Influence of railway wheel tread damage on wheel-rail impact loads and the durability of wheelsets

Dynamic wheel-rail contact forces induced by a severe form of wheel tread damage have been measured by a wheel impact load detector during full-scale field tests at different vehicle speeds.Based on laser scanning,the measured three-dimensional damage geometry is employed in simulations of dynamic vehicle-track interaction to calibrate and verify a simulation model.The relation between the magnitude of the impact load and various operational parameters,such as vehicle speed,lateral position of wheel-rail contact,track stiffness and position of impact within a sleeper bay,is investigated.The calibrated model is later employed in simulations featuring other forms of tread damage;their effects on impact load and subsequent fatigue impact on bearings,wheel webs and subsurface initiated rolling contact fatigue of the wheel tread are assessed.The results quantify the effects of wheel tread defects and are valuable in a shift towards condition-based maintenance of running gear,and for general assessment of the severity of different types of railway wheel tread damage.

FPGA Implementation of Extended Kalman Filter for Parameters Estimation of Railway Wheelset

It is necessary to know the status of adhesion conditions between wheel and rail for efficient accelerating and decelerating of railroad vehicle.The proper estimation of adhesion conditions and their real-time implementation is considered a challenge for scholars.In this paper,the development of simulation model of extended Kalman filter(EKF)in MATLAB/Simulink is presented to estimate various railway wheelset parameters in different contact conditions of track.Due to concurrent in nature,the Xilinx®System-on-Chip Zynq Field Programmable Gate Array(FPGA)device is chosen to check the onboard estimation ofwheel-rail interaction parameters by using the National Instruments(NI)myRIO®development board.The NImyRIO®development board is flexible to deal with nonlinearities,uncertain changes,and fastchanging dynamics in real-time occurring in wheel-rail contact conditions during vehicle operation.The simulated dataset of the railway nonlinear wheelsetmodel is tested on FPGA-based EKF with different track conditions and with accelerating and decelerating operations of the vehicle.The proposed model-based estimation of railway wheelset parameters is synthesized on FPGA and its simulation is carried out for functional verification on FPGA.The obtained simulation results are aligned with the simulation results obtained through MATLAB.To the best of our knowledge,this is the first time study that presents the implementation of a model-based estimation of railway wheelset parameters on FPGA and its functional verification.The functional behavior of the FPGA-based estimator shows that these results are the addition of current knowledge in the field of the railway.

Research on hunting stability and bifurcation characteristics of nonlinear stochastic wheelset system

A stochastic wheelset model with a nonlinear wheel-rail contact relationship is established to investigate the stochastic stability and stochastic bifurcation of the wheelset system with the consideration of the stochastic parametric excitations of equivalent conicity and suspension stiffness.The wheelset is systematized into a onedimensional(1D)diffusion process by using the stochastic average method,the behavior of the singular boundary is analyzed to determine the hunting stability condition of the wheelset system,and the critical speed of stochastic bifurcation is obtained.The stationary probability density and joint probability density are derived theoretically.Based on the topological structure change of the probability density function,the stochastic Hopf bifurcation form and bifurcation condition of the wheelset system are determined.The effects of stochastic factors on the hunting stability and bifurcation characteristics are analyzed,and the simulation results verify the correctness of the theoretical analysis.The results reveal that the boundary behavior of the diffusion process determines the hunting stability of the stochastic wheelset system,and the left boundary characteristic value cL=1 is the critical state of hunting stability.Besides,stochastic D-bifurcation and P-bifurcation will appear in the wheelset system,and the critical speeds of the two kinds of stochastic bifurcation decrease with the increase in the stochastic parametric excitation intensity.

