Rail Vehicle Mechatronics (Ground Vehicle Engineering)

426 Pages·2021·21.448 MB·English

by  Maksym Spiryagin, Stefano Bruni, Christopher Bosomworth, Peter Wolfs, Colin Cole

Rail Vehicle Mechatronics
Ground Vehicle Engineering
Dr. Vladimir V. Vantsevich
Professor and Director
Program of Master of Science in Mechatronic Systems Engineering
Lawrence Technological University, Michigan
Road Vehicle Dynamics
Fundamentals and Modeling Theory and Design, Second Edition
Georg Rill and Abel Arrieta Castro
Driveline Systems of Ground Vehicles
Theory and Design
Alexandr F. Andreev, Viachaslau Kabanau, Vladimir Vantsevich
Road Vehicle Dynamics
Fundamentals and Modeling
Georg Rill
Dynamics of Wheel-Soil Systems
A Soil Stress and Deformation-Based Approach
Jaroslaw A. Pytka
Design and Simulation of Heavy Haul Locomotives and Trains
Maksym Spiryagin, Peter Wolfs, Colin Cole, Valentyn Spiryagin, Yan Quan Sun,
Tim McSweeney
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, Tim McSweeney
Control Applications of Vehicle Dynamics
Jingsheng Yu and Vladimir Vantsevich
Rail Vehicle Mechatronics
Maksym Spiryagin, Stefano Bruni, Christopher Bosomworth, Peter Wolfs,
Colin Cole
For more information about this series, please visit: https://www.crcpress.com/
Ground-Vehicle-Engineering/book-series/CRCGROVEHENG
Rail Vehicle Mechatronics
Maksym Spiryagin, Stefano Bruni,
Christopher Bosomworth,
Peter Wolfs, and Colin Cole
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Library of Congress Cataloging-in-Publication Data
Names: Spiryagin, Maksym, author. | Bruni, Stefano, author. | Bosomworth,
Christopher, author. | Wolfs, Peter, author. | Cole, Colin, author.
Title: Rail vehicle mechatronics / Maksym Spiryagin, Stefano Bruni,
Christopher Bosomworth, Peter Wolfs and Colin Cole.
Description: First edition. | Boca Raton, FL : CRC Press, 2022. | Series: Ground vehicle
engineering | Includes bibliographical references and index.
Identifiers: LCCN 2021029755 (print) | LCCN 2021029756 (ebook) | ISBN
9780367464738 (hbk) | ISBN 9781032148601 (pbk) | ISBN 9781003028994 (ebk)
Subjects: LCSH: Railroad cars–Equipment and supplies. | Mechatronics. |
Railroads–Electronic equipment.
Classification: LCC TF375 .S6955 2022 (print) | LCC TF375 (ebook) |
DDC 625.2–dc23
LC record available at https://lccn.loc.gov/2021029755
LC ebook record available at https://lccn.loc.gov/2021029756
ISBN: 978-0-367-46473-8 (hbk)
ISBN: 978-1-032-14860-1 (pbk)
ISBN: 978-1-003-02899-4 (ebk)
DOI: 10.1201/9781003028994
Typeset in Times
by KnowledgeWorks Global Ltd.
Contents
Preface......................................................................................................................xv
Acknowledgments ..................................................................................................xvii
Authors ....................................................................................................................xix
Chapter 1 Introduction to Rail Vehicle Mechatronics ..........................................1
1.1 Historical Review ......................................................................1
1.2 Theoretical Aspects for the Application of Mechatronic
System .......................................................................................2
1.2.1 Stability and Curving ...................................................3
1.2.1.1 Running Stability of a Railway
Vehicle ..........................................................3
1.2.1.2 Curving Behavior of a Railway
Vehicle ..........................................................4
1.2.2 Damage and Wear of Wheels and Rails .......................5
1.2.2.1 Wear of Wheels and Rails ............................5
1.2.2.2 Rolling Contact Fatigue ................................6
1.2.2.3 Metal Fatigue in Wheels, Axles, Rails,
and Other Types of Damage .........................7
1.2.3 Ride Comfort ................................................................7
1.3 Structure of this Book ...............................................................8
References ..........................................................................................11
Chapter 2 Modeling of Mechanical Systems for Rail Vehicles ..........................15
2.1 Introduction .............................................................................15
2.2 Classification for Theoretical and Experimental-Based
Modeling Approaches .............................................................16
2.2.1 Physical-Based Models ...............................................17
2.2.2 Black-Box Models ......................................................19
2.3 Model of Wheel/Rail Contact .................................................20
2.3.1 Geometric Analysis of Wheel/Rail Contact,
Equivalent Conicity ....................................................22
2.3.2 The Normal Contact Analysis: Normal Force,
Contact Patch, and Normal Stresses ..........................23
2.3.3 The Tangential Contact Analysis: Creepage
versus Creep Force Relationship ................................25
2.3.3.1 Kalker’s Linear Theory ..............................27
2.3.3.2 Heuristic Saturation Laws ..........................27
2.3.3.3 The Fastsim Method ...................................29
2.3.3.4 Kalker’s CONTACT Algorithm .................29
2.3.3.5 Use of Lookup Tables .................................30
v
vi Contents
2.3.4 Wheel/Rail Creep Force Models for Traction and
Brake Studies..............................................................30
2.3.4.1 Polach Model ..............................................31
2.3.4.2 Modified Fastsim ........................................32
2.3.4.3 Example of Identification of Creep
Force Model Parameters from
Measured Data ............................................33
2.4 Modeling of Track and Track Irregularities ............................34
2.4.1 The Track System .......................................................34
2.4.2 Nominal Track Geometry ..........................................35
2.4.3 Track Irregularity .......................................................37
