Development of propulsion systems for electric rail vehicles

The design of high-performance propulsion systems for rail transport requires vertically integrated development structures to handle demanding thermal and electrical load profiles. At InnoTrans 2026 (September 22 to 25, 2026, Messe Berlin, Hall 9, Stand 621), Hirect presents a completely in-house developed 6,000 HP locomotive propulsion system, demonstrating the technical capabilities of its power electronics. This industrial initiative addresses the operational requirements for highly efficient energy conversion, thermal stability under extreme operating conditions, and seamless integration into existing and new rolling stock fleets.

Technical Solution and Responsibilities
The presented system comprises liquid-cooled IGBT traction converters, proprietary control software, traction transformers, and traction motors. As a vertically integrated manufacturer, Hirect is responsible for the entire value chain, ranging from internally manufactured electrical windings to control algorithms. The hardware and software architecture features a modular design, supporting deployment in heavy freight locomotives (such as the WAG-9 class under demanding thermal conditions) as well as in modern Mainline Electric Multiple Unit (MEMU) trainsets.

The system architecture relies on precise monitoring parameters for power electronics and thermal management. The modular approach enables utilization as new-build technology or within the scope of retrofit and hybrid programs.

Deployment and Implementation
Validation of the 6,000 HP propulsion system was achieved through successful freight operations in WAG-9 locomotives under the rigorous operating conditions of the Indian rail network. Building upon this, the current implementation project for the Modern Coach Factory (MCF) of Indian Railways encompasses the supply of complete propulsion systems for four MEMU trainsets within a 24-month program. This project includes the integration of the Train Control and Management System (TCMS) alongside transformers and motors.

Applications and Operational Impact
Target applications comprise high-performance freight transport, electrified regional and commuter traffic, and the modernization of existing rolling stock fleets. Concrete use cases involve energy-efficient operation under extreme thermal loads and the seamless transition from diesel to electric as well as hybrid propulsion concepts.

Resulting operational benefits include increased system availability, improved thermal durability of power components, and precise control of traction energy through the complete in-house development of hardware and software.

Regarding the technological orientation of the platform, Suramya Nevatia, Chairman & Managing Director of Hirect, stated: “Powering Indian Railways locomotives with a propulsion system designed and produced entirely in-house, and delivering the complete power and control systems for modern trainsets, demonstrates the strength of our R&D and our ability to take responsibility for the whole system  from the dielectric coating on our copper wire to the control software.”

Edited by Sucithra Mani, Induportals editor – adapted by AI.

www.hirect.com