Design Calculation and Verification using SIMPACK Wheel/Rail€¦ · · 2009-03-30using SIMPACK...
Transcript of Design Calculation and Verification using SIMPACK Wheel/Rail€¦ · · 2009-03-30using SIMPACK...
November 6, 2001
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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
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13.-14.11.2001 3C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
NSB EMU Class 72:
Regional Trainwith Single Axle Running Gears
Motor bogie (MB) Coupled single axle running gears (EAF)
MB MBEAF EAF EAF
13.-14.11.2001 4C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
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
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13.-14.11.2001 5C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
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
13.-14.11.2001 6C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
SIMPACK Model:
Light Rail Transit Car GTW 2/6Southern New Jersey Transit
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
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13.-14.11.2001 7C. Kossmann, SIMPACK User Meeting 2001
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
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
Stability Analysis:
Light Rail Transit Car GTW 2/6Southern New Jersey Transit
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]
13.-14.11.2001 8C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
Calculation of forces for fatigue investigation, e.g.:
Light Rail Transit Car GTW 2/6Southern New Jersey Transit
u Simulation of curving through 40 m curve
u Evaluation of forces relevant for structuralmechanics
u FEM calculation
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13.-14.11.2001 9C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
Sidewind Analysis
Light Rail Transit Car GTW 2/6Southern New Jersey Transit
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:
13.-14.11.2001 10C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
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
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13.-14.11.2001 11C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
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)
13.-14.11.2001 12C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
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
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13.-14.11.2001 13C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
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
13.-14.11.2001 14C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
BR 128 (Lok 12X) Co-Simulation with MATLAB SIMULINK
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)
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13.-14.11.2001 15C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
BR 128 (Lok 12X) Co-Simulation with MATLAB SIMULINK
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
13.-14.11.2001 16C. Kossmann, SIMPACK User Meeting 2001
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
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
BR 128 (Lok 12X) Co-Simulation with MATLAB SIMULINK
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
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13.-14.11.2001 17C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
BR 128 (Lok 12X) Co-Simulation with MATLAB SIMULINK
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
13.-14.11.2001 18C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
BR 128 (Lok 12X) Co-Simulation with MATLAB SIMULINK
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
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13.-14.11.2001 19C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
BR 128 (Lok 12X) Co-Simulation with MATLAB SIMULINK
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
13.-14.11.2001 20C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
BR 128 (Lok 12X) Co-Simulation with MATLAB SIMULINK
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
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13.-14.11.2001 21C. Kossmann, SIMPACK User Meeting 2001
Design Calculation and Verification using SIMPACK Wheel/Railat Bombardier Transportation, Winterthur
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