Influence of unsupported sleepers on the dynamic stability of ballasted bed based on wheelset impact tests

The unsupported sleeper can change the load characteristics of ballast particles and thus affect the dynamic stability of a ballasted bed.In this work,a laboratory test was constructed on a ballasted track containing unsupported sleepers.The ballasted track was excited by a wheelset,and the influence of unsupported sleepers on the dynamic stability of a ballasted bed was studied.The results show that the main frequency of the sleeper vibration appeared at 670 Hz,and the first-order rigid vibration mode at the frequency of 101 Hz had a significant effect on the condition without the unsupported sleeper.When the sleepers were continuously unsupported,the vibration damping effect of ballasted bed within the frequency range of 0–450 Hz was better than that at higher frequencies.Within the frequency range of 70–250 Hz,the vibration damping effect of the ballasted bed with unsupported sleepers was better than that without the unsupported sleeper.Owing to the excitation from the wheelset impact,the lateral resistance of the ballasted bed with unsupported sleepers whose hanging heights were 30,60,and 90 mm increased by 37.43%,12.25%,and 18.23%,respectively,while the lateral resistance of the ballasted bed without the unsupported sleeper remained basically unchanged.The unsupported sleeper could increase the difference in the quality of the ballasted bed between two adjacent sleepers.In addition,test results show that the hanging height of the unsupported sleeper had little effect on the lateral resistance of a ballasted bed without external excitation,but had an obvious effect on the rate of change of the lateral resistance of a ballasted bed and the acceleration amplitude of the sleeper vibration under the wheelset impact.

Analysis of steering performance of differential coupling wheelset

In order to improve the curving performance of the conventional wheelset in sharp curves and resolve the steering ability problem of the independently rotating wheel in large radius curves and tangent lines, a differential cou- pling wheelset （DCW） was developed in this work. The DCW was composed of two independently rotating wheels （IRWs） coupled by a clutch-type limited slip differential. The differential contains a static pre-stress clutch, which could lock both sides of IRWs of the DCW to ensure a good steering performance in curves with large radius and tangent track. In contrast, the clutch could unlock the two IRWs of the DCW in a sharp curve to endue it with the characteristic of an IRW, so that the vehicles can go through the tight curve smoothly. To study the dynamic performance of the DCW, a multi-body dynamic model of single bogie with DCWs was established. The self-centering capability, hunting stability, and self-steering performance on a curved track were analyzed and then compared with those of the conventional wheelset and IRW. Finally, the effect of coupling parameters of the DCW on the dynamic performance was investigated.

Effect of wheelset flexibility on wheel–rail contact behavior and a specific coupling of wheel–rail contact to flexible wheelset

The fexibility of a train＇s wheelset can have a large effect on vehicle–track dynamic responses in the medium to high frequency range.To investigate the effects of wheelset bending and axial deformation of the wheel web,a specifi coupling of wheel–rail contact with a fexible wheelset is presented and integrated into a conventional vehicle–track dynamic system model.Both conventional and the proposed dynamic system models are used to carry out numerical analyses on the effects of wheelset bending and axial deformation of the wheel web on wheel–rail rolling contact behaviors.Excitations with various irregularities and speeds were considered.The irregularities included measured track irregularity and harmonic irregularities with two different wavelengths.The speeds ranged from 200 to400km/h.The results show that the proposed model can characterize the effects of fexible wheelset deformation on the wheel–rail rolling contact behavior very well.

Influence of dynamic unbalance of wheelsets on the dynamic performance of high-speed cars

With further increasing in running speed of newer high-speed EMUs（electric multiple units）,higher demand for wheelset dynamic balance is required.In order to study the influence of the dynamic unbalance of wheelset on the stability,ride quality,and curving performance for a high-speed car,a detailed dynamic model of a high-speed EMU car is established using the software SIMPACK.The analysis results indicate that the dynamic unbalance of the wheelset significantly influences the dynamic performance of the high-speed car.The increase in dynamic unbalance of the wheelset will decrease the hunting critical speed,worsen the vertical ride quality,and increase the wheelset lateral force,derailment coefficient,and wheel unloading ratio.Therefore,in order to improve the stability,ride quality,and running safety of high-speed car,the values of dynamic unbalance of wheelset should be strictly controlled in manufacturing,and periodically monitored in operation.

