ELECTRONIC GOVERNOR

MICRO CONTROLLER BASED GOVERNOR

(MCBG)
TYPE - MEG 601

® M e d h a Se r v o D r i v e s P v t . L t d .
2 - 3 - 2 /A , C h e r l a p a l l y , H y d e r a b a d 5 0 0 0 5 1 . In d ia . P h - 0 4 0 - 2 7 2 6 4 1 4 4
 Types of Governors
®

on Diesel Electric Locos

 Electro Hydraulic Governor Type-17MG8

 GE & EDC

 Hydraulic Governor
 Woodward

 Electronic Governor
 Medha, Steasalit, Woodward, Laxven and BHEL.
 ® 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 governor in Diesel Electric
Locomotives
• The diesel engine generates the
power.
• The mechanical power is converted in
to electrical power by the Tr.
Alternator. Diesel Tr. HP
Engine Alt.
• The out HP from the Tr. Alt.
connected to Tr. Motor and the
locomotive moves. Fuel
Rack
Governor
• In a diesel engine the HP is
proportional to its RPM. The engine Excitation
Control
speed is selected by driver. The HP
generated at the selected notch
speed is proportional to the quantum
of fuel and inlet air per cylinder.
• The governor should control the fuel
rack to maintain constant engine
RPM.
 ® Working Principle of Governor

• Advance the fuel rack during

cranking
• Control the fuel rack to maintain
engine RPM at the set speed.
Diesel Tr.
 To maintain engine RPM, the HP
LOP Engine Alt.
• Increase
engine/ Decrease the
RPM signal is engine
taken as an
RPM as per the operator’s request.
input.
 Notch signal is taken as an input. Fuel
Rack
• Withdraw fuel rack to Shut down Governor
the engine when lube oil pressure is Eng.RPM
Excitation
dropped. Control
 Lube oil pressure signal is taken
as an input. Notch
• Reduces the excitation under
Control
overload.
 Load control signal is given to Desk
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
Diesel Tr.
pressure is boosted up by turbo HP
(BAP). LOP Engine Alt.
• If BAP is normal, sufficient air is
available for complete burning of Fuel
fuel. Rack
Governor
• Less BAP means in-sufficient air and Eng.RPM
Excitation
fuel is wasted. Control

• Hence to be fuel efficient, the Notch

governor should control the fuel rack
based on the BAP. Control
Desk
 BAP signal is taken as an input.
 Micro Controller Based Governor
®

(MCBG)

• In addition, the fuel oil

BAP Turbo
Pressure signal is also
taken as an input in
MCBG. FOP Diesel Tr. HP
LOP Engine Alt.

• The MCBG has been Fuel

Rack
divided in to two parts Governor
Eng.RPM Excitation
Control
Actuator Unit
Notch
Control Unit
Control
Desk
 Micro Controller Based Governor
®

(MCBG)

 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 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)

MEG 601
 Micro Controller Based Governor
®

(MCBG)
CONTROL UNIT ACTUATOR UNIT
 Block diagram of
®

MCBG
CONTROL UNIT The control unit is again functionally
ACTUATOR UNITdivided into 6
modules.

Display &
The governor works on 72V DC.
72V Power Supply The power supply module derive low voltages
Card
required for other modules.
Display loco parameters.
Load & Clutch
Control Card Provides supply for the clutch coil in the actuator unit.
Provides load control signal to excitation.
Stepper Motor
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
®

MCBG
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 Notch,
Load & Clutch Engine Speed, Fuel Rack position and pressure
Control Card signals etc., from the input card.

Control Stepper Motor

Card Cards (2)
It communicate these parameters to display unit.
Input
Card
 Block diagram of
®

MCBG
CONTROL UNIT
• The driver sitting at control desk opens the notch
Display & to the required position.
• The notch signal is communicated to the input
72V Power Supply card.
Card

Load & Clutch • The control card decides the engine

Control Card RPM for the selected notch.
• Existing RPM is compared with new
RPM level.
Control Stepper Motor
Card Cards (2)

Input • The control card computes the stepper

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

MCBG
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 motor cards communicate this drive signal
Tacho / Control to the stepper motor in the actuator unit.
ESS Desk
 Block diagram of
®

MCBG
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 as
Tacho / Control controlled by the control card.
• The motor torque is amplified through gear box.
ESS Desk
 Block diagram of
®

MCBG
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 pinion
Tacho / Control through an electro magnetic clutch.
ESS Desk
 Block diagram of
®

MCBG
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 & clutch
Tacho / Control control card soon after the MCBG is powered up.
ESS Desk
 Block diagram of
®

