Hiroyuki SAKURAI
Assistant Manager, Rolling Stock Company
Kawasaki Heavy Industries, Ltd. Japan
July 12, 2012 Session: Rolling Stock 2 – Design & Manufacturing 2
Technical Introductions of
Hiroyuki Sakurai
Assistant Manager, Kawasaki Heavy Industries, Ltd. Japan
July 12, 2012, Session: Rolling Stock 2 - Design & Manufacturing 2
Established: October 15, 1896
Paid in Capital: USD $1,272 million (as of March 31, 2012)
2
Copyright © 2012 KHI. All rights reserved.
1.1 Company Profile
Kawasaki Motors Mfg Corp, USA
Lincoln, NE Kawasaki Rail Car, Inc. Yonkers, NY
Rolling Stock Hyogo Works (Rolling Stock)
Industrial & Power Plants Gas Turbine Motorcycles
Aerospace Shipbuilding Tunnel Boring Machines
Net Sales: USD $15,872 billion (FY ending March 31, 2012)
Employees: 33,267 (as of March 31, 2012)
Hiroyuki Sakurai
Assistant Manager, Kawasaki Heavy Industries, Ltd. Japan
July 12, 2012, Session: Rolling Stock 2 - Design & Manufacturing 23
Copyright © 2012 KHI. All rights reserved.
1.2 Chronicle of Shinkansen Development
Kawasaki has been involved in development of all Shinkansen trains
1964: 0 Series (210km/h)
1985: 100 Series (230km/h)
1992: 300 Series (270km/h)
1982: 200 Series (240km/h)
1992: 400 Series (130 or 240km/h)
1997: E4 Series (240km/h)
1997: 500 Series (300km/h)
1997: E3 Series (130 or 275km/h)
1999: 700 Series (285km/h)
2000: 700-7000 Series (285km/h)
2007: N700 Series (300km/h)
1997: E2 Series (275km/h)
E5 Series (320km/h)
E6 Series (130 or 320km/h)
1994: E1 Series (240km/h)
Hiroyuki Sakurai
Assistant Manager, Kawasaki Heavy Industries, Ltd. Japan
July 12, 2012, Session: Rolling Stock 2 - Design & Manufacturing 24
Copyright © 2012 KHI. All rights reserved.
1.3 Export Model High Speed Trains
・ Award/Service Commencement : 2000/2007
・ Max. operating speed :186 mph(300km/h)
・ Fully dedicated newly constructed track
・ System-wide Contract
・ Contractor: Taiwan Shinkansen Corporation
・ Kawasaki supplied 360 cars
Taiwan High Speed Rail Corp.
700T Series
Ministry of Railway,
People’s Republic of China
CRH2
・ Award/ Service Commencement : 2004/2007
・ 125mph(200km/h) EMU for upgraded existing
lines with partially newly constructed tracks
・186mph(300km/h) class EMU for newly
constructed dedicated passenger lines
・Kawasaki provided CRH2 with local partner Sifang:
- 125mph(200km/h) EMU 960 cars
(including berth type)
- 186mph(300km/h) class EMU 480 cars
Hiroyuki Sakurai
Assistant Manager, Kawasaki Heavy Industries, Ltd. Japan
July 12, 2012, Session: Rolling Stock 2 - Design & Manufacturing 25
Copyright © 2012 KHI. All rights reserved.
2.1 Concept of efSET
efSET=
environmentally friendly Super Express Train
Comfort
SafetyEnvironmental Performance
Energy-Saving
Reliability
・High speed train designed by KHI capable of 350 km/h
in revenue service
・Design flexibility enables compliance with major standards
Hiroyuki Sakurai
Assistant Manager, Kawasaki Heavy Industries, Ltd. Japan
July 12, 2012, Session: Rolling Stock 2 - Design & Manufacturing 26
Copyright © 2012 KHI. All rights reserved.
2.2 Main Specifications
Wide Interior
Light Weight
Light Weight
⇒Low energy consumption
⇒Less track maintenance
Item Value
Max. Service Speed 350 km/h
Motor / Trailer Ratio 6M2T
Total Traction Power 9,720 kW
Seating Capacity 510
Width 3,380 mm
Train Length 200m (8 cars)
Train Weight (Tare) 400 t
Train Weight
/ Passenger
0.77t
Max. Axle Load 14.5 t
Computer simulation of energy consumption
Result (Axle load from 17 ton to 14 ton)
→Reduction of Power Consumption = 10%
→Reduction of Greenhouse Gas Emission
= 16,000 ton/year
Hiroyuki Sakurai
Assistant Manager, Kawasaki Heavy Industries, Ltd. Japan
July 12, 2012, Session: Rolling Stock 2 - Design & Manufacturing 27
Copyright © 2012 KHI. All rights reserved.