A Nondestructive Instrumented Wheelset System for Contact Forces Measurements

A nondestructive continuous instrumented wheelset design is proposed based on strain gauges placing inside of the wheel web and wireless telemetry system. The signal feature analysis including frequency contents and high order harmonic ripples is also carried out. The strain gradient decoupling method for vertical and lateral force identification is proposed based on the strain distributions under respective loads. The method implements minimum crosstalk effects and insensitive to the varying contact points. The KMT telemetry system is adopted for wireless inductive powering and signal transferring. The drilling holes on the wheel and axles are avoidable to ensure the integrity and long-term using of the wheelset. Bridging and demodulating schemes for lateral and vertical force are designed respectively as they have dramatic differences at the dynamic signal features. High order harmonic ripple analysis and error estimation are gotten by independent waveforms. Based on the data form calibration test rig, it is indicated that the high order ripple amplitudes are below 10% of the demodulation amplitudes and fulfill designed requirements.

Useful zero friction simulations for assessing MBS codes Pascal’s formula giving wheelsets frequency for zero wheel-rail friction

Present study provides a simple analytical formula,the“Klingel-like formula”or“Pascal’s Formula”that can be used as a reference to test some results of existing railway codes and specifically those using rigid contact.It develops properly the 3D Newton-Euler equations governing the 6 degrees of freedom(DoF)of unsuspended loaded wheelsets in case of zero wheel-rail friction and constant conicity.Thus,by solving numerically these equations,we got pendulum like harmonic oscillations of which the calculated angular frequency is used for assessing the accuracy of the proposed formula so that it can in turn be used as a fast practical target for testing multi-body system(MBS)railway codes.Due to the harmonic property of these pendulum-like oscillations,the squareω2 of their angular frequency can be made in the form of a ratio K/M where K depends on the wheelset geometry and load and M on its inertia.Information on K and M are useful to understand wheelsets behavior.The analytical formula is derived from the first order writing of full trigonometric Newton-Euler equations by setting zero elastic wheel-rail penetration and by assuming small displacements.Full trigonometric equations are numerically solved to assess that the formula providesω2 inside a 1%accuracy for usual wheelsets dimensions.By decreasing the conicity down to 1×10^(−4) rad,the relative formula accuracy is under 3×10^(−5).In order to test the formula reliability for rigid contact formulations,the stiffness of elastic contacts can be increased up to practical rigidity(Hertz stiffness×1000).

Effects of wheelset vibration on initiation and evolution of rail short-pitch corrugation

The initiation and evolution of short-pitch corrugation in Beijing metro line 4 was studied from the viewpoint of wheelset vibration.A three-dimensional elastic model was set up.Numerical simulations were undertaken with this model to analyze the corrugation by the wheelset vertical vibration and torsional vibration.Based on numerical results,the relation between rail corrugation and wheelset vibration,and the relation between the position of electromotor and wheelset vibration were indicated.It is found that avoiding the wheelset-rail resonance is one method of controlling the rail short-pitch corrugation and solving the vibration and noise problem in metro lines.

列车轮对简化模型重力刚度与滚动半径的计算方法

在建立列车轮对简化模型动力学方程中,如果假设侧移和摇头角是微小量,及质心高度保持不变,可以较简便地求出重力刚度和滚动半径等量的近似表达式。本文用几何方法给出了轮对质心高度和滚动半径与侧向位移之间的函数关系,从而可以获得这些量的解析表达式;另外还通过运动学方法,证明了重力刚度和滚动半径等量的简便计算方法是正确的。

