Design and Simulation of Rail Vehicles

329 Pages·2014·24.665 MB·English

by  Maksym Spiryagin;Colin Cole;Yan Quan Sun;Mitchell McClanachan;Valentyn Spiryagin;All authors

Design Simulation
and
Rail Vehicles
of
Ground Vehicle Engineering Series
Series Editor:
Dr. Vladimir V. Vantsevich
Professor and Director
Program of Master of Science in Mechatronic Systems Engineering
Lawrence Technological University, Michigan
Automotive Accident Reconstruction: Practices and Principles
Donald E. Struble
Design and Simulation of Rail Vehicles
Maksym Spiryagin, Colin Cole, Yan Quan Sun, Mitchell McClanachan,
Valentyn Spiryagin, and Tim McSweeney
Dynamics of Wheel–Soil Systems: A Soil Stress and
Deformation-Based Approach
Jaroslaw A. Pytka
Road Vehicle Dynamics: Fundamentals and Modeling
Georg Rill
Driveline Systems of Ground Vehicles: Theory and Design
Alexandr F. Andreev, Viachaslau Kabanau, and Vladimir Vantsevich
Design Simulation
and
Rail Vehicles
of
Maksym Spiryagin
Centre for Railway Engineering, Central Queensland University, Rockhampton, Australia
Colin Cole
Centre for Railway Engineering, Central Queensland University, Rockhampton, Australia
Yan Quan Sun
Centre for Railway Engineering, Central Queensland University, Rockhampton, Australia
Mitchell McClanachan
Centre for Railway Engineering, Central Queensland University, Rockhampton, Australia
Valentyn Spiryagin
Chair of Railway Transport, East Ukrainian National University named after Volodymyr
Dal, Lugansk, Ukraine
Tim McSweeney
Centre for Railway Engineering, Central Queensland University, Rockhampton, Australia
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
MATLAB® is a trademark of The MathWorks, Inc. and is used with permission. The MathWorks does
not warrant the accuracy of the text or exercises in this book. This book’s use or discussion of MAT-
LAB® software or related products does not constitute endorsement or sponsorship by The MathWorks
of a particular pedagogical approach or particular use of the MATLAB® software.
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2014 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20140403
International Standard Book Number-13: 978-1-4665-7567-7 (eBook - PDF)
This book contains information obtained from authentic and highly regarded sources. Reasonable
efforts have been made to publish reliable data and information, but the author and publisher cannot
assume responsibility for the validity of all materials or the consequences of their use. The authors and
publishers have attempted to trace the copyright holders of all material reproduced in this publication
and apologize to copyright holders if permission to publish in this form has not been obtained. If any
copyright material has not been acknowledged please write and let us know so we may rectify in any
future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced,
transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or
hereafter invented, including photocopying, microfilming, and recording, or in any information stor-
age or retrieval system, without written permission from the publishers.
For permission to photocopy or use material electronically from this work, please access www.copy-
right.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222
Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that pro-
vides licenses and registration for a variety of users. For organizations that have been granted a pho-
tocopy license by the CCC, a separate system of payment has been arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are
used only for identification and explanation without intent to infringe.
