Processing the rig test data of an air filling twin-tube shock absorber

A separation method is proposed to design and improve shock absorber according to the characteristics of each force. The method is validated by rig test. The force data measured during rig test is the resultant force of damping force, rebound force produced by pressed air, and friction force. Different characters of damping force, air rebound force and friction force can be applied to seperate each force from others. A massive produced air filling shock absorber is adopted for the validation. The statistic test is used to get the displacement-force curves. The data are used as the input of separation calculation. Then the tests are carried out again to obtain the force data without air rebound force. The force without air rebound is compared to the data derived from the former tests with the separation method. The result shows that this method can separate the damping force and the air elastic force.

Research on the strain gauge mounting scheme of track wheel force measurement system based on high-speed wheel/rail relationship test rig

Purpose-This paper aims to analyze the stress and strain distribution on the track wheel web surface and study the optimal strain gauge location for force measurement system of the track wheel.Design/methodology/approach-Finite element method was employed to analyze the stress and strain distribution on the track wheel web surface under varying wheel-rail forces.Locations with minimal coupling interference between vertical and lateral forces were identified as suitable for strain gauge installation.Findings-The results show that due to the track wheel web’s unique curved shape and wheel-rail force loading mechanism,both tensile and compressive states exit on the surface of the web.When vertical force is applied,Mises stress and strain are relatively high near the inner radius of 710 mm and the outer radius of 1110mmof the web.Under lateral force,high Mises stress and strain are observed near the radius of 670mmon the inner and outer sides of the web.As the wheel-rail force application point shifts laterally toward the outer side,the Mises stress and strain near the inner radius of 710 mm of the web gradually decrease under vertical force while gradually increasing near the outer radius of 1110 mm of the web.Under lateral force,the Mises stress and strain on the surface of the web remain relatively unchanged regardless of the wheel-rail force application point.Based on the analysis of stress and strain on the surface of the web under different wheel-rail forces,the inner radius of 870 mm is recommended as the optimal mounting location of strain gauges for measuring vertical force,while the inner radius of 1143 mm is suitable for measuring lateral force.Originality/value-The research findings provide valuable insights for determining optimal strain gauge locations and designing an effective track wheel force measurement system.

Bogie active stability simulation and scale rig test based on frame lateral vibration control

This paper puts forward a high-speed train bogie active stability method,based on frame lateral vibration control,for improving the stability and critical speed of railway vehicles at high speeds.Two inertial actuators apply active control forces to the front and rear end beams of the bogie frame.A scale model of bogie lateral dynamics is established,as well as the state space equation of the control system.Also,the multi-objective optimization is used to construct state feedback parameters,which take hunting stability and control effort into account.Furthermore,the effects of time-delay in the control system and suspension parameters on bogie hunting stability are studied.The dynamic behaviors and the stability mechanism of the bogie control system are analyzed.Finally,a 1:5 scale test rig is used to conduct a bogie active stability experiment.The results reveal that active control of frame lateral vibration can effectively improve the bogie system's hunting stability margin at high speeds,but time-delay in the control system cannot be ignored.