MCBG
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 new
Tacho / Control position against over travel spring.
ESS Desk
 Block diagram of
®

MCBG
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 Position sensor
sensor
Card
The fuel rack position sensor provide a feed
back signal to the input card and from there it
Eng. RPM Notch
is communicated to the control card. The cycle
Tacho / Control repeats till the required RPM is reached.
ESS Desk
 Block diagram of
®

MCBG
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 Position sensor
sensor
Card
The Control card de-energises the clutch
coil under emergency shutdown. Due to
Eng. RPM Notch
the spring force the output shaft returns
Tacho / Control back to 0 position.
ESS Desk
 Block diagram of
®

MCBG
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 Position sensor
sensor
Card
The control card increases the load
control voltage through Load & clutch
Eng. RPM Notch
control card to reduce the excitation
Tacho / Control under over load conditions.
ESS Desk
 Block diagram of
®

MCBG
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 Position
sensor
Card Pressure Sensor
Module

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

Tacho / Control called pressure sensor module.
ESS Desk
 Block diagram of
®

MCBG
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 Position
Card sensor Pressure Sensor Loco
Module Pressures
Pressure Sensor
Signals LOP, BAP,
FOP
Eng. RPM Notch It receives pressures from loco and convert
Tacho / Control them into electrical signals. It
ESS Desk communicates to the input card.
® CONTROL UNIT

REV 1.0 CU
INSIDE VIEW
® CONTROL UNIT

RESISTOR BOX

CONTROL UNIT (Rev

MOTOR & CLUTCH CONNECTOR 1.0)
SENSOR CONNECTOR REAR VIEW
COMMUNICATION CONNECTOR

INPUT & OUTPUT CONNECTOR

EARTHING STUD
 ® ACTUATOR UNIT

RACK SHAFT WITH FRP SENSOR

CLUTCH

MOTOR

GEAR BOX
 ® ACTUATOR UNIT

SPRING GREASE NIPPLE

BELLOW

OUTPUT SHAFT
 PRESSURE SENSOR SUB-
®

ASSEMBLY

FRP
CONNECTOR
FILTER

FOP LOP BAP

SENSOR SENSOR SENSOR
SENSOR
CONNECTOR

PRESSURE INPUTS
 ® REV 2.0 CONTROL UNIT

HEALTH STATUS
LEDS

ESS / TACHO
SELECTION
DIGITAL INPUT
SWITCH
STATUS LEDS
® REV 2.0 CONTROL UNIT

RESISTOR BOX

ESS CONNECTOR

CONTROL UNIT (Rev

MOTOR & CLUTCH CONNECTOR
2.0)
SENSOR CONNECTOR REAR VIEW
COMMUNICATION CONNECTOR

INPUT & OUTPUT CONNECTOR

EARTHING STUD
 ® CHANGES IN MCBG REV-02

 MCBG is made compatible to work with engine speed signal

either from Tacho Generator or from Microprocessor Control
system (Engine Speed sensor signal).

 A Toggle Switch is provided on MCBG Control card to select the

engine speed signal either from Tacho Generator or
Microprocessor Control System.

 Control unit, Input card, Control card, and Power Supply cards
were modified to suit the new requirement of MCBG Rev.2.
These cards are not interchangeable with MCBG Rev.1.
 ® CHANGES IN MCBG REV-02

 In the Control card working status indication LED is provided to

know the healthiness of the card.

 In Input card LEDs are provided to know the working status of

individual Digital input channels.

 Additional Cable with connector's is required to connect the Engine

Speed signal from Microprocessor Control System

 While working with Microprocessor Control System, MCBG will do

automatic changeover from one ESS to another, if one ESS fails
and vice versa.
® ACTUATOR UNIT CHANGES

PRS BOX SHIFTED TO NOSE

COMPARTMENT

CONNECTORS SHIFTED
FOR EASE OF ACCESS
 CHANGES SUGGESTED BY
®

RDSO

 Shifting of Pressure Sensor box fitment location of MCBG from

the Actuator unit to Nose compartment and shifting of MS
Round connectors in MCBG Actuator unit.
 This Modification will be implemented in existing field units

also. Modification is on Cost basis and on Shed interest.

 Display of Fuel Oil Pressure reading in MEP Driver Display

mode.
 This Modification was implemented in Production units

from Feb’ 09.

 INTERCHANGIBILITY IN REV 1 & 2 GOVERNORS
®
(SUB ASSEMBLIES)

 Actuator units are interchangeable.

 Control unit, control card, input card and power supply cards are not
interchangeable.

 Remaining cards like MEGMC, MEGLC are interchangeable between

old and new governors.

