Analysis of the Temperature Characteristics of High-speed Train Bearings Based on a Dynamics Model and Thermal Network Method

High-speed trains often use temperature sensors to monitor the motion state of bearings.However,the temperature of bearings can be affected by factors such as weather and faults.Therefore,it is necessary to analyze in detail the relationship between the bearing temperature and influencing factors.In this study,a dynamics model of the axle box bearing of high-speed trains is established.The model can obtain the contact force between the rollers and raceway and its change law when the bearing contains outer-ring,inner-ring,and rolling-element faults.Based on the model,a thermal network method is introduced to study the temperature field distribution of the axle box bearings of high-speed trains.In this model,the heat generation,conduction,and dispersion of the isothermal nodes can be solved.The results show that the temperature of the contact point between the outer-ring raceway and rolling-elements is the highest.The relationships between the node temperature and the speed,fault type,and fault size are analyzed,finding that the higher the speed,the higher the node temperature.Under different fault types,the node temperature first increases and then decreases as the fault size increases.The effectiveness of the model is demonstrated using the actual temperature data of a high-speed train.This study proposes a thermal network model that can predict the temperature of each component of the bearings on a high-speed train under various speed and fault conditions.

Studyon Evaluation Methods for Lateral Stability of High-Speed Trains

Taking a high-speed train in China as an example,using computer simulation technology and comparing with the test data,the three current methods including linear stability analysis method,nonlinear stability analysis method and the field testing criterion are studied to evaluate stability of high-speed trains.A new stability evaluation method is proposed which can be used to evaluate lateral stability of high-speed vehicle based on the codes of UIC 515and UIC 518.From the viewpoint of taking the most unfavorable track conditions into account and improving the safety margin,the new method uses the root mean square of bogie lateral acceleration as a criterion to evaluate the lateral stability of high-speed trains.Numerical example shows that the proposed method not only considers the forced vibration caused by track irregularities in the actual practice,but also takes the instability self-excited vibration into account,so it can realize early warning of bogie slight unstable oscillation,meanwhile the method itself does not involve complex algorithms which has the possibility of engineering applications.

PIV analysis and high-speed photographic observation of cavitating flow field behind circular multi-orifice plates

Based on a self-developed hydrodynamic cavitation device with different geometric parameters for circular multi-orifice plates,turbulence characteristics of cavitating flow behind multi-orifice plates,including the effects of orifice number and orifice layout on longitudinal velocity,turbulence intensity,and Reynolds stress,were measured with the particle image velocimetry(PIV)technique.Flow regimes of the cavitating flow were also observed with high-speed photography.The experimental results showed the following:(1)high-velocity multiple cavitating jets occurred behind the multi-orifice plates,and the cavitating flow fields were characterized by topological structures;(2)the longitudinal velocity at each cross-section exhibited a sawtooth-like distribution close to the multi-orifice plate,and each sawtooth indicated one jet issuing from one orifice;(3)there were similar magnitudes and forms for the longitudinal and vertical turbulence intensities at the same cross-section;(4)the variation in amplitude of Reynolds stress increased with an increase in orifice number;and(5)the cavitation clouds in the flow fields became denser with the increase in orifice number,and the clouds generated by the staggered layout of orifices were greater in number than those generated by the checkerboard-type one for the same orifice number.The experimental results can be used to analyze the mechanism of killing pathogenic microorganisms through hydrodynamic cavitation.

Analysis of droplet transfer of pulsed MIG welding based on electrical signal and high-speed photography

In order to study how welding parameters affect welding quality and droplet transfer, a synchronous acquisition and analysis system is established to acquire and analyze electrical signal and instantaneous images of droplet transfer simultaneously, which is based on a self-developed soft-switching inverter. On the one hand, welding current and voltage signals are acquired and analyzed by a self-developed dynamic wavelet analyzer. On the other hand, images are filtered and optimized after they are captured by high-speed camera. The results show that instantaneous waveforms and statistical data of electrical signal contribute to make an overall assessment of welding quality, and that optimized high-speed images allow a visual and clear observation of droplet transfer process. The analysis of both waveforms and images leads to a further research on droplet transfer mechanism and provides a basis for precise control of droplet transfer.

