1 wabtec global services electro pneumatic controlled freight brake system (ecp) general overview...

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Wabtec Global ServicesWabtec Global Services

Electro Pneumatic Controlled Freight

Brake System (ECP) General Overview

Michael ZenertManager Field Service & Training

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ECP OverviewECP Overview

• What is ECP Braking?• The ECP Equipment?

– Locomotive equipment?– Car Equipment?

• How ECP Operates?

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What is ECP Braking?What is ECP Braking?• Electronically Controlled Pneumatic Freight Car BrakesElectronically Controlled Pneumatic Freight Car Brakes:

– Pneumatics Provides the “Muscle”

– Electronic Communications & Control

• Two Conductor Trainline Cable:Two Conductor Trainline Cable:

– Provides Power (230 VDC)

– Overlay Data Communications

– Parallels Brake Pipe Through Entire Train

• Key Brake Functions:Key Brake Functions:

– All Cars Apply/Release Brakes Simultaneously

– Graduated Release Capability

– Brake Pipe used to charge reservoirs only

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Benefits of ECP BrakingBenefits of ECP Braking Improve SafetyImprove Safety

– Reduce Stopping Distances – Typically 50%

– Easier to Operate Save FuelSave Fuel Improved Cargo HandlingImproved Cargo Handling Lower Equipment MaintenanceLower Equipment Maintenance

– Less Brake Shoe Wear

– Less Coupler Wear

– Less Track Wear Increased CapacityIncreased Capacity

– Increased Average Speeds

– Shorter Re-Starting Times After Stops

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Advantages of ECP: Car OwnerAdvantages of ECP: Car Owner

Extended Wheel Life:Extended Wheel Life:

– Even Distribution of Thermal Loads

– Tighter BC Control to Prevent Over-Applications Even Brake Shoe WearEven Brake Shoe Wear Lower Wear & Tear - Lower In-train ForcesLower Wear & Tear - Lower In-train Forces Car System Diagnostics:Car System Diagnostics:

– Support Preventative Maintenance Program

– Reduce Inspection Costs

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Advantages of ECP: Rail OperatorAdvantages of ECP: Rail Operator

Fuel Savings: Elimination of Power BrakingFuel Savings: Elimination of Power Braking Improved Train Handling:Improved Train Handling:

– Simultaneous Braking– Reduction of In-Train Forces

Improved Safety:Improved Safety:– 30 to 60% Reduction of Stopping Distance– Lower Derailment Risks

Cost Effective Addition of Wireline-based Cost Effective Addition of Wireline-based Distributed Power ControlDistributed Power Control

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Comparison of ECP/Non-ECP Full Comparison of ECP/Non-ECP Full Service Stop DistanceService Stop Distance

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Comparison of ECP/Non-ECP Emergency Stop DistanceComparison of ECP/Non-ECP Emergency Stop Distance

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The ECP EquipmentThe ECP Equipment

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ECP-Equipped Locomotive

ECP EOT

ECP 230V Trainline

Brake Pipe

ECP TrainECP Train

ECP-Equipped Cars

Each locomotive, car, and the EOT together form a network.

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ECP/WDP LocomotivesECP/WDP Locomotives

NetworkInterface

Unit

EPIC IIElectronic Air Brake

EPICHandle

ECP Trainline

ECP 230/24 VDCPower Supply

Pneumatic I/OElectrical I/O

Aux.Pneumatic

Rack

LocomotiveID Unit

ComputerDisplay

Unit

TrainlineInterface

Unit

MU Trainline

ECP ConnectorsECP Connectors

Pneumatic I/O

KeystrokeRecorder

CDUPowerSupply

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EPIC CHU, EPIC CCC, & CDUEPIC CHU, EPIC CCC, & CDU

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NIU Processor (ECP HEU)NIU Processor (ECP HEU)

Master Master Controller Controller

for ECPfor ECP

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EPIC II /CCB II AirbrakeEPIC II /CCB II Airbrake

Provides Locomotive

Braking

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Locomotive ECP 230 VDC Power SupplyLocomotive ECP 230 VDC Power Supply

Converts 74 VDC input to 230 VDC output to

power ECP

Provides 24 VDC for sequencing of cars

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Locomotive ID ModuleLocomotive ID Module

Controls the ECP Power Supply in response to NIU commands

Contains and provides locomotive characteristics & identification information for NIU (HEU)

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ECP-Only LocomotivesECP-Only Locomotives

NetworkInterface

Unit

ECPController

ECP Trainline

ECP 230/24 VDCPower Supply

LocomotiveID Unit

ComputerDisplay

Unit

ECP ConnectorsECP Connectors

CDUPowerSupply

BP

PCS

Speed

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ECP Brake ControllerECP Brake Controller

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ECP Brake ControllerECP Brake Controller

Remote Pilot Device (RPD)Remote Pilot Device (RPD)

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ABDXEmergency

Portion

PipeBracket

ECPManifold

ECP 230V Trainline

JunctionBIW

Junction BIW

Manual ReleaseRod

CCIDEnclosure

Car ID

CCD

Battery

Brake Pipe

Car Equipment DiagramCar Equipment Diagram

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ECP Pneumatic ManifoldsECP Pneumatic Manifolds

““Overlay” VersionOverlay” Version““Stand-Alone” VersionStand-Alone” Version

Fits BETWEEN Service Portion & Pipe Bracket

Replaces Service Portion

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ECP Manifold Overlay DiskECP Manifold Overlay DiskECP Manifold Overlay DiskECP Manifold Overlay Disk

Overlay DiskOverlay Disk

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All-Electric ECP ManifoldAll-Electric ECP Manifold

