Class 442 EMU Traction and Brake System Upgrade

SCOPE: Replacement of existing DC traction equipment with new AC traction
invertors and motors. New electrically controlled braking system to allow
regen braking.

RESPONSIBILITIES:

  • Managed team of design engineers responsible for the production of 3D models and 2D drawings, schematics, wiring diagrams, harness drawings and cable lists
  • Ensured all work packages were delivered to budget, technical, quality and delivery requirements
  • Lead design of new equipment and it’s installation to interface new traction and brake systems with existing vehicle
  • Involved in risk identification ensured mitigations were incorporated into design
  • Resource planning and monitoring to ensure milestone targets were achieved
  • Key activities;
    o Complete replacement of braking system – design of pre-assembled pneumatic module which could be built off-site and then installed complete reducing the need for skilled pipework to be carried out below vehicle
    o Design of main supplies case taking DC supply from shoegear and distributing to traction convertors – contained HSCBs, surge arrestors, CTs and VTs
    o New design for motor vehicle wheelset due to existing axle being overloaded
    o Modification to bogie motor nose suspension to accommodate new AC traction motor
    o Design of combined axle end earth brush / speed probe
Units underwent full interior refurbishment during traction upgrade programme so floor panels could be lifted to replace traction cables
Original Westinghouse pneumatically controller brake system replaced with Knorr Bremse EP98
Units in workshop in various states of conversion
Motor bogie with existing EE546 traction motors to be replaced with AC traction motors
Original traction equipment removed and mock-up of new traction converter in place

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