Development of a Test Rig for Axial Strains Measurement in Automobile Wheel

In automobile wheel application, a test rig is vital and used to simulate conditions of the wheel in service in order to affirm the safety and reliability of the wheel. The present work designed a test rig for measuring axial strains in automobile wheel. The wheel used was a five-arm wheel (6JX14H2;ET 42) and Tyre (175 × 65 R 14). Experimental (EXP) test was carried out, with a radial load of 4750 N and inflation pressure of 0.3 MPa, to measure the axil strains which were converted to maximum principal strain values and, compared with data from Finite Element Analysis (FEA) using Creo-Element/Pro 5.0 at wheel’s contact angles of 90 degree (FEA 90 deg), 40 degree (FEA 40 deg) and 30.25 degree (FEA 30.25 deg), respectively. Results show that at the wheel’s point of contact with the ground, maximum principal strain values were highest at the inboard bead seat with a value of about 5.69 × 10-4 mm/mm, followed by the values at the well of about 5.66 × 10-4 mm/mm. The value at the outboard bead seat was least at about 2.22 × 10-4 mm/mm, which was due to the presence of spikes at this location that tends to resist imposed radial loads. However, the highest mean maximum principal strain values at the locations of inboard, well and outboard, were about 2.11 × 10-4 mm/mm, 3.78 × 10-4 mm/mm and .99 × 10-4 mm/mm, respectively. With the highest single value of about 5.69 × 10-4 mm/mm, the inboard bead seat was the most strained location of the wheel. Overall results showed that all values of maximum principal strains were below the threshold value of about 1 × 10-2 mm/mm. The values obtained for EXP and FEA could be said to be in close agreement when compared with the threshold value. With this in mind, the rig is recommended for use in related experimental procedures.

Corrosion behavior and failure mechanism of SiC whisker and c-AlPO_(4) particle-modified novel tri-layer Yb_(2)Si_(2)O_(7)/mullite/SiC coating in burner rig tests

The corrosion behavior of environmental barrier coatings(EBCs)directly affects the service life and stability of ceramic matrix composite(CMC)structural parts in the aero-engines.The silicon carbide(SiC)whisker toughening phase and c-AlPO_(4) bonding phase are firstly used to improve the service life of novel tri-layer Yb_(2)Si_(2)O_(7)/mullite/SiC EBCs in the burner rig test.The formation of penetrating cracks in Yb_(2)Si_(2)O_(7)/mullite/SiC coating caused the failure of coating at 1673 K.The SiC whiskers in mullite middle coating significantly inhibited the formation of penetrating cracks in Yb_(2)Si_(2)O_(7)/mullite/SiC coating,and efficiently prevented the oxidation of carbon fiber reinforced silicon carbide(C_(f)/SiC)samples for 360-min thermal cycles(24 times)with a weight loss of 6.19×10^(−3) g·cm^(−2).Although c-AlPO_(4) particles further improved the service life of SiC_(w)-mullite(SM)coating,the overflow of PO_(x) gas aggravated the formation and expansion of cracks in the Yb_(2)Si_(2)O_(7) outer coating,and caused the service life of overall Yb_(2)Si_(2)O_(7)/c-AlPO_(4)-SiC_(w)-mullite(ASM)/SiC coating to be slightly lower than that of Yb_(2)Si_(2)O_(7)/SM/SiC coating.This study guides the design of modified tri-layer EBCs with long service life in high-temperature and high-speed gas environment.

Real-time multibody modeling and simulation of a scaled bogie test rig

In wheel–rail adhesion studies,most of the test rigs used are simplified designs such as a single wheel or wheelset,but the results may not be accurate.Alternatively,representing the complex system by using a full vehicle model provides accurate results but may incur complexity in design.To trade off accuracy over complexity,a bogie model can be the optimum selection.Furthermore,only a real-time model can replicate its physical counterpart in the time domain.Developing such a model requires broad expertise and appropriate software and hardware.A few published works are available which deal with real-time modeling.However,the influence of the control system has not been included in those works.To address these issues,a real-time scaled bogie test rig including the control system is essential.Therefore,a 1:4 scaled bogie roller rig is developed to study the adhesion between wheel and roller contact.To compare the performances obtained from the scaled bogie test rig and to expand the test applications,a numerical simulation model of that scaled bogie test rig is developed using Gensys multibody software.This model is the complete model of the test rig which delivers more precise results.To exactly represent the physical counterpart system in the time domain,a real-time scaled bogie test rig(RT-SBTR)is developed after four consecutive stages.Then,to simulate the RT-SBTR to solve the internal state equations and functions representing the physical counterpart system in rigs used are simplified designs such as a single wheel or wheelset,but the results may not be accurate.Alternatively,representing the complex system by using a full vehicle model provides accurate results but may incur complexity in design.To trade off accuracy over complexity,a bogie model can be the optimum selection.Furthermore,only a real-time model can replicate its physical counterpart in the time domain.Developing such a model requires broad expertise and appropriate software and hardware.A few published works are available which deal with real-time modeling.However,the influence of the control system has not been included in those works.To address these issues,a real-time scaled bogie test rig including the control system is essential.Therefore,a 1:4 scaled bogie roller rig is developed to study the adhesion between wheel and roller contact.To compare the performances obtained from the scaled bogie test rig and to expand the test applications,a numerical simulation model of that scaled bogie test rig is developed using Gensys multibody software.This model is the complete model of the test rig which delivers more precise results.To exactly represent the physical counterpart system in the time domain,a real-time scaled bogie test rig(RT-SBTR)is developed after four consecutive stages.Then,to simulate the RT-SBTR to solve the internal state equations and functions representing the physical counterpart system in equal or less than actual time,the real-time simulation environment is prepared in two stages.To such end,the computational time improved from 4 times slower than real time to 2 times faster than real time.Finally,the real-time scaled bogie model is also incorporated with the braking control system which slightly reduces the computational performances without affecting real-time capability.