采用弹性车轮的独立轮对有轨电车曲线通过动力学性能研究

采用动力学仿真软件SIMPACK,利用离散刚度阻尼单元模拟弹性车轮的弹性变形特性,建立了三编组现代有轨电车列车动力学计算模型,对比分析了曲线半径R400 m线路条件下弹性车轮在时域和频域内的减振性能,讨论了50~400 m不同半径的曲线线路条件下不同轮对形式的弹性车轮对中间拖车曲线通过性能的影响。计算结果显示:弹性车轮能够减小20~40 Hz、50~70 Hz和180~300 Hz频率范围内的车体垂向振动以及20~550 Hz范围内的车体横向振动。从轮对横移量和轮重减载率看,曲线半径R200 m左右是弹性车轮传统轮对和弹性车轮独立轮对曲线导向能力的分界点;从轮轨横向蠕滑率、轮对摇头角、脱轨系数和轮轴横向力看,曲线半径R100 m左右是分界点。

VMD引导的轮对与轴承复合故障诊断方法

针对列车轮对轴承系统复合故障难以辨识与诊断问题,提出一种变分模态分解(variational mode decomposition,VMD)引导的多故障特征提取匹配方法.首先,为避免预定义模式数在运行过程中对先验知识依赖从而对诊断结果造成影响,对原始轴箱振动数据进行逐阶VMD分解,模式数为2~N;其次,对VMD分解获取的本征模态函数(VMD intrinsic mode functions,VIMF)进行相关峭度计算,提取相关峭度最大的VIMF;然后,将相关峭度最大的VIMF进行平方包络分析,提取故障特征频率;最后,将所提方法与快速峭度谱、相关峭度谱方法进行对比.仿真信号和试验数据分析表明:所提方法完全规避了VMD模型中关键参数K的选择问题,可以准确、有效地分别提取出轮对和轴承的故障特征;与快速谱峭度与相关谱峭度方法相比,获取的故障特征谐波分量在数量和信噪比上均具有明显优势.

高铁轮对高精度测量系统设计与实现

针对国内轮对尺寸测量手段落后、精度不高、测量效率以及自动化水平低的问题,设计并实现了一种接触式轮对外形尺寸自动化测量系统。该系统利用接触式触发测头以及位移传感器实现了轮对外形尺寸自动化测量,并通过相对测量原理以及温度补偿算法实现了包括内侧距离、轮位、轴颈直径等长度尺寸及径向尺寸的高精度测量。通过在高铁轮对生产组装现场实际试验及试用验证,该系统的测量结果具有高精度和高一致性,满足高铁轮对各个尺寸的测量精度要求。

基于张量分解的地铁车轮健康指数构建

地铁在运行过程中,车轮踏面、轮缘与轨道持续磨损会导致车轮性能退化。对车轮退化过程中的不同状态进行识别和评估是车辆故障预测与健康管理的关键环节。近年来,基于振动信号和机器学习的地铁车轮退化状态智能识别技术在降低人工依赖、优化镟修策略方面作用显著。但由于在实际运行过程中,地铁轮对通常受载荷、路况等因素影响,振动信号易受强噪声干扰,导致退化趋势不显著,难以直接识别其状态变化。为解决这一问题,文章提出一种基于张量重构的健康指标构建方法。该方法首先基于张量分解可有效挖掘信号高维本质信息的优点,利用张量Tucker分解获得原始信号的核心张量;其次,采用张量重构和Savitzky-Golay滤波方法对信号进行降噪处理;最后,在此基础上,利用深度自动编码器网络提取深度退化特征,建立车轮退化过程的健康指标。依托北京地铁某线路实际运行的车轮振动信号数据所进行的实验结果表明,采用该方法构建的健康指标具有良好的趋势性和单调性,能够准确描述轮对整个退化过程,所得到的异常预警位置与轮径值磨损变化和实际镟修记录准确对应。该方法的提出为地铁轮对健康管理提供一种智能化的解决方案,具有良好的实用价值。

柔性轮对高速列车通过道岔的动力学响应

为研究高速列车在柔性轮对条件下通过道岔时的动力响应,采用刚柔耦合动力学仿真方法,基于CRH380高速列车模型建立柔性轮对结构条件下的车辆—道岔刚柔耦合动力学模型。以柔性轮对高速列车模型为研究对象,通过18号高速道岔,分析轮对柔性与全刚体结构条件下的车辆模型的安全性、轮轨动态相互作用、车体振动加速度及轮轨接触位置分布指标。仿真结果表明,柔性轮对高速列车模型对车辆的轮轨动态相互作用影响较大,对安全性、车体振动加速度及轮轨接触位置分布等动力学指标影响较小。

