Design Calculation and Verification using SIMPACK Wheel/Rail€¦ · · 2009-03-30using SIMPACK Wheel/Rail ... uthe narrowest curve uRunning with maximum speed on straight track

November 6, 2001

1

Design Calculation and Verification

C. Kossmann, SIMPACK User Meeting 2001

using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur

13.-14.11.2001 2C. Kossmann, SIMPACK User Meeting 2001

Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur

Bombardier Transportation, Site WinterthurBusiness Unit Bogies

Competent for

u Single Axle Running Gears

u Bogies for Regional Trains

u Bogies for Locomotives

u Bogies for Intercity Trains

Using SIMPACK for projects since April 2000

November 6, 2001

2



NSB EMU Class 72:

Regional Trainwith Single Axle Running Gears

Motor bogie (MB) Coupled single axle running gears (EAF)

MB MBEAF EAF EAF



NSB EMU Class 72:

u Running quality calculationswith elastic carbody structure byINTEC GmbH in 1999

u By practicable changes on thecarbody and on the bogies thespectra of the carbodyaccelerations were improved

u Results of the Running QualityType Test in Norway (Summer2001) show good agreement withsimulation results

Original spectrum of verticalcarbody accelerations

Improved spectrum of verticalcarbody accelerations

November 6, 2001

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u Bogies based on LVT 646 (DB AG) andGTW Hessische Landesbahn

Light Rail Transit Car GTW 2/6Southern New Jersey Transit

u Trailer bogie new designed to enable running through 40 mcurves



SIMPACK Model:


u Articulated vehicle (3 carbodies)

u Motor bogie under Power Unit

u Used Force Elements:Spring-Damper Elements (parallel, seriell)Friction Element

u 2 trailer bogies with smaller wheels

November 6, 2001

4


Wheelset 2 (TRL)5% damping

v=115 km/h (71.5 mph)

-2.0

-1.5

-1.0

-0.5

0 .0

0 .5

1 .0

1 .5

2 .0

0.0 0.5 1 .0 1.5 2.0

Time [s]

Late

ral d

ispl

acem

ent

[mm

]

Wheelset 2 (TRL)0% damping

v=137 km/h (85 mph)

-2.0

-1.5

-1.0

-0.5

0 .0

0 .5

1 .0

1 .5

2 .0

0.0 0 .5 1 .0 1.5 2.0

Time [s]

Lat

eral

dis

pla

cem

ent

[mm

]

Chart of StabilityVehicle Tare Weight

0

25

50

75

100

125

150

175

200

225

250

275

300

0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6

Conicity λ

Cri

tica

l Sp

eed

[km

/h]

0

20

40

60

80

100

120

140

160

180

Cri

tical

Spe

ed [

mph

]

D=0% trailer truck D=5% trailer truckD=0% motor truck D=5% motor truckVlimit=106 km/h=66 mph

motor truck

trailer truck


Stability Analysis:


u Parameter Variation with linearizedwheel/rail contact:Not possible with two wheelset types

u Stability investigation with linearwheel/rail contact in time domain withfriction element

u Simulation with track irregularitiesand high conicityEvaluation of lateral acceleration atthe bogie frames

Lateral acceleration at truck frame above axlebox 1 (TRL)

- 8- 6- 4- 202468

0 5 10 15 20 25 30Time [s]

Acc

eler

atio

n [m

/s2]



Calculation of forces for fatigue investigation, e.g.:


u Simulation of curving through 40 m curve

u Evaluation of forces relevant for structuralmechanics

u FEM calculation

November 6, 2001

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Sidewind Analysis


u the narrowest curve

u Running with maximum speed on straight track withirregularities

u Running slowly through a curve with maximum superelevation

Evidence that Q > 0 and Y/Q below the limit value for:



CP 2000:Regional Train with Jacobs Bogies

• Simulation model made by INTECGmbH in 2000

• Modification of the simulation modeland Running Quality Calculations byBombardier Transportation(Switzerland) in Pratteln

• Eigenvalue and Stability calculationsby Bombardier Transportation(Switzerland) in Winterthur

⇒ Dynamic simulation project atdifferent sites with SIMPACKpracticable

November 6, 2001

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SIMPACK “Lok-Pool”

u BR 145u BR 146u BR 101

Complete parameterization ofLocomotives models:

Substructures: Bogies and CarbodiesParameters: mass properties, marker

position, stiffness anddamping values

u Blue Tigeru BR 128 (12X)