Test Rig Effect on Performance Measurement for Low Loaded Large-Diameter Fan for Automotive Application

Large diameter fans with low solidity are widely used in automotive application for engine cooling. Their designs with small chord length help reducing the torque on the electrical motor and providing a good aerodynamic compromise between several operating conditions, some of these being at high flow rate. Their global performances are measured according to the ISO standard DP 5801, which allows comparison of results from different facilities. However, some variations in global performances are observed when considering results from two different test rigs. On a fan selected for the purpose of this study, up to 6 % of efficiency is lost on the worst case. As efficiency is more than ever a key factor to select a component, some experimental and numerical investigations were conducted to analyze the fan behavior on each facility. Two sets of measurement and simulation are performed and compared. Geometries considered for the domain of computation include the test rig plenum, the torquemeter, the ground and a large domain for the atmospheric conditions. The exact fan geometry with tip clearance and under-hub ribs is also considered. Numerical results show a good agreement with experiment in both cases when convergence is reached and for low flow rate when computations are switched to unsteady mode. Comparisons show that simulations are able to capture the different fan behaviors depending on the confguration and those efficiency losses previously observed are correctly predicted. These results are further analyzed to perform some post-processing. Blade loading remains identical for both cases but disparities appear in the wake and its interaction with the surrounding. Tiny details that are often neglected during experiment and/or simulation appear to be the cause of slight variations. Position of the torquemeter and shape of the plenum are among the parameters that various and that have cumulative effects. Efficiency being a ration of pressure and torque, variations are rather important. Finally, these results are discussed in terms of rules for conception and a new geometry less sensible to loss of efficiency is proposed.

Automatic lifting system design and application of large load powered support test rig

This paper presented a design of an automatic lifting system. It is used for large load powered support and improves the old method wherein powered support lifting depends on manual control. This system applies a high accuracy gear shunt motor to match the flow for 4 lifting cylinders, and also allocates bypass throttles to realize automatic lifting. Through the dis- placement sensor feedback the height deviation among 4 lifting cylinders during the whole lifting process, when the deviation is up to the sitting value, the corresponding bypass throttle is operated immediately to reduce the deviation, so that the moving platform of the powered support would not be stuck. Through real application, it is shown that this system can realize automatic lifting of powered support; the lifting speed is controlled between 5 and 10 mm/s, and the final aligning accuracy is up to 1 mm.