TEST METHOD OF HIGH-SPEED ON-OFF VALVE DYNAMIC CHARACTERISTICS

According to the valve port features of high speed on-off valve and its actions, the valve port can be simplified into an a-type half bridge construction. A method that tests the dynamic characteristics of the high speed on-off valve by the output pressure signal of the a-type half bridge is proposed. Having analyzed the factors related to the dynamic characteristics of an a-type half bridge, a rule for designing the outlet chamber＇s volume is worked out. According to the rule, a test stand is built to test the self-developed high-speed on-off valve. From the test results, it can be seen that with the outlet chamber＇s volume controlled by the rule the rise time of the pressure signals driven by signals with different frequencies changes very little. The test results conform to the simulation results, which nroves the correctness of the method.

Analysis of Temperature Rise in High-Speed Permanent Magnet Synchronous Traction Motors by Coupling the Equivalent Thermal Circuit Method and Computational Fluid Dynamics

To solve the problem of temperature rise caused by the high power density of high-speed permanent magnet synchronous traction motors,the temperature rise of various components in the motor is analyzed by coupling the equivalent thermal circuit method and computational fluid dynamics.Also,a cooling strategy is proposed to solve the problem of temperature rise,which is expected to prolong the service life of these devices.First,the theoretical bases of the approaches used to study heat transfer and fluid mechanics are discussed,then the fluid flow for the considered motor is analyzed,and the equivalent thermal circuit method is introduced for the calculation of the temperature rise.Finally,the stator,rotor loss,motor temperature rise,and the proposed cooling method are also explored through experiments.According to the results,the stator temperature at 50,000 r/min and 60,000 r/min at no-load operation is 68℃ and 76℃,respectively.By monitoring the temperature of the air outlets inside and outside the motor at different speeds,it is also found that the motor reaches a stable temperature rise after 65 min of operation.Coupling of the thermal circuit method and computational fluid dynamics is a strategy that can provide the average temperature rise of each component and can also comprehensively calculate the temperature of each local point.We conclude that a hybrid cooling strategy based on axial air cooling of the inner air duct of the motor and water cooling of the stator can meet the design requirements for the ventilation and cooling of this type of motors.

An investigation into high-speed train interior noise with operational transfer path analysis method

Passengers’demands for riding comfort have been getting higher and higher as the high-speed railway develops.Scientific methods to analyze the interior noise of the high-speed train are needed and the operational transfer path analysis(OTPA)method provides a theoretical basis and guidance for the noise control of the train and overcomes the shortcomings of the traditional method,which has high test efficiency and can be carried out during the working state of the targeted machine.The OTPA model is established from the aspects of“path reference point-target point”and“sound source reference point-target point”.As for the mechanism of the noise transmission path,an assumption is made that the direct sound propagation is ignored,and the symmetric sound source and the symmetric path are merged.Using the operational test data and the OTPA method,combined with the results of spherical array sound source identification,the path contribution and sound source contribution of the interior noise are analyzed,respectively,from aspects of the total value and spectrum.The results show that the OTPA conforms to the calculation results of the spherical array sound source identification.At low speed,the contribution of the floor path and the contribution of the bogie sources are dominant.When the speed is greater than 300 km/h,the contribution of the roof path is dominant.Moreover,for the carriage with a pantograph,the lifted pantograph is an obvious source.The noise from the exterior sources of the train transfer into the interior mainly through the form of structural excitation,and the contribution of air excitation is non-significant.Certain analyses of train parts provide guides for the interior noise control.

An Optimal Feed Interpolator Based on G^2 Continuous Bézier Curves for High-Speed Machining of Linear Tool Path

A numerical control (NC) tool path of digital CAD model is widely generated as a set of short line segments in machining. However, there are three shortcomings in the linear tool path, such as discontinuities of tangency and curvature, huge number of line segments, and short lengths of line segments. These disadvantages hinder the development of high speed machining. To smooth the linear tool path and improve machining efficiency of short line segments, this paper presents an optimal feed interpolator based on G^2 continuous Bézier curves for the linear tool path. First, the areas suitable for fitting are screened out based on the geometric characteristics of continuous short segments (CSSs). CSSs in every area are compressed and fitted into a G^2 Continuous Bézier curve by using the least square method. Then a series of cubic Bézier curves are generated. However, the junction between adjacent Bézier curves is only G^0 continuous. By adjusting the control points and inserting Bézier transition curves between adjacent Bézier curves, the G^2 continuous tool path is constructed. The fitting error is estimated by the second-order Taylor formula. Without iteration, the fitting algorithm can be implemented in real-time environment. Second, the optimal feed interpolator considering the comprehensive constraints (such as the chord error constraint, the maximum normal acceleration, servo capacity of each axis, etc.) is proposed. Simulation and experiment are conducted. The results shows that the proposed method can generate smooth path, decrease the amount of segments and reduce machining time for machining of linear tool path. The proposed research provides an effective method for high-speed machining of complex 2-D/3-D profiles described by short line segments.

