Simulation Analysis and Verifcation of Temperature and Stress of Wheel-Mounted Brake Disc of a High-Speed Train

During the braking process,a large amount of heat energy is generated at the friction surfaces between the brake disc and pads and rapidly dissipates into the disc volume.In this paper,a three-dimensional thermo-mechanical coupling model of high-speed wheel-mounted brake discs containing bolted joints and contact relationships is established.The direct coupling method is used to analyze the temperature and stress of the brake discs during an emergency braking event with an initial speed of 300 km/h.A full-scale bench test is also conducted to monitor the temperatures of the friction ring and bolted joints.The simulation result shows that the surface temperature of the friction ring reaches its peak value of 414°C after 102 s of braking,which agrees well with the bench test result.The maximum alternating thermal stress occurs in the bolt hole where the maximum circumferential compressive stress is−658 MPa and the maximum circumferential tensile stress is 134 MPa.During the braking process,the out-of-plane deformation of the middle part of the friction ring is larger than that of the edge,which increases the axial tensile load of the connecting bolt.This work provides support for the design of brake discs and connecting bolts.

Position Control Optimization of Aerodynamic Brake Device for High-speed Trains

The aerodynamic braking is a clean and non-adhesion braking, and can be used to provide extra braking force during high-speed emergency braking. The research of aerodynamic braking has attracted more and more attentions in recent years. However, most researchers in this field focus on aerodynamic effects and seldom on issues of position control of the aerodynamic braking board. The purpose of this paper is to explore position control optimization of the braking board in an aerodynamic braking prototype. The mathematical models of the hydraulic drive unit in the aerodynamic braking system are analyzed in detail, and the simulation models are established. Three control functions--constant, linear, and quadratic--are explored. Two kinds of criteria, including the position steady-state error and the acceleration of the piston rod, are used to evaluate system performance. Simulation results show that the position steady state-error is reduced from around 12-2 mm by applying a linear instead of a constant function, while the acceleration is reduced from 25,71-3.70 m/s2 with a quadratic control function. Use of the quadratic control function is shown to improve system performance. Experimental results obtained by measuring the position response of the piston rod on a test-bench also suggest a reduced position error and smooth movement of the piston rod. This implies that the acceleration is smaller when using the quadratic function, thus verifying the effectiveness of control schemes to improve to system performance. This paper proposes an effective and easily implemented control scheme that improves the position response of hydraulic cylinders during position control.

Analysis of torque transmitting behavior and wheel slip prevention control during regenerative braking for high speed EMU trains

The wheel-rail adhesion control for regenerative braking systems of high speed electric multiple unit trains is crucial to maintaining the stability,improving the adhesion utilization,and achieving deep energy recovery.There remain technical challenges mainly because of the nonlinear,uncertain,and varying features of wheel-rail contact conditions.This research analyzes the torque transmitting behavior during regenerative braking,and proposes a novel methodology to detect the wheel-rail adhesion stability.Then,applications to the wheel slip prevention during braking are investigated,and the optimal slip ratio control scheme is proposed,which is based on a novel optimal reference generation of the slip ratio and a robust sliding mode control.The proposed methodology achieves the optimal braking performancewithoutthewheel-railcontactinformation.Numerical simulation results for uncertain slippery rails verify the effectiveness of the proposed methodology.

Opening Angle Rules of the Aerodynamic Brake Panel

In order to get the relationship between aerodynamic brake effect and the opening angle,based on a high-speed train model in CFD software FLUENT,the aerodynamic force properties from brake panels with different opening angles were analyzed as well as the flow field's variation laws. Six cases were researched,taking opening angles 45°,60°,75°,80°,85° and 90° respectively.Three-dimensional Reynolds-average Navier-Stokes equation combined with k-ε turbulence model was utilized. The control equation was discretized and solved by finite volume method.SIMPLE method was also considered to couple the pressure and velocity fields and search the numeric solutions. Conclusions can be achieved from the results which are shown as follows. When the opening angle increases from 45° to 75°,the aerodynamic forces and the central area with larger pressure increase fast,and the flow field distribution changes greatly; when the opening angle increases from75° to 90°,the aerodynamic forces and the central area with larger pressure increase slowly, and the flow field distribution changes slightly; considering train boundary and opening performance of the wind resistance brake mechanism,the opening angle should be 75°.

Rail temperature rise characteristics caused by linear eddy current brake of high-speed train

The rail temperature rises when the linear eddy current brake of high-speed train is working, which may lead to a change of rail physical characteristics or an effect on train operations. Therefore, a study concerning the characteristics of rail temperature rise caused by eddy current has its practical necessity. In the research, the working principle of a linear eddy current brake is introduced and its FEA model is established. According to the generation mechanism of eddy current, the theoretical formula of the internal energy which is produced by the eddy current is deduced and the thermal load on the rail is obtained. ANSYS is used to simulate the rail temperature changes under different conditions of thermal loads. The research result shows the main factors which contribute to the rising of rail temperature are the train speed, brake gap and exciting current. The rail temperature rises non-linearly with the in- crease of train speed. The rail temperature rise curve is more sensitive to the exciting current than the air gap. Moreover, the difference stimulated by temperature rising between rails of 60 kg/m and 75 kg/m is presented as well.

