Maintenance of rolling stock

1
Maintenance of rolling stock Reliability and
Maintenance Cost
2
Contents
1. About JR East
2. Change of maintenance of rolling stock
3. Low maintenance cost and high reliability
4. Challenge for new rolling stock
3
1. About JR East
4
Profile of Japan Railway Company Group
Operation length About 27,400 kilometers
Number of passengers About 390 billion
passenger-km per year (Shinkansen 74.46
billion passenger-km per year ) Number of
Rolling Stock About 64,000 cars
Ministry of Land, Infrastructure and Transport
land transport statistics handbook
Data 2004
5
Service area of East Japan Railway Company and
number of rolling stock
Number of rolling stock (JR-EAST)
Model Model number
EC shinkansen 929
EC conventional lines 10,858
EC subtotal 11,787
DC DC 536
EL EL 89
DL DL 91
SL SL 2
PC PC 247
FC FC 445
total total 13,197
Tohoku Shinkansen
Joetsu Shinkansen
Joban line Ltd.exp
Chuo line Ltd.exp
Data 2005.3.31
Narita Express (called "N'EX" )
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Metropolitan area of East Japan Railway Company
and number of rolling stock
Number of rolling stock
(Tokyo Metropolitan Area)
model series number
Old type 101 2
Old type 103 138
Old type 107 54
Old type 201 781
Old type 113 718
Old type 115 147
Old type 415 303
New type 203 170
New type 205 1,341
New type 207 10
New type 211 579
New series? (209,E217, E501) 209 1,036
New series? (209,E217, E501) E501 60
New series? (209,E217, E501) E217 745
New series ? (E231,E531) E231 2,235
New series ? (E231,E531) E531 15
Total Total 8,334
series E231 for suburban
series E501 for Joban-Line
series E231 for Yamanote-Line
series 209 for Keihintohoku-Line
Data 2005.4.1
series E217 for Yokosuka-Line
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The evolution of commuter trains in JR EAST
1960 1970 1980 1990 2000 2005
Series 103 (1963)
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Contents
1. About JR East
2. Change of maintenance of rolling stock
3. Low maintenance cost and high reliability
4. Challenge for new rolling stock
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2. Change of Maintenance of Rolling Stock
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Comparison of old series electric cars (Series
103) and new series electric cars (Series 209)
Series 103
Series 209
Weight down 34
Energy consumption down 53
Maintenance costs down 50
Control circuit
Inverter control
Resistance control
Traction motor
DC motor
AC motor
Auxiliary power unit
Motor Generator
Inverter
Body
Carbon steel (High tensile Steel)
Stainless steel body
11
Evolution from old series electric cars (Series
103) to new series electric cars (Series 209) (
Control Unit )
? New Series 209 ? ( VVVF inverter )
?Old Series 103 ? ( Rheostat Control )
Control board
Relay Units
Cam Of Control Circuit
Cam Of Rheostat Control
Semiconductor Units
Computerization
Less Contact
12
Evolution from old series electric cars (Series
103) to new series electric cars (Series 209) (
Main-Motors )
? New Series 209 ? ( Brushless AC-Motor )
?Old Series 103 ? ( DC-Motor With Brushes )
Weight 800kg
Weight 490kg
Intermediate oil supply pump
Stator
Commutator
Armature
Rotor
Brush holder
Brushless
Small-size Light-weight
Lubrication structure (Outside)
13
Evolution from old series electric cars (Series
103) to new series electric cars (Series 209)
(Auxiliary Power Supply)
? New Series 209 ? ( SIV Static Inverter )
?Old Series 103 ? ( Motor Generator )
Stator
commutator
Printed circuit board
Brush
Computerization
Less Contact
Armature
14
More evolution of new series electric
cars(practical use of IT)
Series E231
Series 209
Monitor device
TIMS Train Information Management System
Simplification Integration Low- maintenance
Control transmission device
Multiplex transmission of control signal
Large reduction in car wiring
Central control of train set
Simplification of inspection
Large reduction of NFB
Crew support function
15
Investigation of New maintenance system (For
New series Electric cars)
2.4 million km group
(ex. )
2.4 million km
1.2 million
1.8 million
0.6 million
Body
VVVF Control Unit
Main Motor
Wheel
Bogie
Pantograph
1.2 million km group
Air-conditioning Unit
600,000 km group
For efficient maintenance, components should be
grouped according to their expected life
16
New maintenance system (For new series electric
cars)
Conventional
Monthly inspection (every 90 days)
General inspection (every 8 years)
Important parts inspection (every 4
years/600,000km)
New Inspection System
Function maintenance (monthly)every 90 days
Car body maintenance (car body electronic parts
) every 2.4 million km
Equipment maintenance (bogies, main motor) every
1.2 million km
Designated maintenance (air-conditioning unit,
pantograph) every 600,000km
Function maintenance (yearly)every 360 days
Condition inspection and replacing of consumable
parts
Rolling stock overhaul
Maintenance of important parts (equipment
maintenance)
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Contents
1. About JR East
2. Change of maintenance of rolling stock
3. Low maintenance cost and high reliability
4. Challenge for new rolling stock
18
3. Low Maintenance Cost and High Reliability
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Comparison of maintenance costs (new maintenance
system and conventional system)
New Inspection System Effect
Conventional
Maintenance costs
General Inspection
New Inspection System
Important parts Inspection
Car body maintenance
General Inspection
Designated maintenance
Equipment maintenance
Important parts Inspection
Designated maintenance
60
120
180
240
run km
Important Inspection
General Inspection
Important Inspection
General Inspection
Conventional
New Inspection System
Designated maintenance
Equipment maintenance
Designated maintenance
Car body maintenance
(refreshment)
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Change of electric railcars on metropolitan lines
and maintenance cost
Maintenance costs (Assume 1991 100)
(cars)
Introduction of New Series Electric-cars
Period extension
New series
Introduction of New Inspection System
Old series
(Year)
21
The effect of improving rolling stock and
changing maintenance
Old series
New series