Mounted on Pipe Bracket

Replaces Service Portion

Contains MV’s to charge and vent BC

Contains transducers for BCP, BP, & Reservoir

Manual Release Rod & 2 Manual Release Pushbuttons Pneumatic Emergency LockoutPneumatic Emergency Lockout

MANUAL RELEASE PUSHBUTTONS

MANUAL RELEASE ROD CLEVIS CONNECTION

Pipe Bracket Stud Locations

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Freight Car ECP EquipmentFreight Car ECP Equipment

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Car Control and Identification Device (CCID)Car Control and Identification Device (CCID)

Contains car specific data required to determine braking

Normally powered from 230 VDC Trainline

Battery provides 4 hour backup

Controls manifold in response to NIU(HEU) commands

LED

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CCID InternalsCCID Internals

Battery

CCDCCID

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Emergency Portion Emergency Portion

Wabtec design utilizes standard AAR emergency portion.– Compatible with standard AAR pipe bracket – Detects drop in BP and propagates pneumatic

emergency– Equalizes emergency reservoir and brake cylinder

at a controlled rate

NYAB EP-60 has only the capabilities of a vent valve,

and is not compatible with the Wabtec ECP manifold.

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ECP Freight-MateECP Freight-Mate® ® ConnectorConnector

Mated Inter-Car Connectors

End of Car ConnectorsInter-Car Connector

Designed to Designed to separate if not done separate if not done manually, to protect manually, to protect

car permanent car permanent wiringwiring

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ECP ConnectorECP Connector

l

Note length compared to Brake Pipe hose

Maintain connector 5-

inches above rail

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Locomotive Wireline TerminationLocomotive Wireline TerminationLocomotive Wireline TerminationLocomotive Wireline Termination

Head End TerminationHead End Termination

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Freight-Mate® Connectors Freight-Mate® Connectors Freight-Mate® Connectors Freight-Mate® Connectors

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End Of Train (EOT)End Of Train (EOT)

Provides the last node of the ECP Network

Connects to both Brake Pipe and 230 VDC trainline

Has BPP transducer, motion sensor, HVM

Battery backup

Continuously reports BPP and trainline voltage to NIU

MUST be connected for ECP RUN operation

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ECP OperationECP Operation

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ECP-Equipped Locomotive

ECP EOT

ECP 230V Trainline

Brake Pipe

S-4200 ECP S-4200 ECP

ECP-Equipped Cars

Initialization: Acquire, Sequencing

Modes: Init, Run, Switch, Cutout

Messaging: Beacons, Polling, Exceptions, Low Bandwidth

Source of Charging Air ONLY

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ECP NotesECP Notes – General Guidelines For Train General Guidelines For Train AssemblyAssembly

After each car has passed both a pneumatic and ECP single car test, connect the Brake Pipe glad hand fittings and open the BP angle cocks on both ends of the car.

Connect the FreightMate® connections between the cars.

Connect the EOT to the end of the Brake Pipe via it’s glad hand fitting and open the angle cock.

Connect a locomotive or locomotives to the first car’s coupler and Brake Pipe.

Connect the HET to the locomotive and the FreightMate® connector to the car.

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ECP NotesECP Notes – General Guidelines For Train General Guidelines For Train AssemblyAssembly

Reset the penalty brake and charge the train Set a Full Service Automatic Brake Select ECP Operations, Initialization Mode Once HEU has found EOT & all the cars

(Acquire Function), the system will then enter into the Sequencing function

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How ECP Works How ECP Works

NIU/HEU searches for HET, PS’s, & LID’s, turns on PS (8 Sec) to wake up and acquire cars/EOT

If EOT found trainline power continuously applied

Prior to entering RUN Mode, after the consist has been acquired and the car count confirmed by the engineer, the train is sequenced.

Each Car ID Device and Locomotive ID Device contains circuitry to detect current and switch in/out a small electrical load on the trainline used for the sequencing function during ECP Initialization

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How ECP Sequencing Works How ECP Sequencing Works During sequencing the vehicle’s position in the train, relative

to the Lead locomotive and its directional orientation are determined and stored by the Head End Unit (HEU). This is accomplished by counting pulses in the trainline current, as sensed by each Locomotive and Car ID, as the switchable load on each vehicle is momentarily connected to the trainline and then disconnected. This creates a small current pulse.

Those vehicles that are downstream of the location on the trainline that switched in the load do NOT detect the current pulse, while those upstream will. The Head End Unit repeats these commands for each vehicle acquired during initialization. By knowing the pulse count for each vehicle in the consist, which the Locomotive/Car ID Devices store and report to the Head End Unit, the vehicle’s relative position in the train can be determined.

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ECP-Equipped Locomotive ECP EOT

ECP 230V Trainline

Brake Pipe

CCID Acquisition Sequence:3 1 2

Sequencing Pulse Count3 2 1

ECP Sequencing ExampleECP Sequencing Example

Switchable LoadSwitchable Load

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How ECP Sequencing Works How ECP Sequencing Works By switching the load on to the trainline and then sensing

whether or not that vehicle could detect its own pulse, combined with the car specific data as to which end of the vehicle the load is installed (stored in the vehicle ID device), orientation of the vehicle with respect to the front of the train can be determined

Train sequencing is performed each time RUN Mode is entered

Once in RUN, the operator moves the brake control, sends request to NIU. NIU puts brake request on to ECP trainline

CCID’s read request, and command ECP Manifold MV’s to apply/release BCP

BRAKE PIPE PRESSURE DOES NOT CHANGEDOES NOT CHANGE DURING AN AUTOMATIC BRAKE APPLICATION

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ECP Modes Of OperationECP Modes Of Operation

• RunRun– Full functionality of ECP

• SwitchSwitch– Operation with no EOT communications– Cutting in and out cars– Speed Limited

• Cut OutCut Out– CCID’s all cut out– Used to shutdown the ECP System

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Thank you, any questions?