characteristics, like headways, punctuality and safety.
The main brakes objective is to find effective adhesion management solutions for a still safer and better performing brake system in low adhesion conditions, improve the overall train safety and reduce wheels LCC.
During the previous project PINTA, the focus was on collaborative work to better describe the properties of different adhesion conditions and also the effect of certain train parameters on adhesion. This was also fed into the development of a new Wheel Slide Protection (WSP) test rig. Within this PINTA2 project, the information has been used as a basis for the development of products up to TRL4.
The PINTA2 Consortium has written a fact sheets public Report on May 2020 following the Audit Day on 16/4/2020 and related comments to D10.2 Dissemination, Communication and Exploitation Plan.
We propose to use this document -publishable under S2R web site- to inform public on the main PINTA2 results achieved during the Period 1, in complement with D10.2 which is a public document
The PINTA2 Progress beyond the state of the art has not changed at the end of Period1 compared to what has been written in the §1.4.1 submitted Proposal.
The ambitions of S2R which are inherited by PINTA2 require substantial ground-breaking improvements in the Traction and Brakes systems addressed by the Project.

PINTA2 State-of-the-art and needed progress :
Traction equipment are heavy and large (volume) : we plan smaller and lighter frequency transformers, high speed motors and natural cooling systems thanks to new SiC semi-conductor technology used in an optimised manner
Non-driven independent wheels in low floor High Speed Trains (HST) : we plan higher line capacity due to a reduction of dwell time at stations thanks to new independent driven wheel assemblies integrated in low-floor HSTs
Efficient traction systems based on Silicon-Insulated Gate Bipolar Transistors : we plan more efficient traction systems thanks to new Silicon Carbide (SiC) semi-conductors.
Most of the time noise problems in the development cycle of the Traction system are being discovered lately at prototype test bench stage, being very costly to solve. : we plan early stage low noise traction system and component design thanks to predicted noise signature.
Reliability of Traction could be improved and life time prediction of semi-conductors in real train operational conditions is needed : we plan new methodology to predict lifetime, improve design and validation processes to achieve significant progress in reliability on Traction.
Long and costly validation and certification : We plan new methodology and tools toward a virtual validation & certification of the traction systems and components. We plan transfer of test from train to static test bench and simulators, work on standards/norm as needed to help more virtual proofs to replace physical tests.

Highly changeable properties of the wheel-rail contact are influencing rail traffic characteristics, including safety and punctuality. Sanding and Wheel Slide Protection are typically employed, but are far from providing the optimum that would be technically feasible : We plan new technologies of wheel-rail contact braking to better cope with the variance of the adhesion characteristics and, combined with a more sophisticated WSP technology, allowing the reduction of braking distances in low adhesion condition, improving the overall train safety, and reduce the wheel LCC.

Expected results until the end of the project : TRL4-5 for new Tractions System and components based on SiC semi-conductors (for tramway, metro, sub-urban and regional trains) or Wheel motor for HST. TRL4 for new braking systems.

Societal impact : improvement of Life Cycle Cost of the trains, improvements of technical perfomances of Traction and Braking system and components like weigh savings, energy and maintenance savings, noise reduction, volume savings, reliability improvments will help to have more productive and attractive trains.