• Brush-less electric components
• Fewer parts that wear
• Less wear because of light weight
• Checking condition of rolling
• stock with information systems

More effective life-cycle based maintenance
contents and methods
Reduction of failures
Reduction of maintenance cost
High reliability
22
Rates of failures that affect transportation
service
Number of failures per million car-kilometers
(2004.42005.3)
Failures causing delays of more than10 minutes
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Method for calculating Reliability
Reliability measured by MTBF(Mean Time Between
Failures)
t0
t1
t2
tn
Up State
t1
t2
tn
Down State
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Reliability of series 209 and series E231
Recently Availability of series E231 is good.
In early times, the rates were similar.
series 209 on Keihintohoku-Line series E231 on
Sobu-Line of Commuter
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Parts Reliability of series E231
Reliability of Auxiliary power supply and Air
compressor is high rate
105
104
MTBF (hour)
Reliability of Door unit and Brake unit is low
rate
103
102
107
105
106
104
Total running time (hours)
series E231 for Sobu-Line of Commuter
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Method for calculating availability
Availability is based on down time rate
Down time rate 1 - A
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Down time rate of series E231
10X10-4
5X10-4
Down time rate
0
105
106
103
107
104
Total running time (hours)
series E231 for Sobu-Line of Commuter
28
Parts Down time rate of series E231
10X10-4
5X10-4
Down time rate
Door unit and Brake unit failure have serious
effects on transport service.
0
105
106
107
104
Total running time (hours)
series E231 for Sobu-Line of Commuter
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Reliability and Availability analysis result

• MTBF of series E231 stabilized at 0.2million
  hours, and after that , MTBF improved.
• Door unit MTBF of series E231 is bad.
• Availability of series E231 improved with time.
• 4. Door unit availability of series E231 is bad.

