Demanding climatic environments require much more rigorous custom solutions to offer the customer the same reliability as other stable contexts. A factor such as extreme temperature is a stress factor for all components and this is one of the most common challenges at Premium PSU we face.
We present this interview format, with the collaboration of Ignasi Bonet – Sales & Business Development Manager – where he explains one of his case studies in the railway sector. The product is a battery charger designed to run at temperatures between -40°C and 70°C.
Ignasi, Which were the customer’s objectives?
Our customer is a train manufacturer and they needed a railway AC/DC battery charger with an IP65 protection rating (input 360 … 528VAC and output 16.8 … 30V and 250A), this charger is equipped on the trains that the manufacturer supplied to the state-owned company of the United Arab Emirates. This company is responsible for the administration and development of the country’s railway network and its subsequent management and operation.
We aim to cover all three-phase nominal supply voltages on the market, i.e. 400Vac, 440Vac and 480Vac, with a single product. The output is for 24Vdc NiCd batteries, which are precisely those of these trains (specifically the NiCd 20 cells 220Ah SAFT SRX 220 FR or NiCd 20 cells 160Ah SAFT MRX 120).
In addition, we also plan to complete the range with a 10kW model for 110Vdc batteries very soon.
What problems did they want to solve?
They needed a solution with a competitive price but at the same time robust enough to guarantee its good performance in the highly demanding conditions required in the desert, where erosion and temperatures are extreme. Also, they wanted to improve the efficiency and power factor of the chargers they previously used in similar applications.
What is the application for our product? Where is it installed or located?
The railway AC/DC battery charger BDS-10K is mounted directly outside, underneath the train frame to power its NiCd batteries. That means exposing fully to the very high temperatures of the desert.
Why did they choose Premium PSU’s customized solution?
We offered a product that met all their technical needs, with a competitive price and reasonable lead times. We also assured them of a 30-year supply of the product.
Finally, they were interested in having a versatile product that we could supply in different IP ratings and with an extended temperature range of -40 to 55˚C/º70˚ C, so they could put it into other future projects.
How has Premium PSU impacted the customer objectives?
They have a much more versatile, modern and efficient battery charger, with a power factor of 0.94 that allows them to adjust both the cable cross-section and the thermal protection thermal gauge of the equipment. All this with a more than reasonable MTBF of 91kh at 40˚C and MTBFS of 102kh at 40˚C and a service life of 30 years. Otherwise, they have been able to incorporate other functionalities that they considered important such as:
– Battery SOC (State Of Charge).
– Maintenance port for accessing the event log
– CAN BUS communication
Discover more: Railway AC/DC Battery Charger
In the world of engineering and technology, innovation is the key to success. The development of efficient and reliable power systems is crucial for various industries, and one such innovation is the AC/DC battery charger BDS-10K. This groundbreaking device is a result of meticulous design and engineering, aimed at addressing the challenges of weight, efficiency, and environmental robustness.
Weight Efficiency Maximization
The railway AC/DC battery charger BDS-10K series’ core objective is to minimize weight while maximizing efficiency. Weighing a mere 60kg, this compact and lightweight charger boasts an impressive efficiency rating of 93-94%. This high efficiency ensures that nearly all supplied power is effectively transformed, rendering it a remarkably cost-effective solution.
Power Factor Correction (PFC) and DC/DC Conversion
The efficiency of the railway AC/DC battery charger BDS-10K hinges on its innovative design, specifically the integration of Power Factor Correction (PFC) and a DC/DC converter. The PFC, embedded within the AC/DC stage, ensures effective utilization of power from the source. Achieving an outstanding 0.93% power factor through active PFC, the BDS-10K sets a new standard in energy conversion efficiency.
Moreover, the charger incorporates a bidirectional power flow and galvanic isolation-enabled DC/DC converter, known as DAB. This feature makes it apt for a wide array of applications, including battery systems, renewable energy, and low to medium voltage networks. The DAB’s adaptable design offers superior efficiency surpassing 98%, and it can be tailored to meet specific voltage and power requirements.
Cutting-Edge Communication Protocols
The railway AC/DC battery charger BDS-10K is furnished with advanced communication protocols like CAN BUS and Ethernet. These capabilities facilitate seamless integration into various systems, allowing for efficient monitoring and control of the charging process.
Versatile and Adaptive Design
The railway AC/DC battery charger BDS Series stands out for its adaptability and versatility. Designed with modularity in mind, it can be configured for different output setups to match specific project requirements. This modular design also aids in heat dissipation, ensuring optimal performance even in demanding environmental conditions.
This railway AC/DC battery charger series represents a significant advancement in power system technology. Its innovative design, exceptional efficiency, and adaptability position it as a game-changer in the industry. With the capacity to cater to diverse project and application needs, it sets a new standard for battery charging solutions. As the demand persists for more efficient, reliable, and environmentally resilient power systems, the BDS-10K emerges as a frontrunner in innovation, poised to drive the future forward.