Multi-point Contact of the High-speed Vehicle-turnout System Dynamics

The wheel-rail contact problems, such as the number, location and the track of contact patches, are very important for optimizing the spatial structure of the rails and lowering the vehicle-turnout system dynamics. However, the above problems are not well solved currently because of having the difficulties in how to determine the multi-contact, to preciously present the changeable profiles of the rails and to establish an accurate spatial turnout system dynamics model. Based on a high-speed vehicle-turnout coupled model in which the track is modeled as flexible with rails and sleepers represented by beams, the line tracing extreme point method is introduced to investigate the wheel-rail multiple contact conditions and the key sections of the blade rail, longer nose rail, shorter rail in the switch and nose rail area are discretized to represent the varying profiles of rails in the turnout. The dynamic interaction between the vehicle and turnout is simulated for cases of the vehicle divergently passing the turnout and the multi-point contact is obtained. The tracks of the contact patches on the top of the rails are presented and the wheel-rail impact forces are offered in comparison with the contact patches transference on the rails. The numerical simulation results indicate that the length of two-point contact occurrence of a worn wheel profile and rails is longer than that of the new wheel profile and rails; The two-point contact definitely occurs in the switch and crossing area. Generally, three-point contact doesn’t occur for the new rail profile, which is testified by the wheel-rails interpolation distance and the first order derivative function of the tracing line extreme points. The presented research is not only helpful to optimize the structure of the turnout, but also useful to lower the dynamics of the high speed vehicle-turnout system.

Vibration and acoustic radiation of bogie area under random excitation in high-speed trains

Based on the experiments on a platform with real vehicle structure and finite element simulation, the vibration and interior acoustic radiation under random excitations of high-speed trains’ bogie area were studied. Firstly, combined with line tests, a vehicle body with a length of 7 m was used as the research object. By comparing the results of experiment and simulation, the accuracy of the finite element model was verified. Secondly, the power spectral density curves at typical measuring points in bogie area were obtained by processing and calculating the line test data, which was measured when the vehicle ran at high speeds, and the standard vibration spectrum of the bogie area was obtained by the extreme envelope method. Furthermore, the random vibration test and simulation prediction analysis of the real vehicle structure were carried out to further verify the accuracy of the noise and vibration prediction model. Finally, according to the vibration and acoustic radiation theory, the indirect boundary element method was adopted to predict the acoustic response of the real vehicle. The analysis shows that the simulated power spectral density curves of acceleration and sound pressure level are highly consistent with the experimental ones, and the error between the simulated prediction and the experimental result is within the allowable range of 3 dB.

Theoretical Research and Experimental Validation of Elastic Dynamic Load Spectra on Bogie Frame of High-speed Train

When a train runs at high speeds, the external exciting frequencies approach the natural frequencies of bogie critical components, thereby inducing strong elastic vibrations. The present international reliability test evaluation standard and design criteria of bogie frames are all based on the quasi-static deformation hypothesis. Structural fatigue damage generated by structural elastic vibrations has not yet been included. In this paper, theoretical research and experimental validation are done on elastic dynamic load spectra on bogie frame of high-speed train. The construction of the load series that correspond to elastic dynamic deformation modes is studied. The simplified form of the load series is obtained. A theory of simplified dynamic load–time histories is then deduced. Measured data from the Beijing–Shanghai Dedicated Passenger Line are introduced to derive the simplified dynamic load–time histories. The simplified dynamic discrete load spectra of bogie frame are established. Based on the damage consistency criterion and a genetic algorithm, damage consistency calibration of the simplified dynamic load spectra is finally performed. The computed result proves that the simplified load series is reasonable. The calibrated damage that corresponds to the elastic dynamic discrete load spectra can cover the actual damage at the operating conditions. The calibrated damage satisfies the safety requirement of damage consistency criterion for bogie frame. This research is helpful for investigating the standardized load spectra of bogie frame of high-speed train.