2.4.4 Track Models for Vehicle Dynamics Simulation .......38
2.4.4.1 Rigid Track Model ......................................39
2.4.4.2 Co-Following Sectional Models .................39
2.4.4.3 Finite Element Models ................................39
2.4.4.4 Model of Switches and Crossings ...............40
2.5 Model of Suspension Components ..........................................40
2.5.1 Primary and Secondary Suspensions in Railway
Vehicles ......................................................................40
2.5.2 Coil Springs, Rubber Springs, and Bushings .............42
2.5.3 Friction-Based Suspension Components ....................43
2.5.4 Hydraulic Dampers ....................................................44
2.5.5 Air Spring Suspension ................................................45
2.6 Pantograph-Catenary Interaction ............................................47
2.7 Traction and Braking Dynamics, Control and
Modeling ..................................................................................49
2.7.1 Principles of Traction Braking Dynamics ..................49
2.7.2 Design Principles of Traction and Braking
Control ........................................................................51
2.7.3 Modeling of the Traction Systems .............................54
2.8 Train Dynamics .......................................................................55
2.8.1 Train Dynamics for a Single Vehicle .........................55
2.8.2 Longitudinal Train Dynamics ....................................55
2.9 Pneumatic Brake Models .........................................................58
2.10 Modeling of Inter-Car Forces ..................................................60
References ..........................................................................................62
Chapter 3 Modeling of Electrical Systems for Rail Vehicles .............................67
3.1 Electrical Topologies ...............................................................67
3.1.1 Diesel Electric Locomotives ......................................67
3.1.2 Electric Locomotives..................................................67
3.1.3 Hybrids .......................................................................69
3.1.3.1 Principles of Hybridization for Rail
Vehicles .......................................................69
3.1.3.2 Hybrid Topologies .......................................70
Contents vii
3.2 Traction Power Supplies ..........................................................71
3.2.1 Alternators and Generators ........................................71
3.2.2 Rectifiers.....................................................................71
3.2.2.1 Thyristor Rectifiers .....................................72
3.2.2.2 PWM Rectifiers ..........................................73
3.2.3 Energy Storage ...........................................................74
3.2.3.1 Batteries ......................................................74
3.2.3.2 Flywheels ....................................................75
3.2.3.3 Super Capacitors .........................................76
3.2.4 Dynamic Braking Energy Management ....................76
3.3 Traction Motors and Power Electronics ..................................77
3.3.1 DC Motors ..................................................................77
3.3.1.1 Machine Models .........................................78
3.3.1.2 Case Studies ................................................79
3.3.2 Induction Machines ....................................................80
3.3.2.1 Machine Models .........................................80
3.3.2.2 Field-Oriented Control................................81
3.3.2.3 Direct Torque Control .................................86
3.3.2.4 Case Studies ................................................89
3.3.3 Synchronous Machines ..............................................91
3.3.3.1 Machine Models .........................................91
3.3.3.2 Machine-Commutated Converters .............93
3.3.3.3 Field-Oriented Control................................93
3.3.3.4 Case Studies ................................................94
3.3.4 Brushless DC ..............................................................94
3.3.4.1 Machine Models .........................................96
3.3.4.2 Field-Oriented Control................................96
3.3.4.3 Case Studies ................................................97
3.3.5 Slip Control ................................................................97
3.3.5.1 Case Studies ................................................98
References ..........................................................................................99
Chapter 4 Control Systems................................................................................103
4.1 Introduction ...........................................................................103
4.2 Open-Loop and Closed-Loop Control Systems ....................103
4.3 Classical Control ...................................................................105
4.3.1 Closed-Loop Transfer Function ...............................105
4.3.2 PID Feedback Control ..............................................107
4.4 Modern Control Approach ....................................................108
4.4.1 State Space Representation ......................................108
4.4.2 Pole Placement Method ............................................109
4.4.3 Observer Design Technique .....................................110
4.4.4 Optimal Control .......................................................112
4.4.4.1 Linear–Quadratic Regulator .....................113
4.4.4.2 Kalman Filter ............................................113
viii Contents
4.4.4.3 Linear–Quadratic–Gaussian Control .....115
4.4.4.4 H and H Methods ...................................115
2 ∞
4.4.4.5 Model Predictive Control..........................117
4.5 Non-Classical Control Methods ............................................118