基于整车路面谱的副车架开裂台架试验及仿真

针对前悬架稳定杆与副车架连接处在整车试验场耐久测试过程中出现的疲劳破坏问题,通过对稳定杆进行贴片标定,获得了试验场环境下稳定杆的连杆力和稳定杆扭转相对位移的强化耐久路谱,设计搭建了稳定杆副车架系统的物理台架,并按照耐久性规范进行了台架试验。试验结果表明:该台架试验装置能良好地再现整车耐久路试下的断裂位置,疲劳寿命相对于整车耐久路试的疲劳寿命偏差仅为2.5%。在此基础上,建立了稳定杆与副车架多体的仿真模型,设定了与系统试验台架相同的约束边界,通过虚拟迭代的方法及准静态有限元疲劳寿命分析法对系统进行了仿真分析。仿真得到稳定杆连杆力和稳定杆扭转相对位移信号,与测试结果进行对比分析可以看出,时域下相位和幅值重合度良好,频域下的PSD谱重合度较高,穿级计数载荷统计基本一致,载荷相对损伤均在1附近,相关风险位置处的仿真疲劳寿命与整车耐久试验寿命偏差比为6.25%,获得了较高精度的风险位置载荷,实现了耐久风险位置的复现。最后,基于仿真模型对副车架风险位置处进行了结构优化设计,改进后的方案顺利通过了后续的台架试验和整车耐久路试。

试验台约束对滑动轴承动特性识别精度的影响

在滑动轴承的动特性测试中,试验台参数对动特性测试精度有重要的影响。以某倒置式轴承动特性试验台为研究对象,基于轴承动力学正反问题,提出滑动轴承动特性系数识别精度的仿真评估方法,分析不同激振频率时试验台约束参数对轴承动特性系数识别精度的影响规律,并对激振频率和约束参数的取值范围进行优选。结果表明:在较低激振频率的条件下,当约束刚度和约束阻尼取值较小时,动特性系数的识别精度受测试误差的影响不大,随着约束刚度和约束阻尼取值增大到一定值,动特性系数的识别精度受测试误差的影响迅速增大。针对研究的试验台,选择激振频率在30~300 Hz之间,选择试验台约束刚度小于试验轴承刚度的0.3%,试验台约束阻尼小于试验轴承阻尼的7%时,能够保证较好的轴承动特性系数的测试精度。

透平试验件对试验台横振不平衡响应的影响

重型燃气轮机透平试验台系统由试验台和试验件两部分构成。对于已经建成的试验台,需要考虑不同试验件对试验台横振不平衡响应的影响。本文利用机械阻抗综合法的阻抗匹配原理,将未知试验件的动力学特性模化为交界面上的机械阻抗,来确定试验件对试验台横振不平衡响应的影响,得出未知试验件的设计限制范围。同时,建立了某个试验件和试验台的动力学模型,分析了该系统的横向振动不平衡响应,验证了试验件不平衡响应的设计限制范围的有效性。

永磁电动悬浮多工况下的电磁力特性研究

永磁电动悬浮系统由于自身弱阻尼的特点,运行过程中磁体的姿态易受外界扰动而发生改变,从而影响系统的电磁力特性。该文针对磁体倾斜、横移、偏转等工况,采用解析计算、仿真分析、实验验证相结合的方法来研究系统电磁力特性。首先阐述系统的结构及原理,推导Halbach永磁体阵列在水平、倾斜、偏转状态下的磁场分布函数,建立适用于系统多工况的三维解析模型;其次,搭建三维仿真模型,仿真结果验证了解析模型的正确性,并结合解析模型对比分析系统典型工况下的浮阻特性和悬浮能力;最后,依托组内自研的最高设计时速为600km/h的动轨实验台,分析了系统在固定参数下的电磁力特性和垂向自稳定能力,并验证解析模型的准确性及磁体在不同横移位置的电磁力特性。

