MICRO CONTROLLER BASED GOVERNOR

(MCBG)
TYPE - MEG 601

Medha Servo Drives (P) Ltd.,

Hyderabad,
Andhra Pradesh, India.
 Types of
Governors
on
Diesel Electric Locomotives
 Types of Governors
on Diesel Electric Locos

• Electro Hydraulic Governor Type-17MG8

– GE & EDC
• Hydraulic Governor
– Woodward
• Electronic Governor
– Medha, Steasalit, Woodward and BHEL.
Basic functions of a
Governor
Basic functions of Governor
• Cranks the engine when operator demands.
• Increase / Decrease engine RPM as per the
notch selection.
• Maintain the engine RPM from no load to
full load.
• Provide load control signal to reduce over
load on the engine to maintain constant
engine RPM.
• Shuts down the engine on demand by
operator or any safety device is operated.
 Role of a Governor in
Diesel Electric Locomotive
 Role of governor in Diesel
Electric Locomotives
• The diesel engine generates the power.
• The mechanical power is converted in to
electrical power by the Tr. Alternator.
• The out HP from the Tr. Alt. connected to Diesel Tr.
Tr. Motor and the locomotive moves. HP
Engine Alt.
• In a diesel engine the HP is proportional
to its RPM. Fuel
Rack
• The engine speed is selected by driver. Governor
• The HP generated at the selected notch Excitation
speed is proportional to the quantum of Control
fuel and inlet air per cylinder.
• The governor should control the fuel rack
to maintain constant engine RPM.
• The governor should reduce the electrical
load and maintain constant RPM
 Working Principle of
Governor
• Advance the fuel rack during cranking
• Control the fuel rack to maintain engine
RPM at the set speed.
 To maintain engine RPM, the engine Diesel Tr.
RPM signal is taken as an input. HP
LOP Engine Alt.
• Increase / Decrease the engine RPM as
per the operator’s request. Fuel
 Notch signal is taken as an input. Rack
Governor
• Withdraw fuel rack to Shut down the Eng.RPM
Excitation
engine when lube oil pressure is Control
dropped.
Lube oil pressure signal is taken as Notch
an input.
Control
• Reduces the excitation under overload.
Desk
 Load control signal is given to
Excitation control system.
 Working Principle of
Governor
• With out sufficient quantity of air, all
the fuel admitted does not burn BAP Turbo
• In the diesel engine, the inlet air
pressure is boosted up by turbo (BAP).
Diesel Tr.
HP
• If BAP is normal, sufficient air is LOP Engine Alt.
available for complete burning of fuel.
• Less BAP means in-sufficient air and Fuel
Rack
fuel is wasted. Governor
Eng.RPM
• Hence to be fuel efficient, the governor Excitation
should control the fuel rack based on the Control
BAP.
Notch
 BAP signal is taken as an input.
Control
Desk
 Micro Controller Based Governor

• The MCBG is a solid state control system.

• Minimal moving components are used.
• The fuel rack position is controlled through a
stepper motor.
• The stepper motors are very good for any precision
control of movement.
• A powerful 16 bit micro controller is used to control
the stepper motor.
• Digital PID control is adopted for fast and smooth
response of engine RPM to reduce engine hunting.
 Micro Controller Based Governor
(MCBG)

• In addition the fuel oil Pressure

signal is also taken as an input BAP Turbo
in MCBG
FOP Diesel Tr.
HP
• The MCBG has been LOP Engine Alt.
divided in to two parts Fuel
MCBG Rack
Actuator Unit Governor Excitation
Eng.RPM
Control
Control Unit
Notch

Control
Desk
 Block diagram of
Micro Controller Based Governor

Micro Controller Based Governor

MCBG
Micro Controller Based Governor

CONTROL UNIT ACTUATOR UNIT

 Block diagram of
Micro Controller Based Governor
CONTROL UNIT The control unitACTUATOR
is again functionally
UNIT
divided into 6 modules.