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Contents
1. About JR East
2. Change of maintenance of rolling stock
3. Low maintenance cost and high reliability
4. Challenge for new rolling stock
31
4. Challenge for New Rolling Stock
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Target Concepts of the AC Trains
Ecology ? Energy-saving (lighter car body,
etc.) ? Zero-emission
Improvement of the reliability of
transportation ? Improvement of credibility ?
Reduction in the time necessary for
restoration ? Improvement of the passenger safety
Improvement of passenger service ? IT-based
information service in trains ? Easing of
congestion ? Improvement of comfort in trains
Cost-reduction
? Total cost-reduction by the change of car
systems (initial, running, maintenance)
Barrier-free ? Consideration for physically
handicapped passengers
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AC Train technologies for high availability
Summary
Distributed Autonomous Systems
Self-check and first aid
Main power unit, Auxiliary power unit
Self-check
VVVF inverter
VVVF inverter
First aid
High speed circuit breaker
High speed circuit breaker
Line breaker
Transmission for driver
Line breaker
lt old system gt ltAC-Traingt
Mutual backup
Electrical Transmission of Instructions
ATS-P, door closing control units, brake system
Transmission of Monitoring Data


Transmission of Visual Image Information
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Change to Distributed Autonomous Systems
Power control system
VVVF inverter
Motor
old system
AC-train
1VVVF-4MM control segmentations3
1VVVF-1MM control segmentations12
35
Mutual Back up System by the Application of IT
? Mutual backup for ATS-P
? Mutual backup for door closing control units
? Mutual backup for brake system
BCUBrake Control Unit
BOUBrake Operation Unit
36
Self-Check system and Transmission of Monitoring
Data
Transmission of Monitoring Data and Visual Image
Information




Transmission of orders
Command





?
?
?
?
?
?





Command No. 702, issued time 1725, issuer



Driver
Train No. 1751H
Display of monitoring data Front view
video
Monitoring display
Change of the departing/arriving Line
Description of notice





Changing train station Takao Line number ??


Sending/receiving control table


Drivers cabin
Command No.
Issued time
Train No
Reception
Receipt confirmed
Delete indication
Not received
702
1725
1751H driver
702
1725
1751H conductor
Received
Electrical Transmission of Instructions
Monitoring unit
Front monitoring camera
Terminal unit
Front view video
Monitor central unit
Monitor central unit
Breakdown
VVVF
Self-Check Function and Emergency Function
?? Disconnected ?? Normal Operation
Permitted
Trouble occurred ??
part Disconnect? YES NO
System running
Drivers cabin
37
New Rolling Stock with Redundant Design, from
AC-Train Technology
?Dual main component?
2 Pantographs per car (Series E231 has 1
pantograph per car)
Signal line and processor of train control unit
Door control unit
Safety equipment (ATS-P)
Brake control unit (Control car)
Air compressor
Proportion of motor car to trailer car is
increased (6M4T).
Auxiliary power supply
High Availability rolling stock (Low rate of
failure that affect transportation service)
Outside view
38
Simulation of Reliability of type E233 and series
E231
Suppose that field data of series E231 failure
was zero for Door unit, TIMS, Air compressor and
Safety equipment because of Redundant Design
104
MTBF ratio improve 50 up
103
MTBF (hour)
102
103
105
106
107
104
Total running time (hours)
series E231 for Sobu-Line of Commuter
39
Simulation of Down time rate of type E233 and
series E231
Suppose that field data of series E231 failure
was zero for Door unit, TIMS, Air compressor and
Safety equipment because of Redundant Design
10X10-4
Down time ratio improved, down time reduce 50
5X10-4
Down time rate
0
103
105
106
107
104
Total running time (hours)
series E231 on Sobu-Line of Commuter
40
Conclusion
1. In JR East, we developed commuter trains
based on new concepts and introduced them in
large quantities after privatization. 2.
Concepts of the new rolling stocks are low-cost,
light-weight, energy saving and digital control
transmission. In addition, maintenance cost were
reduced to half for the new maintenance system,
which matched maintenance methods with the change
of rolling stock. 3. We are moving forward with
new rolling stock development to improve
reliability with reduction of maintenance cost.
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Maintenance of rolling stock Reliability and
Maintenance Cost
42
Another Reliability analysis ,FIT and DIT
FIT (Failure In Time) is a reliability parameter
, failure per billion train hour per
component. For example, if 10 thousand
components work for 100 thousand train hours, and
there is one failure, this is 1 FIT.
DIT (Down In Time) is an availability parameter
that is defined as total down time per billion
train hours.
Failure is analyzed by component, Door unit,
Control unit, Bogie and so on.