Kinematical Analysis and Simulation of High-Speed Plate Carrying Manipulator Based on Matlab

In order to construct the more effective kinematics method for industry, by taking a high-speed plate handing robot as an example, the structure and parameters of the robot linkages are analyzed, and the standard Denavit-Hartenberg method is applied to establish the coordinates and the kinematic equation of the linkages. Depending on the graphics and matrix calculation ability of Matlab especially including the Robotics Toolbox, the handling robot has been modeled and its kinematics, inverse kinematics and the trajectory planning have been simulated. Therefore, the correctness of kinematic equation has been verified, meanwhile, the functions of displacement, velocity, acceleration and trajectory of all the joints are also obtained. In a further step, this has verified the validity of all the structure parameters and pro- vided a reliable basis for the theoretical research on the design, dynamics analysis and trajectory planning of the ma- nipulator control system.

A Fast Approach for Predicting Aerodynamic Noise Sources of High-Speed Train Running in Tunnel

The aerodynamic noise of high-speed trains passing through a tunnel has gradually become an important issue.Numerical approaches for predicting the aerodynamic noise sources of high-speed trains running in tunnels are the key to alleviating aerodynamic noise issues.In this paper,two typical numerical methods are used to calculate the aerodynamic noise of high-speed trains.These are the static method combined with non-reflective boundary conditions and the dynamic mesh method combined with adaptive mesh.The fluctuating pressure,flow field and aerodynamic noise source are numerically simulated using the abovemethods.The results showthat the fluctuating pressure,flow field structure and noise source characteristics obtained using different methods,are basically consistent.Compared to the dynamic mesh method,the pressure,vortex size and noise source radiation intensity,obtained by the static method,are larger.The differences are in the tail car and its wake.The two calculation methods show that the spectral characteristics of the surface noise source are consistent.The maximum difference in the sound pressure level is 1.9 dBA.The static method is more efficient and more suitable for engineering applications.

Characteristic analysis of mechanical thermal coupling model for bearing rotor system of high-speed train

Based on Newton’s second law and the thermal network method,a mechanical thermal coupling model of the bearing rotor system of high-speed trains is established to study the interaction between the bearing vibration and temperature.The influence of lubrication on the vibration and temperature characteristics of the system is considered in the model,and the real-time relationship between them is built up by using the transient temperature field model.After considering the lubrication,the bearing outer ring vibration acceleration and node temperature considering grease are lower,which shows the necessity of adding the lubrication model.The corresponding experiments for characteristics of vibration and temperature of the model are respectively conducted.In the envelope spectrum obtained from the simulation signal and the experimental signal,the frequency values corresponding to the peaks are close to the theoretical calculation results,and the error is very small.In the three stages of the temperature characteristic experiment,the node temperature change of the simulation model is consistent with the experiment.The good agreement between simulation and experiments proves the effectiveness of the model.By studying the influence of the bearing angular and fault size on the system node temperature,as well as the change law of bearing lubrication characteristics and temperature,it is found that the worse the working condition is,the higher the temperature is.When the ambient temperature is low,the viscosity of grease increases,and the oil film becomes thicker,which increases the sliding probability of the rolling element,thus affecting the normal operation of the bearing,which explains the phenomenon of frequent bearing faults of high-speed trains in the low-temperature area of Northeast China.Further analysis shows that faults often occur in the early stage of train operation in the low-temperature environment.

Electromagnetic Analysis and Optimization of High-speed Maglev Linear Synchronous Motor Based on Field-circuit Coupling

High speed maglev train has become a new non-contact transportation mode mainly studied in recent years because of its non-sticking and high speed characteristics.Firstly,the finite element model of the long stator linear synchronous motor(LSM)is established based on the structure of the test prototype.After calculation,it is compared with the experimental data and verified.On this basis,a field-circuit coupling model based on inverter circuit is established,and the influence of carrier wave ratio change on the output characteristics of LSM is calculated and analyzed.Finally,the filter circuit is introduced into the field-circuit coupling model,and the influence of the filter circuit on the output characteristics of the LSM is compared and analyzed.