 Rev 1 Governor is not suitable to use with ESS.

 Improvements done in
®
MEG-54 Software

 During cranking time, if engine RPM is not received to MCBG

for certain time, then bringing back fuel rack to zero (No fuel)
position.
 Fuel Pump Breaker Tripped or Low FOP fault added.
 During cranking time, if engine RPM is not building up more
than 200 RPM then moving the fuel rack to 30 mm after 10 sec.
 Updation of MCBG time with GPS time when loco is provided
with MEP (2A or 3.06) & LRMS.
 To avoid Engine overshooting at the time of cranking when no
Engine RPM to MCBG.
 Improvements done in
®
DSP21 or DSPN21 Software

 Fuel Pump Breaker Tripped or Low FOP fault

message added.
 Tacho based messages are replaced with Tacho/
ESS.
 Cranking Abandoned & Failed to crank due to No
Engine RPM signal messages are added.
 ® REV 3.0 CONTROL UNIT

PEN DRIVE /
LAPTOP
SELECTION
 ® CHANGES IN MCBG REV-03

 Notch, Engine RPM and LCP signals through

communication. If Comm. fails, it will switch over to
hardware.

 New Micro controller adopted to suit the new requirements.

 From Sept’ 2011 onwards started in regular production.

 CU NO: 4004

 AU NO: 3627
 ® CHANGES IN MCBG REV-03

 Hardware Changes:
 FDP – 15 sec (10 sec prior and 3 sec later to the fault)

 Not in the RDSO Specification

 Pen Drive for data downloading (in shutdown only)

 RS 232 communication for data down loading and configuration

 USB for data down loading (FDP)

 ODL feature (additional hardware): Through RS 232 port.

 ® CHANGES IN MCBG REV-03

 Hardware Changes:

 LED’s on the front fascia of MCBG

 (A) Health Blink Green

 (B) Fault OFF Red

 (C) RTC / USB Blink Yellow

 (D) +5V for CC ON Yellow

 ® CHANGES IN MCBG REV-03

 Software Changes:
 Low Fuel oil pressure (or) Fuel pump breaker tripped.

 Avoiding ERPM overshooting during cranking, in case of ESS signal

missing, MCBG brings the fuel rack to zero position

 Time delay reduced from 20 to 10 sec, if ERPM is less than 200

rpm

 “Tacho/ESS” text changed in fault message

 MCBG RTC updation from MEP through communication for every

Power ON / day change. This is effective from MEP V-3 (3.06) and
above & 2A.
 Salient features of MCBG

® M e d h a Se r v o D r i v e s P v t . L t d .
2 - 3 - 2 /A , C h e r l a p a l l y , H y d e r a b a d 5 0 0 0 5 1 . In d ia . P h - 0 4 0 - 2 7 2 6 4 1 4 4
 ® Salient Features

 Functionally plug-in modules.

 Defective sub-assembly can be replaced in position
 Minimum internal wiring to increase reliability.
 A 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 different class of locomotives.
 All most all parameters are made user settable to suit for
different 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

® M e d h a Se r v o D r i v e s P v t . L t d .
2 - 3 - 2 /A , C h e r l a p a l l y , H y d e r a b a d 5 0 0 0 5 1 . In d ia . P h - 0 4 0 - 2 7 2 6 4 1 4 4
 Advantage of Medha MCBG
over other Governors.
®

• Zero running maintenance up to 4 years.

• No Schedule maintenance up to 48 months
– Against 24 months of conventional governor.
• 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 through 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.
 Advantage of Medha MCBG
over other Governors.
®

• Tuning of governor parameters are 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.
 Advanced Features

® M e d h a Se r v o D r i v e s P v t . L t d .
2 - 3 - 2 /A , C h e r l a p a l l y , H y d e r a b a d 5 0 0 0 5 1 . In d ia . P h - 0 4 0 - 2 7 2 6 4 1 4 4
 ® 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.
Hoote
 The driver needs to press the r
acknowledge button for certain
severe faults.
 Error log can be Down Loaded to a
LAPTOP/PC Acknowledge
Button
 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 provided to
shut down the engine in case of engine OSTA
over speeding. Test KEY

 This electronic OSTA trips before the

mechanical OSTA. This is an additional
feature.
 Facility to test both electronic and
mechanical OST through key lock switch Dry Run
 Dry run test through push button. Push
button
 ® 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.
 ® 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 RPMs
 Provision for setting RPMs 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 3.5 Kg / Cm²
 FUEL OIL pressure range from 0 t o 6 Kg / Cm²
 LUBE OIL pressure range from 0 to 10 Kg / Cm²
 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

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® Training Team

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