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Transcript of Impact of running gear design on train energy consumption partner, is RUN2RAIL (Innovative Running...

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    Faculty of Civil and Industrial Engineering

    Master’s Degree in Transport Systems Engineering

    Mohamed Nabil Mohamed Mohamed Elsayed Eldigwi

    Matricola 1187465

    Supervisor Co-Supervisor

    Prof.Gabriele Malavasi Prof. Riccardo Licciardello

    A.A. 2017-2018

    Impact of running gear design on train energy consumption

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    Impact of running gear design on train energy

    consumption

    Faculty of Civil and Industrial Engineering

    Master’s Degree in Transport Systems Engineering

    Mohamed Nabil Mohamed Mohamed Elsayed Eldigwi

    Matricola 1187465

    Supervisor Co-Supervisor

    Prof. Gabriele Malavasi Prof. Riccardo Licciardello

    A.A. 2017-2018

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    Acknowledgments

    I would like to express my sincere gratitude to my supervisor Prof. Gabriele Malavasi,

    Dr.Riccardo Licciardello, Marco Antongnoli and Massimiliano Bruner for the

    continuous support of my master study and research, for the patience, motivation,

    enthusiasm, and immense knowledge. Their guidance helped me in all the time during

    my research and during writing my thesis.

    I would like to thank every faculty member namely Professors Stefano Ricci, Guido

    Gentile, Mattia Giovanni Crespi, Antonio Musso, Paola Di Mascio, Gaetano Fusco,

    Massimo Guarascio and Liana Ricci, who have taught and guided me in all aspects.

    I was one of the fortunate students who had the privilege of being taught by such

    esteemed professors.

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    Index

    INTRODUCTION ...................................................................................................................................... 1

    STATE OF ART ...................................................................................................................................... 3

    OBJECTIVES: ........................................................................................................................................ 5

    1 THE ANATOMY OF RAILWAY RUNNING GEAR ..................................................................................... 6

    1.1 MAIN FUNCTIONS OF THE RUNNING GEAR AND TERMINOLOGY ................................................ 6

    1.2 BOGIE COMPONENTS .................................................................................................................... 7

    A. WHEELSETS ................................................................................................................................. 7

    B. AXLE BOXES ............................................................................................................................... 10

    C. WHEELS ..................................................................................................................................... 13

    D. SUSPENSION ............................................................................................................................. 14

    E. BOGIE FRAME SHAPE ................................................................................................................ 32

    F. BRAKING SYSTEM ...................................................................................................................... 37

    G. CAR BODY CONNECTION .......................................................................................................... 40

    2 IMPACTS OF INNOVATIVE RUNNING GEAR WITH COMPOSITE MATERIAL ....................................... 51

    2.1 OVERVIEW OF A SINGLE AXEL RUNNING GEAR .......................................................................... 51

    2.2 REFERENCE CASE: ROME–CIVITACASTELLANA–VITERBO RAILWAY ........................................... 57

    2.4 MASS REDUCTION ....................................................................................................................... 60

    2.5 WHEEL MAINTENANCE COSTS .................................................................................................... 62

    2.6 Energy consumption ................................................................................................................... 65

    CASE 1: ENERGY CONSUMPTION WITH VARYING SPEED ............................................................. 67

    CASE 2: ENERGY CONSUMPTION WITH DISTANCE ....................................................................... 68

    CASE 3: ENERGY CONSUMPTION WITH PASSENGER OCCUPANCY RATE ..................................... 70

    CASE 4: ENERGY CONSUMPTION WITH AUXILIARY POWER ......................................................... 71

    3 RELEVANT REGULATION AND STANDARDIZATION DOCUMENTS ...................................................... 72

    3.1 IMPORTANCE OF REGULATION AND STANDARDIZATION DOCUMENTS .................................... 72

    3.2 CONDITION MONITORING / HEALTH MONITORING ................................................................... 73

    A. ISEE (1451) ................................................................................................................................ 73

    B. OSA-CBM ................................................................................................................................... 74

    3.3 Materials and manufacturing processes ..................................................................................... 77

    4 MAIN CONCLUSIONS .......................................................................................................................... 80

    REFERENCES ..................................................................................................................................... 83

    ACRONYMS AND ABBREVIATIONS .................................................................................................... 85

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    List of figures Fig.I.1: SF300 Running gear Siemens Transportation Systems................................................. 2

    Fig.I.2: conventional running gear vehicle.................................................................................3

    Fig.I.3: Single axle running gear vehicle.....................................................................................3

    Fig.I.4: Copenhagen S train........................................................................................................4

    Fig.I.5: High-speed train with bogie type locomotives and single-axle coaches.......................4

    Fig.1.1: Wheelset typology........................................................................................................9

    Fig.1.2: The rolling surface of wheels........................................................................................9

    Fig.1.3: Axle boxes....................................................................................................................12

    Fig.1.4: Axle boxes for high speed train....................................................................................13

    Fig.1.5: type of wheels..............................................................................................................14

    Fig.1.6: suspension classification..............................................................................................15

    Fig.1.7: Airspring.......................................................................................................................16

    Fig.1.8: Helical springs...............................................................................................................17

    Fig.1.9: Flexi-coil........................................................................................................................18

    Fig.1.10: Rubber for primary and secondary suspension..........................................................19

    Fig.1.11: Hourglass shape for secondary suspension................................................................20

    Fig.1.12: Classification of suspensions systems according to the geometry.............................21

    Fig.1.13: Cylindrical guides inside the spring............................................................................22

    Fig.1.14: DT200 suspension......................................................................................................23

    Fig.1.15: Cylindrical laminated rubber......................................................................................24

    Fig.1.16: Swing arm...................................................................................................................25

    Fig.1.17: Swing arm on CRH-1A train........................................................................................25

    Fig.1.18: Horizontal leaf springs................................................................................................26

    Fig.1.19: MD-522 Bogies by Bombardier...................................................................................26

    Fig.1.20: Two diagonal link arms...............................................................................................27

    Fig.1.21: CL 624 Bogies by Alstom.............................................................................................28

    Fig.1.22: Horn liner guides........................................................................................................2