STRUCTURE EVOLUTION OF POLYMER CHAINS FOR NECKING FORMATION IN HIGH-SPEED FIBER SPINNING PROCESS

Finite element method is used to simulate the high-speed melt spinning process, based on the equation system proposed by Doufas et al. Calculation predicts a neck-like deformation, as well as the related profiles of velocity, diameter, temperature, chain orientation, and crystallinity in the fiber spinning process. Considering combined effects on the process such as flow-induced crystallization, viscoelasticity, filament cooling, air drag, inertia, surface tension and gravity, the simulated material flow behaviors are consistent with those observed for semi-crystalline polymers under various spinning conditions, The structure change of polymer coils in the necking region described by the evolution of conformation tensor is also investigated. Based on the relaxation mechanism of macromolecules in flow field different types of morphology change of polymer chains before and in the neck are proposed, giving a complete prospect of structure evolution and crystallization of semi-crystalline polymer in the high speed fiber spinning process.

Sensitivity analysis of distributed parameter elements in high-speed circuit networks

This paper presents an analysis method, based on MacCormack＇s technique, for the evaluation of the time domain sensitivity of distributed parameter elements in high-speed circuit networks. Sensitivities can be calculated from electrical and physical parameters of the distributed parameter elements. The proposed method is a direct numerical method of time-space discretization and does not require complicated mathematical deductive process. Therefore, it is very convenient to program this method. It can be applied to sensitivity analysis of general transmission lines in linear or nonlinear circuit networks. The proposed method is second-order-accurate. Numerical experiment is presented to demonstrate its accuracy and efficiency.

Numerical modelling of vibration response in loess hills due to a high-speed train on railway viaduct

In order to accurately analyze vibration characteristics and site effects of loess hills under moving load of a highspeed train,four types of loess hill models under railway viaduct was established by ABAQUS of finite element analysis software by field test.The dynamic response and stability of loess hills under two different vibration sources under high-speed train load were studied by using two-dimensional equivalent linear response timehistory analysis,and the influence of the mechanical parameters of loess on the vibration of different types of loess hill was analyzed.Results show that there are obvious differences between peak displacement cloud maps of loess hills under the railway viaduct under gravity and train load action.We analyzed the influence of the change of elastic modulus on vibration propagation of soil of foundation and loess knoll,and found that the change of elastic modulus of soil in different position of foundation has more effect on vibration propagation than that of loess knoll soil.At the same time,the vertical acceleration cloud maps of the four types of loess hills are obviously different.

Parametric analysis of wheel wear in high-speed vehicles

In order to reduce the wheel profile wear of highspeed trains and extend the service life of wheels, a dynamic model for a high-speed vehicle was set up, in which the wheelset was regarded as flexible body, and the actual measured track irregularities and line conditions were considered. The wear depth of the wheel profile was calculated by the well-known Archard wear law. Through this model, the influence of the wheel profile, primary suspension stiffness, track gage, and rail cant on the wear of wheel profile were studied through multiple iterafive calculations. Numerical simulation results show that the type XP55 wheel profile has the smallest cumulative wear depth, and the type LM wheel profile has the largest wear depth. To reduce the wear of the wheel profile, the equivalent conicity of the wheel should not be too large or too small. On the other hand, a small primary vertical stiffness, a track gage around 1,435-1,438 mm, and a rail cant around 1：35-1：40 are beneficial for dynamic performance improvement and wheel wear alleviation.

Computation of Impact Factor of High-Speed Railway Bridge by KTX Train Riding Test

The design live load of railway is divided into common railway and high-speed railway separately inKorea. Accordingly, the Korean design specification of railway specifies the impact factor for common railway and high-speed railway respectively. The impact factor for high-speed railway is based on Eurocode. Since the impact factor criteria inKoreawere established by adopting those of the Eurocode and without dedicated investigation relying on research results reflecting the domestic circumstances, thorough examination should be implemented on these criteria. Therefore the evaluation of impact factor based on field tests is required. Both dynamic and static vertical displacements are necessary to compute the impact factor. The dynamic response can be obtained from the measurement of deflection of the bridge slab crossed by the firstKoreahigh-speed train (KTX, Korea Train eXpress) running at high-speed. The main difficulties encountered are in obtaining static response because static response corresponds to the response of the bridge when the train remains immobile on the bridge or crosses the bridge at speed slower than5 km/hr. This study introduces the static response derived by applying the moving average method on the dynamic response signal. To that goal, field measurements was conducted under train speeds of5 km/hr and ranging from100 km/hr to300 km/hr on Yeonjae Bridge located in the trial section of the Gyeonbu High-Speed Railway Line before its opening. The validity of the application of the moving average method is verified from comparison of measured static response and derived static response by moving average method. Moreover, evaluation is conducted on the impact factor computed for a bridge crossed by the KTX train running at operational speed.