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com
Contents
Preface.......................................................................................................................xi
Authors ...................................................................................................................xiii
Chapter 1 Introduction ..........................................................................................1
References ............................................................................................6
Chapter 2 Unpowered Rail Vehicle Design ..........................................................9
2.1 Introduction ...............................................................................9
2.2 Types of Wagons ........................................................................9
2.3 Wagon Frames .........................................................................11
2.4 Suspension Elements ...............................................................13
2.5 Bogies ......................................................................................14
2.6 Wheelsets and Bearings ..........................................................15
2.7 Wagon Bodies ..........................................................................17
2.8 Brake Systems .........................................................................18
2.9 Coupling ..................................................................................20
2.9.1 Coupling Mechanisms ................................................21
2.9.2 Longitudinal Damping ...............................................21
2.10 Standards .................................................................................23
2.11 Acceptance Tests .....................................................................24
2.11.1 Roll Test ......................................................................24
2.11.2 Twist Test ....................................................................24
2.11.3 Bounce Test ................................................................25
2.11.4 Critical Speed .............................................................25
2.11.5 Curving Test ...............................................................25
2.11.6 Wind Overturning ......................................................25
2.11.7 Combination of Events ...............................................25
2.12 Advances in Rail Vehicle Design ............................................26
Chapter 3 Design of Locomotives.......................................................................27
3.1 History of Locomotives ...........................................................27
3.1.1 Diesel Traction and Manufacturing of
Diesel–Electric Locomotives .....................................28
3.1.2 Electrical Traction and Electrical Locomotives .........29
3.1.3 Magnetic Levitation Locomotives (Trains) ................30
3.2 Traction Rolling Stock .............................................................30
3.2.1 Electric Locomotives..................................................33
3.2.2 Electric Multiple Units ...............................................36
3.2.3 Diesel Locomotives ....................................................38
3.2.4 Diesel Multiple Units ..................................................42
v
vi Contents
3.2.5 Gas Turbine–Electric Locomotives ............................45
3.2.6 Hybrid Locomotives ...................................................45
3.2.7 Magnetic Levitation Trains ........................................49
3.3 Common Locomotive Components and Systems ....................51
3.3.1 Classification of Main Components ...........................51
3.3.1.1 Locomotive Frames and Bodies .................51
3.3.1.2 Bogies .........................................................52
3.3.1.3 Locomotive Traction Drives .......................55
3.3.2 Suspension and Its Elements ......................................57
3.3.2.1 Leaf Spring Suspension ..............................58
3.3.2.2 Helical (or Coil) Spring Suspension ...........58
3.3.2.3 Air Spring Suspension ................................58
3.3.2.4 Hydraulic Suspension .................................60
3.3.2.5 Electro-Mechanical Suspension .................61
3.3.2.6 Dampers ......................................................61
3.3.2.7 Combinations of Several
Suspension Elements ..................................62
3.3.2.8 Active Suspension .......................................62
3.3.3 Connection between a Locomotive Frame
and Bogies ..................................................................64
3.3.3.1 Centre Pivots ...............................................64
3.3.3.2 Side Bearers ................................................66
3.3.3.3 Links and Linkages ....................................67
3.3.3.4 Traction Rods ..............................................67
3.3.4 Brake Systems and Their Devices ..............................67
3.3.4.1 Basic Components of
Brake Systems.............................................68
3.3.4.2 Dynamic Brake Systems .............................69
3.3.4.3 Electromagnetic Brakes ..............................69
3.3.4.4 Rail Brakes .................................................70
3.3.5 Classification of Locomotive Electric Traction ..........70
3.3.5.1 DC Traction ................................................71
3.3.5.2 AC Traction .................................................71
3.4 Locomotive Design: New Perspectives ...................................72
Chapter 4 General Modelling Techniques ..........................................................79
4.1 Dynamics of Bodies ................................................................79
4.1.1 Rail Vehicle ................................................................79
4.1.2 Train ...........................................................................82
4.2 Wheel–Rail Contact Patch ......................................................83
4.3 Brake Modelling ......................................................................84
4.3.1 Pneumatic Brakes .......................................................85
4.3.2 Electronically Controlled Pneumatic Brakes .............87
4.3.3 Wheel Brakes .............................................................87
4.3.4 Disc Brakes ................................................................88
Contents vii
4.4 Aerodynamics ..........................................................................88