低压等离子喷涂NiCoCrAIYTa涂层的抗燃气热冲击性能研究

为了保障涡轮叶片材料的抗高温氧化与耐热腐蚀性能,采用低压等离子喷涂技术在航空发动机涡轮叶片试验件上成功制备了NiCoCrAlYTa涂层。通过对不同粉末制备的NiCoCrAlYTa涂层进行1000℃/75 h燃气热冲击试验,研究了带涂层叶片尺寸、涂层表面形貌、相组成和显微组织、涂层厚度和均匀性等性能参数的变化。结果表明:热冲击试验后,不同涂层叶片的整体尺寸未发生显著变化,表明涂层在高温环境下具有稳定的尺寸;涂层表面形成了Al_(2)O_(3)膜和NiAl_(2)O_(4)尖晶石,保留了较好的结构完整度,这有助于提高涂层的耐腐蚀性能;涂层的物相组成主要包括γ-Ni、γ’-Ni_(3)Al和少量的β-NiAl,形成了贫Al区、互扩散区、二次反应区等典型微区结构,析出的TCP相为R相,表明在热冲击过程中涂层发生了相变;不同粉末制备的NiCoCrAlYTa涂层均表现出了良好的抗热冲击性能,为航空发动机涡轮叶片的高温应用提供了可行的涂层方案。

低周疲劳的结构应变法在铁路货车上的工程应用

为了开展铁路货车车体焊接结构的低周疲劳寿命预测,详细推导了理想弹塑性结构应变计算理论,基于计算理论进行了程序设计,并通过焊接接头试验进行了验证.进一步开展了平面应变焊接接头模型的仿真计算结果和结构应变法计算结果的对比,探讨结构应变法的使用条件.最后,将虚拟台架与结构应力变结合开展了快捷货车的低周疲劳寿命分析的工程应用.结果表明:提出的低周疲劳的结构应变方法及其计算程序,当结构应力与屈服强度的差值在150 MPa以内时,理想弹塑性结构应变计算结果与实际结果一致,能够解决铁路货车低周疲劳寿命预测问题;当结构应力与屈服强度差值超过150 MPa后,随着结构应力的增加,误差也增加.该文的研究为低周疲劳的结构应变法工程推广应用提供了良好的技术支撑.

基于环形试验台的钢轨短波长波磨产生机理研究

介绍一种具有小半径曲线轨道的环形试验台,并对其钢轨表面短波长波磨的形成原因进行分析。环形试验台上车辆运行6 000圈后,在低轨表面观察到钢轨波磨以3.31 mm的波长再现。通过力锤敲击对轨道动态特性进行频率响应函数测试,并在行车条件下对波磨附近处高低轨的振动加速度进行数据采样,采用短时傅里叶变换对采样数据在频域上进行分析。根据试验台的实际尺寸建立轨道三维实体有限元模型,并对其进行模态分析和频响分析。结合试验和仿真的结果分析轨道结构动态特性与钢轨波磨的相关性。结果表明,试验车辆运行速度为12 km/h时,3.3 mm波长波磨的通过频率为1 007 Hz。低轨的1阶垂向Pinned-Pinned频率为2 277 Hz,低轨的1阶横向Pinned-Pinned频率为1 015 Hz,与波磨通过频率相吻合。车辆通过小曲线半径时,低轨上的横向振动幅值远大于高轨上的振动幅值,且低轨上的横向Pinned-Pinned频率1 015 Hz容易被激发,形成与共振频率对应的波磨,且在不同行车速度下低轨被激发出来的横向Pinned-Pinned频率几乎不会受速度的影响,振动幅值随着速度的减小依次降低。低轨频率响应函数试验测试的结果和有限元仿真的结果相吻合,验证了所建立的有限元模型的准确性,且在白噪声的激励下,有限元模型中低轨的横向Pinned-Pinned频率极易被激发出来,其模态振型表现为以钢轨弹性扣件支撑点相对固定。轨道结构波磨的产生主要与轨道结构中高频固有特性相关,钢轨横向Pinned-Pinned模态被激发加剧了钢轨的横向振动是导致小曲线半径低轨钢轨波磨形成的原因。

