Clayton Equipment CB40 Locomotives For London Underground Ltd

London Underground was the first, and is one of the busiest, passenger metro systems in the world. Since 1863, the network in, and under, the British capital has enabled London to become one of the preeminent world cities. It is estimated that 1.27 billion journeys are made yearly on the network, a figure projected to rise to 1.5 billion by 2023.

Locomotive Prior To Conversion

Locomotive Prior To Conversion

Regular maintenance is required to meet this demand and currently a renewals programme valued at approximately £2 billion is underway, as London Underground moves towards a 24-hour service. To help this happen, Clayton Equipment is in the process of converting 14 old Schoma diesel locomotives to Clayton Equipment CB40 specification battery-electric traction.

Where other companies said that the work was not possible within the timeframe required by London Underground, Clayton Equipment, with its history and expertise of electric locomotives and battery technology, said that it was!

Working closely together, Clayton Equipment with their experience of building mainline, tunnelling and mining locomotives for over 75 years, and London Underground with their knowledge of operational constraints and a unique range of signalling systems, ensured that the tight programme was realised.

Clayton Equipment’s solution for London Underground

The project involved the conversion of the noisy, smelly and polluting diesel locomotives, which were prohibited from operating inside the deep tube underground network, to electric (battery and 3rd/4th rail) tractive power.

Locomotive 3D CAD Modelled

Locomotive 3D CAD Modelled

Clayton Equipment CB40 Hauling 130 Tonne Load For Duty Cycle Endurance Testing

Key features of the project are:

  • Removal of all diesel related components and systems
  • Ensuring the locomotives are kinematic gauge compliant
  • Design the new electric traction system, including:
    • Full 3D CAD design with FEA
    • On-board battery charging; by regenerative braking, from the traction rail power and from the depot shore supply
    • Hydrogen gas monitoring
    • Operational from both the 3rd/4th traction rails and the on-board battery
    • Maintaining the operability of the signalling systems
    • Sufficient battery capacity to cater for the arduous duty cycle
    • Sufficient power and torque to haul 120 tonnes; negotiate 1:30 gradients; and to travel at up to 49 kph.
  • Chassis, suspension and brake modifications
  • Interface with the existing PLC and to provide tandem operation
  • Additional new features, including:
    • Retractable Sleet Brushes to aid traction, ready for winter
    • Retractable 3rd and 4th rail shoe gear
    • Driver’s information display
    • 340v DC, 32A and 90A auxiliary power sockets
    • Depot shore supply sockets
    • USB and 12v DC auxiliary cab supplies
    • Paint overhaul
    • New jumper cables and connectors
    • An improved driver’s seat
    • A cab heater and air conditioning system
  • Full approvals, including product acceptance, EMC testing and track testing
  • Operator, Maintenance and Parts Manuals, together with Operator and Maintainer training

Product Realisation

Clayton Equipment CB40 On Test Hauling A 130 Tonne Load Up A 1:30 Gradient

Locomotives Being Converted At Clayton Equipment

Locomotives Being Converted At Clayton Equipment

Locomotives Being Tested At Wirksworth, Derbyshire

Locomotives Being Tested At Wirksworth, Derbyshire