Display &
The governor works on 72V DC.
72V Power Supply
Card The power supply module derive low
voltages required for other modules.
Load & Clutch Display loco parameters.
Control Card Provides supply for the clutch coil in the
actuator unit.
Stepper Motor Provides load control signal to excitation.
Cards (2) There are two stepper motor control cards.
Provides drive signal to the stepper motor.
Input
Card Receive notch signals from the
locomotive.
Receive pressure signals from actuator
unit.
Transmits these signals to control card
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT ACTUATOR UNIT
The Control Card consists a Micro
Controller with its peripherals.
Display &
72V Power Supply
Card
It receives various input signals like
Load & Clutch Notch, Engine Speed, Fuel Rack
Control Card position and pressure signals etc.,
from the input card.

Control Stepper Motor

Cards (2)
Card It communicate these parameters to
Input display unit.
Card
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT
• The driver sitting at control desk
Display & opens the notch to the required
position.
72V Power Supply
Card • The notch signal is communicated to
the input card.
Load & Clutch • The control card decides the
Control Card engine RPM for the selected
notch.
• Existing RPM is compared
Control Stepper Motor with new RPM level.
Card Cards (2)

Input • The control card computes the

Card stepper motor direction and the
angular movement required for
new fuel rack position.
• It gives signal to the stepper
Eng. RPM Notch motor cards to drive the motor.
Tacho / Control
ESS Desk
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT ACTUATOR UNIT

Display &
72V Power Supply Stepper Motor
Stepper motor
Card
signal

Load & Clutch

Control Card

Control Stepper Motor

Card Cards (2)

Input
Card

Eng. RPM Notch The stepper motor cards communicate

Tacho / Control this drive signal to the stepper motor in
ESS Desk the actuator unit.
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT ACTUATOR UNIT

Display &
72V Power Supply Stepper Motor
Stepper motor
Card
signal
Gear Box
Load & Clutch
Control Card

Control Stepper Motor

Card Cards (2)

Input
Card

Eng. RPM Notch • The stepper motor slowly rotates in steps

Tacho / Control as controlled by the control card.
ESS Desk • The motor torque is amplified through
gear box.
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT ACTUATOR UNIT

Display &
72V Power Supply Stepper Motor
Stepper motor
Card
signal
Gear Box
Load & Clutch
Control Card EM -Clutch

Control Stepper Motor Rack & Pinion

Card Cards (2)

Input
Card

Eng. RPM Notch • The torque is transmitted to the rack and

Tacho / Control pinion through an electro magnetic clutch.
ESS Desk
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT ACTUATOR UNIT

Display &
72V Power Supply Stepper Motor
Stepper motor
Card
signal
Gear Box
Load & Clutch
Control Card EM -Clutch
Clutch signal

Control Stepper Motor Rack & Pinion

Card Cards (2)

Input
Card

Eng. RPM Notch • The clutch coil gets supply from the load &
Tacho / Control clutch control card soon after the MCBG is
ESS Desk powered up.
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT ACTUATOR UNIT

Display &
72V Power Supply Stepper Motor
Stepper motor
Card
signal
Gear Box
Load & Clutch
Control Card EM -Clutch Output
Clutch signal
shaft
Control Stepper Motor Rack & Pinion
Cards (2) To Fuel
Card Rack
Input
Card
• The rack & pinion converts this rotary
motion into vertical motion.
Eng. RPM Notch
• The output shaft moves the fuel rack to the
Tacho / Control
new position against over travel spring.
ESS Desk
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT ACTUATOR UNIT

Display &
72V Power Supply Stepper Motor
Stepper motor
Card
signal
Gear Box
Load & Clutch
Control Card EM -Clutch Output
Clutch signal
shaft
Control Stepper Motor Rack & Pinion
Cards (2) To Fuel
Card Rack
Fuel Rack Position
Input Fuel Rack sensor
Card Position sensor

The fuel rack position sensor provide a

feed back signal to the input card and
Eng. RPM Notch
from there it is communicated to the
Tacho / Control
control card. The cycle repeats till the
ESS Desk
required RPM is reached.
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT ACTUATOR UNIT

Display &
72V Power Supply Stepper Motor
Stepper motor
Card
signal
Gear Box
Load & Clutch
Control Card EM -Clutch Output
Clutch signal
shaft
Control Stepper Motor Rack & Pinion
Cards (2) To Fuel
Card Rack
Fuel Rack Position
Input Fuel Rack sensor
Card Position sensor