BR 128 (Lok 12X)Co-Simulation with MATLAB SIMULINK

SIMPACK modelw originated from completely parameterised BR 146 modelw substructures: bogies and carbodyw adaptation to 12X data

November 6, 2001

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BR 128 (Lok 12X) Co-Simulation with MATLAB SIMULINK

Hollow shaft

Gear wheel

Coupling betweengear wheel andhollow shaft

Rotor and pinion

Motor and gear box(Wire frame)

Gear box suspensionat head beam

Motor suspension atcross beam

Lateral motor damper

Detailed drive model

- Hollow shaft

- Gear wheel

- Pinion and Rotor

- Motor and gearbox




Hollow shaft

Right wheel

Coupling betweenwheel and hollowshaft

Torsional stiffnessof wheelset shaft

Left wheel

Wheelset with torsional-elastic axle Eigenmodes of drive

„Rattern“ (21.7 Hz)

„Rollieren“ (49.2 Hz)

November 6, 2001

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Necessity of extension of wheel/rail contact model

u Possible for use in vehicledynamics (small creep)

u Used for longitudinal and lateraldirections

u Function of creep

u Necessary for drive dynamics(large creep - slip)

u Usually used only forlongitudinal direction

u Function of slip velocity

Creep

Cre

ep f

orc

e

dry

wet

Vehicle Dynamics

Slip velocity

Cre

ep f

orc

e

dry

wet

Drive Dynamics User routine for thefriction law ofwheel/rail contact force


0

0.1

0.2

0.3

0 5 10 15 20 25creep [%]

adh

esio

n c

oef

fici

ent

40 km/h, Approximation 40 km/h, Measurement20 km/h, Approximation 20 km/h, Measurement60 km/h, Approximation 60 km/h, Measurement



Approximation of measured creep force function

Measurement with 12X (watered rail )Evaluation of

w maximum friction coefficient µ0

w ratio of µ∞ (limit friction coefficient

at infinity slip velocity ) to µ0

w coefficient of exponential friction

decrease

w Kalker factor in area of adhesion

w Kalker faktor in area of slip

November 6, 2001

9




Implementation of mechanical model in SIMULINK control

SIMPACK output:

w Rotating speed of rotor 3

w Rotating speed of rotor 4

w Velocity

SIMPACK input:

w Driving torque of rotor 3

w Driving torque of rotor 4




Simulation results: Starting up on straight track with variable friction coefficient

Driving torques

-12'000

-10'000

-8'000

-6'000

-4'000

-2'000

0

0 5 10 15 20 25 30Time [s]

Torq

ue [N

m]

Driving torque 3 Driving torque 4 Desired torque

Vehicle velocity

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

0 5 10 15 20 25 30Time [s]

Vel

oci

ty [m

/s]

Friction coefficient

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0 20 40 60 80 100

Distance [m]

mu

e

left rail right rail

November 6, 2001

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Longitudinal creep force / Normal force

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.00 0.05 0.10 0.15 0.20 0.25 0.30

Creep

Cre

ep f

orc

e ra

tio

T/N

Tx4 l / N4 l Tx4 r / N4 r

Simulation results: Starting up on straight track with variable friction coefficient

Longitudinal creep

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0 5 10 15 20 25 30Time [s]

Cre

ep

sx3 r sx3 l sx4 r sx4 l

Longitudinal creep forces

0

5'000

10'000

15'000

20'000

25'000

30'000

35'000

0 5 10 15 20 25 30Time [s]

Fo

rce

[N]

Tx3 r Tx3 l Tx4 r Tx4 l




Simulation results: Starting up on straight track followed by curvingComparison with measurements with 12X (Kanderviadukt, Aug. 2001)

Forces in axle rods (difference right-left)

-20'000

-15'000

-10'000

-5'000

0

5'000

10'000

15'000

20'000

0 100 200 300 400 500 600 700 800 900Distance [m]

Fo

rce

[N]

Fx3 measured Fx4 measured Fx3 calc. Fx4 calc.

300m right curve 385m left curve 290m right curve

November 6, 2001

11



Present and further activities

4 System Locomotive:New bogies based on BR 145/146:

w Unsuspended Drivew Suspended Drive

w Each variation with or without couplingsystem for radial steering

Co-simulation:

w Getting more experience using SIMATw Building up additional know-howw Applying co-simulation in further fields of bogie engineering

Documents

Design Calculation and Verification using SIMPACK Wheel/Rail€¦ · · 2009-03-30using SIMPACK Wheel/Rail ... uthe narrowest curve uRunning with maximum speed on straight track