4.5.1 Fuzzy Control ...........................................................118
4.5.2 Neural Network-Based Control ................................120
References ........................................................................................121
Chapter 5 Actuators ..........................................................................................127
5.1 Introduction ...........................................................................127
5.2 Electro-Mechanical Actuators ...............................................128
5.2.1 Direct Current Motors ..............................................129
5.2.2 Alternating Current Motors......................................132
5.2.2.1 Induction Motors ......................................133
5.2.2.2 Synchronous Motors .................................134
5.2.3 Mechanical Transmission .........................................137
5.2.3.1 Gear Trains ...............................................137
5.2.3.2 Ball Screw Transmission ..........................138
5.2.4 Model of an Electromechanical Actuator with
Brushless AC Motor .................................................139
5.3 Hydraulic Actuators ...............................................................141
5.3.1 Fluid Power System Basics .......................................141
5.3.2 Hydraulic Fluids Properties .....................................143
5.3.3 Managing Hydraulic Fluids ......................................144
5.3.4 Hydraulic Cylinders .................................................145
5.3.5 Hydraulic Motors .....................................................148
5.3.6 Modeling Control Valves .........................................150
5.3.7 Closed-Loop Circuits ...............................................153
5.3.8 Dynamic Performance Modeling of Actuator
Systems .....................................................................155
5.3.9 Applications ..............................................................159
5.3.10 Overall Summary .....................................................164
5.4 Pneumatic Actuators .............................................................164
5.4.1 Pneumatic Power System Basics ..............................164
5.4.2 Air Properties ...........................................................166
5.4.3 Pneumatic Cylinders ................................................167
5.4.4 Air Motors ................................................................170
5.4.5 Control Valves ..........................................................172
5.4.6 Restrictions and Chokes ...........................................174
5.4.7 Applications ..............................................................176
5.4.7.1 Railway Air Braking ................................176
5.4.7.2 Railway Air Suspensions ..........................179
5.4.8 Overall Summary .....................................................182
References ........................................................................................182
Contents ix
Chapter 6 Sensors .............................................................................................185
6.1 Introduction ...........................................................................185
6.2 Displacement Sensors ............................................................186
6.2.1 Resistive Sensors ......................................................186
6.2.2 Capacitive Sensors ....................................................187
6.2.3 Linear Variable Differential
Transformers ............................................................187
6.3 Encoders ................................................................................189
6.4 Speed Sensors ........................................................................191
6.5 Accelerometers ......................................................................192
6.5.1 Piezoelectric Accelerometers ...................................194
6.5.2 Capacitive Accelerometers .......................................196
6.6 Pressure Sensors ....................................................................196
6.7 Measurement of Force and Torque in Mechatronic
Railway Vehicles ...................................................................196
References ........................................................................................198
Chapter 7 Modeling of Complex Systems ........................................................199
7.1 Basic Principle of Complex System Design ..........................199
7.2 Introduction of Co-simulation ...............................................202
7.3 Co-simulation Techniques .....................................................203
7.4 Review of the Existing Multi-Body Software Packages
and Their Co-simulation Functionalities ...............................204
7.4.1 Gensys and Matlab®/Simulink .................................204
7.4.2 Simpack and Simulink .............................................211
7.4.3 VI-Rail (ADAMS/Rail) and Simulink .....................213
7.4.4 Vampire and Simulink .............................................214
7.4.5 Universal Mechanism and Simulink ........................215
7.5 Design of Co-simulation Interfaces .......................................215
7.5.1 Design of the Simple Simulink Model and
Generation of the Shared Library ............................215
7.5.2 Shared Library Integration in the Code ...................218
7.5.3 Compilation and Execution of the Code ..................222
7.6 Case Studies...........................................................................223
7.6.1 Co-simulation for a Locomotive Traction
Control Study ...........................................................223
7.6.1.1 Multi-body Model of a Heavy Haul
Locomotive in Gensys ..............................224
7.6.1.2 Model of a Locomotive Simplified
Traction System ........................................226
7.6.1.3 Dynamic Response Test to Variations
of Adhesion Conditions at the Wheel-
Rail Interface ............................................231