The Control card de-energises the

clutch coil under emergency
Eng. RPM Notch
shutdown. Due to the spring force
Tacho / Control
the output shaft returns back to 0
ESS Desk
position.
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT ACTUATOR UNIT
Excitation
Display &
72V Power Supply Stepper Motor
Stepper motor
Card
signal
Gear Box
Load & Clutch
Control Card EM -Clutch Output
Clutch signal
shaft
Control Stepper Motor Rack & Pinion
Cards (2) To Fuel
Card Rack
Fuel Rack Position
Input Fuel Rack sensor
Card Position sensor

The control card increases the load

control voltage through Load &
Eng. RPM Notch
clutch control card to reduce the
Tacho / Control
excitation under over load
ESS Desk
conditions.
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT ACTUATOR UNIT
Excitation
Display &
72V Power Supply Stepper Motor
Stepper motor
Card
signal
Gear Box
Load & Clutch
Control Card EM -Clutch Output
Clutch signal
shaft
Control Stepper Motor Rack & Pinion
Cards (2) To Fuel
Card Rack
Position Feedback
Input Fuel Rack
Card Position sensor Pressure Sensor
Module

Eng. RPM Notch The Actuator unit has got a sub-

Tacho / Control assembly called pressure sensor
ESS Desk module.
 Block diagram of
Micro Controller Based Governor
CONTROL UNIT ACTUATOR UNIT
Excitation
Display &
72V Power Supply Stepper Motor
Stepper motor
Card
signal
Gear Box
Load & Clutch
Control Card EM -Clutch Output
Clutch signal
shaft
Control Stepper Motor Rack & Pinion
Cards (2) To Fuel
Card Rack
Position Feedback
Input Fuel Rack
Card Position sensor Pressure Sensor Loco
Module Pressures
Pressure
Sensor Signals
LOP, BAP,
FOP
Eng. RPM Notch It receives pressures from loco and
Tacho / Control convert them into electrical signals. It
ESS Desk communicates to the input card.
Control Unit
 RESISTOR BOX

