Modularization of High Voltage Section

Abstract: Today, Alstom has several types of High-Voltage sections (HV), which are adapted for every new type of train. Some are very similar in size and components and others are more different. The purpose of this master's thesis was to come up with a way to split this HV box into smaller modules and assemble them using frame- and fastener concepts to simplify the manufacturing and assembly of the HV section. The work consisted of concept generation in parallel or both the frames and fasteners, then evaluating them through matrices using different priorities and parameters. The detail-construction used supported simulations and discussions with Alstom to come up with the final product while incorporating the existing demands of lifespan, durability, and IP-rating. The result was two different fastening concepts between modules which were named “Twist Lock” and “Corner Cut”. They are both using a frame design that utilized adaptable plates that differentiated depending on the intended purpose of the module and its placement in the configuration. The majority of the frame is standardized for all modules while smaller gland plates with different electrical connections are placed depending on the internal components. The fasteners were chosen for ease of assembly according to set strength requirements. “Corner Cut” uses the corners on the exterior of the frame to assemble using bolts and nuts. The “Twist Lock” concept is fastened through the interior and the frame was adjusted so that assembly does not interfere with the internal components. If one of the concept is chosen to be used, Alstom will be able to offer eight different configurations, instead of the two configurations that they have today. To proceed, the attachment must be tested practically based on the set strength requirements.