4.5 Introduction to FEM ................................................................88
4.6 FEM of Rail Vehicle Structure ................................................89
4.7 FEM of Rail .............................................................................90
4.8 Rail Track, Sub-Structure and Bridge Modelling ...................91
4.9 Pantograph Modelling .............................................................93
4.10 Modelling Techniques .............................................................93
4.10.1 Dynamic Model Elements ..........................................94
4.10.2 Numerical Integrators ................................................95
References ..........................................................................................95
Chapter 5 Multibody Dynamics ........................................................................101
5.1 Introduction to Multibody Dynamics ....................................101
5.2 Kinematics .............................................................................102
5.3 Dynamics ...............................................................................104
5.3.1 Newton–Euler Equations .........................................104
5.3.2 D’Alembert’s Principle and Generalised Forces ......104
5.3.3 Lagrange’s Equation .................................................105
5.3.4 Dynamic Equations ..................................................106
5.4 Elements ................................................................................108
5.4.1 Rail Vehicle Modelling Axis System .......................108
5.4.2 Inertia Elements .......................................................109
5.4.3 Suspension Elements ................................................109
5.4.4 Constraint Elements .................................................112
5.5 Rigid Body versus Flexible Body ..........................................112
5.6 Multibody Dynamics Software for Rail
Vehicle Dynamics ..................................................................113
5.6.1 NUCARS ..................................................................114
5.6.2 GENSYS ...................................................................116
5.6.3 VAMPIRE ................................................................118
5.6.4 ADAMS/Rail (Now VI-Rail) ...................................120
5.6.5 SIMPACK .................................................................121
5.6.6 Universal Mechanism ...............................................122
5.6.7 In-House Packages ...................................................123
5.6.8 Benchmarks and Comparisons .................................126
References ........................................................................................126
Chapter 6 Longitudinal Train Dynamics ..........................................................129
6.1 Introduction to Longitudinal Train Dynamics ......................129
6.2 Modelling Longitudinal Train Dynamics .............................130
6.2.1 Train Models ............................................................130
6.2.2 Modelling Vehicle Inputs .........................................133
6.2.2.1 Locomotive Traction and Dynamic
Braking .....................................................134
6.2.2.2 Propulsion Resistance ...............................138
viii Contents
6.2.2.3 Curving Resistance ...................................140
6.2.2.4 Gravitational Components ........................144
6.2.2.5 Pneumatic Brake Models ..........................144
6.2.3 Wagon Connection Models ......................................150
6.2.3.1 Conventional Auto-Couplers and
Draft Gear Packages .................................153
6.2.3.2 Slackless Packages ....................................160
6.2.3.3 Drawbars ...................................................160
6.2.4 Train Configurations ................................................161
6.2.5 Train Dynamics Model Development and
Simulation ................................................................162
6.3 Interaction of Longitudinal Train and Lateral/Vertical
Wagon Dynamics ..................................................................170
6.3.1 Wheel Unloading, Wheel Climb and Rollover
on Curves Due to Lateral Components of
Coupler Forces ..........................................................175
6.3.2 Wagon Body and Bogie Pitch Due to Coupler
Impact Forces ...........................................................180
6.3.3 Wagon Liftoff Due to Vertical Components of
Coupler Forces ..........................................................186
6.4 Longitudinal Comfort ............................................................188
6.5 Energy Considerations ...........................................................191
6.6 Train Control, Management and Driving Practices ..............192
6.7 Design Considerations ...........................................................195
References ........................................................................................196
Chapter 7 Rail Vehicle–Track Interaction Dynamics .......................................199
7.1 Introduction ...........................................................................199
7.2 Modelling of Rail Vehicles ....................................................199
7.3 Modelling of Tracks ..............................................................201
7.4 Modelling of Wheel–Rail Contact ........................................204
7.5 Example of a Three-Dimensional Rail Wagon–Track
System Dynamics Model .......................................................210
7.5.1 Wagon Subsystem .....................................................210
7.5.2 Track Subsystem .......................................................212
7.6 Numerical Integration Methods ............................................216
7.6.1 Improved Fourth-Order Runge–Kutta Method ........217
7.6.2 Modified Newmark-β Method ..................................218
7.6.3 Comparison of the Two Solution Schemes ...............220
7.7 Vehicle Dynamic Performances ............................................224
7.7.1 Derailments ..............................................................224
7.7.1.1 Nadal Formula ..........................................225
7.7.1.2 Derailment Simulation Due to Train
Collision ....................................................226
7.7.2 Rail Ride Comfort ....................................................226