2.3 Main Circuit System
Basic trainset :6M2T
MTr : Main Transformer
M : Traction Motor
CI : Converter/Inverter
APU : Auxiliary Power Unit
T* : Trailer Car
M* : Motor Car
Designed to enable
increasing/decreasing train set by
units of two cars
Compatible with a wide variety
of train set formations
1号車:Tc 2号車:M 2 3号車:M 1 4号車:M 2
5号車:M 1 6号車:M 2 7号車:M 1 8号車:Tc
1号車:Tc 2号車:M 2 3号車:M 1 4号車:M 2
5号車:M 1 6号車:M 2 7号車:M 1 8号車:TcCar 6:M2 Car 7:M1Car 5:M1 Car 8:T
Car 1:T Car 2:M2 Car 3:M1 Car 4:M2
Multi-unit system (2 cars = 1 unit) ensures system redundancy(*)
(*)Possible to continue operation even if one unit fails
Mtr CI CI
AC単相25000V
M 2車 M 1車
APU
MM MM MM MM
Mtr CI CI
AC単相25000V
M 2車 M 1車
APU
MM MM MM MM MM MM MM MM
AC Single-phase 25,000 V
M2 M1
1 Unit
MTr
Hiroyuki Sakurai
Assistant Manager, Kawasaki Heavy Industries, Ltd. Japan
July 12, 2012, Session: Rolling Stock 2 - Design & Manufacturing 28
Copyright © 2012 KHI. All rights reserved.
2.4 Brake System
Features
Combined regenerative direct brake system (electric command)
Trainset braking control enables regenerative braking to near 0 km/h
Compatible with indirect brake system (air command) used in Europe
Reliable brake system based on high speed rail in Japan
Motor Axle
Trailer AxleT M M M M M M T
Regenerative Braking
Reliable regenerative braking means less brake pad wear and lower maintenance cost
Regenerative Brake
Mechanical Brake
Necessary brake force
Car No. 1 2 3 4 5 6 7 8
PAT. by JR Central in 1992
Hiroyuki Sakurai
Assistant Manager, Kawasaki Heavy Industries, Ltd. Japan
July 12, 2012, Session: Rolling Stock 2 - Design & Manufacturing 29
Copyright © 2012 KHI. All rights reserved.
2.5 Bogie (Truck)
・Ensures safe and stable performance up to 350 km/h
・Designed to be capable of complying with international standards
Based on lightweight bolster-less bogie
Radius arm beam type
AxleEN compatible
Bogie FrameAWS compatible
Yaw DamperTwo parts per side ensures travel
stability during part failure
Full Active
Actuator
Secondary Suspension
System
Rigidity and comfort of
air springs with
anti-rolling system
Carbody Tilt System
Simple and inexpensive
system uses conventional
air springs
Foundation Brake
Traction MotorsCompact, high-power
motors
Detectors*Bogie frame
acceleration
*Journal Box
acceleration
*Journal Bearing
temperature
*Gear Box
temperature
Primary Suspension
Pneumatic caliper
Power TransmissoinMono-link type
Hiroyuki Sakurai
Assistant Manager, Kawasaki Heavy Industries, Ltd. Japan
July 12, 2012, Session: Rolling Stock 2 - Design & Manufacturing 210
Copyright © 2012 KHI. All rights reserved.
2.6 Carbody (Crashworthiness / Fire Resistance)
℃620
20
350
Analyze thermal conduction and deformation
Predict by Analysis Fire Resistance
Verification of Actual Floor
Fire Resistance
Collision with Conventional Equipment Collision post / Corner post
Crashworthiness
Hiroyuki Sakurai
Assistant Manager, Kawasaki Heavy Industries, Ltd. Japan
July 12, 2012, Session: Rolling Stock 2 - Design & Manufacturing 211
Copyright © 2012 KHI. All rights reserved.
2.7 Aerodynamics (Flow-induced vibration)
Growth of turbulent flow
between train and tunnel wall
Two trains coupled
Rapid growth of turbulent flow around discontinuities
such as a coupler that connects two trains and the tail of the train
The analytical results can be obtained within several days
using our high-performance computing (HPC) systems
and be applied to the design immediately.
The aerodynamic yawing moments vibrate the car bodies.
A shape that reduces aerodynamic forces gives efSET its
Superior Ride Quality.RM
S o
f a
ero
dyn
am
ic y
aw
ing
mo
me
nt
actin
g o
n e
ach
ca
r b
od
y
Coupler position
between 2 train sets
Unsteady CFD analysis with complete composition model around train set
Tunnel WallCar No1
Car No8
Car No9
Car No12