基于信息交互的牵引系统控制策略研究

采用独立轮对的有轨电车可最大程度降低低地板车辆的地板高度,无需高站台设计且方便乘客上下车,发展前景十分广阔。但是独立轮对理论上不存在纵向蠕滑力,曲线导向能力下降,因此对列车牵引制动过程中的出力及控制策略提出更高要求,针对独立轮对有轨电车的特点,本文介绍了一种牵引变流器的设计方案及控制策略,从主电路设计、工作原理、硬件结构等方面进行阐述,基于双功率模块的信息交互,从顶层给出牵引力的优化施加目标,基于分段同步调制及矢量控制策略,实现列车牵引力输出的优化控制。最后,通过现场牵引制动试验及极端恶劣线路空转滑行试验验证了所提设计方案的有效性,对独立轮对牵引系统及类似应用场合的牵引系统硬件设计及控制策略具有一定的指导意义。

风载作用下高速列车曲线通过性能研究

在风载和曲线欠超高叠加的不利工况下,高速列车的运行安全性表现出复杂的变化规律,因此需要针对风载作用下高速列车的曲线通过安全性进行深入研究。采用空气动力学和车辆动力学相结合的分析方法,考虑车速和风速变化、实际轮轨匹配及线路激励情况,建立瞬态风载模型、横风作用下高速列车空气动力学模型及车辆动力学模型;对高速列车在不同车速和风速作用下的气动载荷变化规律进行分析,并对其以不同速度通过不同欠超高曲线线路时的脱轨系数、轮重减载率和轮轴横向力等车辆关键动力学参数的变化规律进行分析,研究风载和曲线欠超高对高速列车脱轨和倾覆的影响。结果表明:风速变化引起的侧向力系数变化幅度大于车速;在风载和曲线欠超高叠加的不利工况下,除轮重减载率安全裕量明显降低外,轮轴横向力的安全裕量也降低,且车辆关键悬挂部件工作状态恶化,其中二系横向止档的位移迅速增大且工作状态接近压并,左右两侧空气弹簧压力差也迅速增大,车辆动力学性能的安全裕量明显下降。

机车轮对动态检测系统过渡段设计与动态分析

机车轮对的磨损是影响机车运营稳定性的不利因素,该文设计的机车轮对动态检测线路是一种新型不驻车检测机车轮对磨损状态的专用轨道线路,显著提高轮对磨损状态的检测效率。检测线路轨道间距为1568 mm,宽于标准轨距1435 mm,此时轮对与轨道正常接触区域显著暴露,便于对轮对磨损状态进行检测。通过有限元方法模拟机车通过过渡线路的动态分析,验证该检测方法的可行性。模拟结果表明,从轨道强度、轨道变形及轮对搭载量3个方面综合评价,该机车轮对动态检测线路具有较强实用性,能够满足23 t轴重机车以36 km/h速度安全通过的要求,实现不驻车情况下对轮对磨损状态进行安全检测。

基于高速动车组实测轮轨力的轨道缺陷评价方法

高速铁路轨面低塌、波磨以及各类轮轨型面匹配不良问题均会影响旅客乘坐舒适度,甚至威胁动车组运行安全。上述轨道缺陷在实践运用中不易发现,但长期存在会造成轮轨接触关系极度恶化,严重影响车辆及轨道结构使用寿命。文中基于安装有连续测力轮对的高速铁路综合检测列车,在日常巡检中取得的覆盖全国高速线路的轮轨力实测数据,进行了深入的统计分析及现场对照,提出了一种全新的轨道缺陷评价方案,能够准确给出轨道缺陷类型、缺陷严重程度、具体里程等信息,为工务部门日常检修和维护提供了重要依据,在实践运用中效果良好。