MOTOR & CLUTCH

CONNECTOR
CONTROL
SENSOR CONNECTOR UNIT
COMMUNICATION CONNECTOR
REAR VIEW
INPUT & OUTPUT CONNECTOR

EARTHING STUD
FUEL RACK DRIVE
RACK SHAFT WITH FRP SENSOR

CLUTCH

MOTOR

GEAR BOX
 FUEL RACK DRIVE

SPRING GREASE NIPPLE

BELLOW

OUTPUT SHAFT
PRESSURE SENSOR SUB
ASSEMBLY
FRP
CONNECTOR
FILTER

FOP LOP BAP

SENSOR SENSOR SENSOR
SENSOR
CONNECTOR

PRESSURE INPUTS
Salient features of
MCBG
 Salient Features
• Functionally plug-in modules.
– Defective sub-assembly can be replaced in position
• Minimum internal wiring to increase reliability.
• A powerful 16 bit micro controller with stepper motor
and digital PID control for precise positioning of fuel
rack.
– Smooth control of fuel rack and no hunting.
• Electromagnetic clutch for automatic shutdown.
– Immediate return of fuel rack to zero position.
 Salient Features
• On line tuning of parameters through LAPTOP to
optimise the performance.
– Very quick tuning of governor with out down
loading.
• Adaptability for deferent class of locomotives.
– All most all parameters are made user settable to suit for
deferent class of locomotives.
• Security against un-authorised access to governor
parameters.
 Salient Features
• User friendly menu driven software for
– view / set parameters
– Down load error log to laptop / PC
• Bigger display:
– 20 character X 4 line VFD display for clear visibility.
• Fuel rack position sensor failure made fault tolerant:
– Loco can work with out any problem even fuel rack position
sensor failed.
• Failure of BAP sensor, the governor automatically
disables the BAP based rack limitation.
– Manual bypass is also available in case of problem with loco.
Advantages of
MCBG
 Advantage of Medha MCBG
over other Governors.
• Zero running maintenance up to 5 years.
– No oil and moving parts.
• No Schedule maintenance up to 48 months
– Against 24 months of conventional governor.
• Minimal Overhauling time after 48 months
– Matter of 1 day against 3 to 4 days.
• Easy break down maintenance without unloading.
– Being modular system, the defective module can
be replaced.
• Display of engine related parameters for the driver.
 Advantage of Medha MCBG
over other Governors.
• Error log and Fault diagnostics.
– Errors with real time and date are recorded in
non volatile memory and can be down loaded
to a Laptop
• Notch wise run hours are recorded and can be
down loaded to Laptop.
– To facilitate load factor calculation in a section
• Low engine cranking time
– 5 to 10 seconds as against 25 to 30 seconds.
Saves battery life.
Advantage of Medha MCBG
over other Governors.
• Precise control of Fuel rack trough stepper motor.
– Against Hydraulic/Electro hydraulically operated pilot
valve.
– Practically no hunting. Increase fuel efficiency.
• Independent Notch wise engine RPM setting.
– In other governor certain notch RPMS are interdependent
on other notch RPMs.
• Independent notch wise Low lube oil shut down Pressures.
– In GE/EDC governor only one setting from 1 to 8 notch
– In Woodward governor Idle and 8th notch settings only.
Intermediate notch settings are not possible.
Advantages of Medha MCBG
over other Governors.
• Tuning of governor is digital setting through Laptop.
– Against spring adjustments on trial and error in
Woodward governor.
• Dry run test facility to test free travel of the rack
– To test free travel of the fuel rack.
• Mechanical OSTA test facility
– Not available with Woodward Governor
• Electrical OST test facility
– Additional feature over other governors.
 Installation
• The MCBG is designed for WDM & WDG series class of
locomotives.
• The MCBG actuator unit is designed to suit W/W governor
base with out any change in fuel linkage.
• The MCBG control unit is designed to suit for W/W
governor wiring scheme.
• However Amphenal plug wiring has to be replaced with
new cable and connector supplied along with the unit.
• To replace 17MG-8 (GE/EDC) governor:
– Governor base is required to change to W/W governor base .
– Electrical wiring scheme has to be changed to W/W governor
scheme.
Advanced Features
 Display Parameters
• Displays the following
Diesel Engine parameters:
– LOP (Lube Oil pressure)
– FOP (Fuel Oil Pressure)
– BAP (Booster Air Pressure)
– Notch (Notch position)
– Engine RPM
– LCP (Load Control Position)
• These parameters are
continuously monitored and
displayed on the screen.
 Fault Diagnosis
• On line Fault Diagnostics.
• Display fault Message with
Hooter Sounding
• Error Log with Real Time and
Date in Non Volatile Memory.
Hooter
• The driver needs to press the
acknowledge button for certain
severe faults.
• Error log can be Down Loaded to Acknowledge
Button
a LAPTOP/PC
• Notch wise diesel engine run
time counter is provided to
conduct Load factor trials.
 Test Facilities
• Being micro controller based governor,
and electronic OSTA has been
OSTA
provided to shut down the engine in Test KEY
case of engine over speeding.
• This electronic OSTA trips before the
mechanical OSTA. This is an
additional feature.
Dry Run
• Facility to test both electronic and
Push button
mechanical OST through key lock
switch
• Dry run test through push button.
 SYSTEM SPECIFICATION
• OPERATING SUPPLY VOLTAGE : 40 V to 90 V DC
– Can accept a Voltage dip of 22 V DC for 0.8 sec during Cranking
• USER SETTABLE SPEEDS
– Provision for setting speeds for the eight independent notches.
• LOAD CONTROL
– From maximum to minimum field position change in 8.5 to 11 sec.
– From minimum to maximum field position change in 25 to 30 sec.
• PRESSURE SENSORS
– BOOST AIR pressure range from 0 to 3 Kg / Sq Cm
– FUEL OIL pressure range from 0 t o 6 Kg / Sq Cm
– LUBE OIL pressure range from 0 to 10 Kg / Sq Cm
• DISPLAY
– 20 Character X 4 Line Alpha Numeric VFD
• ACTUATOR UNIT
– Working capacity > 16.3 N m
– Rack Travel from 0 to 30 mm
 MEG 601
Mr. SHASIKANTH REDDY (MGR/MKTG)
098852 86611
Mr. T TIRUVENGALAYYA (MGR/CS)
098852 29200
Mr. A RAJESH KHANNA (ENGR/CS)
098852 65097
Mr. R ANIL KUMAR (PRODUCT ENGR)
098852 65098
THANK YOU