Virtual vibration test rig for fatigue analysis of dozer push arms

To obtain accurate fatigue life results for construction machinery components,acquiring load spectra is crucial,as their authenticity and validity directly determine the precision of the analysis.In working conditions,component attitudes change continuously,but they remain static on the vibration test rig(VTR),so the acquired target signals should match with the actual component attitudes in the driving signal generation.This paper proposes an efficient and economical simulation-based virtual VTR for fatigue analysis of dozers.First,the relationship between the push arm rotation angle and the cylinder stroke is established,since the cylinder strokes can be measured easily in data acquisition experiments.Second,load decomposition is used to determine the attitude relationship between virtual VTR conditions and actual conditions,and target signals are calculated based on this attitude relationship and measured data.According to the system's frequency response function,the driving signals are iterated until the system's response signals converge with the target signals.Finally,the iteratively obtained load spectra are utilized for fatigue life analysis.The results show that the virtual VTR can effectively and accurately obtain the results of fatigue analysis and has engineering application significance.

Analysis of wheel-rail adhesion redundancy considering the thirdbody medium on the rail surface

Purpose–In response to the problem of insufficient traction/braking adhesion force caused by the existence of the third-body medium on the rail surface,this study aims to analyze the utilization of wheel-rail adhesion coefficient under different medium conditions and propose relevant measures for reasonable and optimized utilization of adhesion to ensure the traction/braking performance and operation safety of trains.Design/methodology/approach–Based on the PLS-160 wheel-rail adhesion simulation test rig,the study investigates the variation patterns of maximum utilized adhesion characteristics on the rail surface under different conditions of small creepage and large slip.Through statistical analysis of multiple sets of experimental data,the statistical distribution patterns of maximum utilized adhesion on the rail surface are obtained,and a method for analyzing wheel-rail adhesion redundancy based on normal distribution is proposed.The study analyzes the utilization of traction/braking adhesion,as well as adhesion redundancy,for different medium under small creepage and large slip conditions.Based on these findings,relevant measures for the reasonable and optimized utilization of adhesion are derived.Findings–When the third-body medium exists on the rail surface,the train should adopt the low-level service braking to avoid the braking skidding by extending the braking distance.Compared with the current adhesion control strategy of small creepage,adopting appropriate strategies to control the train’s adhesion coefficient near the second peak point of the adhesion coefficient-slip ratio curve in large slip can effectively improve the traction/braking adhesion redundancy and the upper limit of adhesion utilization,thereby ensuring the traction/braking performance and operation safety of the train.Originality/value–Most existing studies focus on the wheel-rail adhesion coefficient values and variation patterns under different medium conditions,without considering whether the rail surface with different medium can provide sufficient traction/braking utilized adhesion coefficient for the train.Therefore,there is a risk of traction overspeeding/braking skidding.This study analyzes whether the rail surface with different medium can provide sufficient traction/braking utilized adhesion coefficient for the train and whether there is redundancy.Based on these findings,relevant measures for the reasonable and optimized utilization of adhesion are derived to further ensure operation safety of the train.

城市轨道交通靴轨关系试验台研制

为了利用试验设备开展靴轨受流与磨耗研究工作,根据城市轨道交通靴轨受流特点,研制靴轨关系试验台。详细介绍试验台各组成部分、工作原理及试验过程。仿真计算及试验验证表明,试验台能够较为真实地模拟现场集电靴滑板与接触轨的受流与磨耗情况,靴轨关系试验台的可靠性满足需求。

仿真与试验相结合的衬套耐久失效解决办法

针对耐久性路试出现的衬套开裂问题,基于虚拟试验场(VPG)技术搭建整车多体动力学模型在特征路面进行仿真,提取该衬套在特征路面上的受力及变形,通过仿真结果初步判断出了开裂原因为衬套轴向变形增大及径向受力方向与空心方向夹角偏大的共同作用导致衬套开裂,并通过有限元仿真模拟及零部件台架试验进一步验证了这一判断。基于VPG技术对衬套优化方案进行了正向设计,随后通过台架试验验证了优化方案的有效性,最终顺利通过耐久性路试验证。