列车制动盘散热特性分析及拓扑优化

针对紧急制动工况下制动盘散热问题,采用计算流体力学分析方法对某型通风式制动盘进行了散热特性研究。对制动盘内部流道速度场和对流换热等进行评估,在此基础上,采用由N-S方程与达西定律耦合成的Brinkman方程拓扑优化,实现制动盘散热能力提升的优化目标。结果表明:优化后的模型在整个制动工况中散热量提高了13.46%。

轻量化高速列车制动盘材料-结构研究进展

400 km/h高速列车紧急制动的强热负荷,导致制动盘温升高、温度分布梯度大和热衰减强,已超出钢质制动盘能载极限,开发耐高温强耐磨的制动盘材料,同时提升制动盘通风散热能力成为制动技术发展瓶颈。综述高速制动盘材料从高强度铸钢和锻钢、轻量化铝基复合材料至耐高温耐磨碳陶复合材料和表面改性技术发展历程,随着碳陶复合材料的台架试验和表面改性技术的摩擦磨损试验研究的深化,表面改性轻质复合材料是制动盘材料未来发展方向。概述通风制动盘内部散热层散热筋结构形貌优化、摩擦层表面耐磨性能改善的发展现状,内部散热筋由直通道设计逐渐演化为弯曲、支柱以及分形通道,镂空结构能更好地加速空气流动提高散热;表面摩擦层引入打孔或划线,更易于摩擦粉尘的抛离从而稳定摩擦因数,保持制动效果;但复杂通风导流结构和打孔划线增加了制备工艺的难度,提出高速制动盘结构构型设计需要综合材料热力学性能、制备工艺及耐热耐磨需求,形成材料-结构-功能—体化设计理念,为实现更高速的制动盘优化设计提供参考。

直线轨道涡流制动对高速列车制动动力学特性的影响

列车制动性能直接影响车辆运行安全性和平稳性、稳定性,本文研究了加装直线轨道涡流制动系统对不同动力分配方式的高速列车制动动力学特性的影响规律.首先建立了6M2T和4M4T两种编组方式的列车动力学仿真模型,并与线路实验数据进行对比,验证了模型的有效性.基于该模型,研究了不同时速下的列车在不同动力分配形式下的动力学特性.针对惰行工况、电空制动工况与加装直线轨道涡流制动系统的联合制动工况,分别研究了第1、5、8节车厢的Sperling指标、脱轨系数、轮重减载率、轮轨作用力的变化规律,研究结果表明,动力分配方式、制动特性对车辆动力学性能有显著影响,涉及的关键动力学性能指标均满足安全限值标准,研究结果将为高速列车加装直线轨道涡流制动系统提供理论参考.

计及实时最大功率约束的高速磁浮列车再生制动能量存储利用

针对高速磁浮列车牵引供电系统结构及运行规则特殊性导致再生制动能量无法主动利用、能量回馈方式对局域网电压影响大的问题,在对高速磁浮列车牵引供电系统结构和能量流动机理进行分析的基础上,给出基于地面式超级电容储能的高速磁浮列车再生制动能量回收利用系统拓扑结构;考虑高速磁浮列车再生制动能量回收系统容量配置小、超级电容工作电压变化明显的特性,以高效回收再生制动能量为目标,将储能系统实时的可运行最大功率作为约束功率,制定相应的能量管理策略,实现系统不同工况下的能量管理,并通过分层控制策略实现整个再生制动能量利用系统的高效运行。通过仿真验证所提再生制动能量回收利用系统及控制策略的有效性,结果表明:所提方案可使高速磁浮列车牵引能耗降低21.83%;与储能系统采用固定功率约束的功率分配方式相比,再生制动能量利用率提高了11.9%。

列车刹车闸片冶金材料成分配比优化研究

为了促进我国列车刹车闸片粉末冶金材料的发展,研究分析了不同增强组元对粉末冶金材料制备的摩擦材料性能影响。研究分析的2种增强组元分别是羰基铁粉和磷铁粉,粉末冶金材料的基体为超细铜粉,润滑组元为镀铜石墨,摩擦组元为铬铁粉。结果显示,时速低于275 km/h时,磷铁粉材料的摩擦系数更高,时速高于275 km/h时,羰基铁粉的摩擦系数更高,时速为350 km/h时,羰基铁粉材料磨损量为0.625 mg/kJ,磷铁粉材料磨损量为1.634 mg/kJ,研究还探讨了磷铁粉及羰基铁粉对列车刹车材料摩擦性能的影响,对我国粉末冶金材料、制备列车刹车闸片的发展具有指导意义。

沙粒介入高速列车制动界面对摩擦块摩擦磨损行为的影响

针对沙区铁路的列车制动摩擦磨损问题,基于自主研制的高速列车制动摩擦磨损试验台,开展了戈壁沙、沙漠沙介入制动界面后影响摩擦块摩擦磨损行为的试验研究.重点探究了2种不同沙粒介入制动界面后摩擦块表面摩擦磨损特性的演变过程及其差异,结果表明:戈壁沙、沙漠沙的介入,都会破坏摩擦块表面的原始磨屑堆积层,进而改变界面接触状态及磨损特性.戈壁沙介入后的摩擦块表面不易形成稳定的摩擦层,且显露出更多的石墨成分,降低了界面摩擦系数及平均温度.而沙漠沙介入后,由于其粒径相对较小,在摩擦块表面堆积了更多的沙粒,形成了沙粒磨屑混合堆积层,这种堆积层增大了界面摩擦系数和平均温度,并对摩擦块基体材料造成严重损伤.

考虑摩擦块形状及轮轨蠕滑的列车制动黏滑振动行为分析

制动盘与摩擦块之间相互摩擦引起的黏滑振动直接影响高速列车制动系统的稳定性并威胁车辆安全运行.为探明摩擦块形状对高速列车制动系统黏滑振动的影响,本文中针对高速列车制动系统常用的五边形和六边形摩擦块,在相对低速条件下开展了盘-块黏滑振动试验,辨识了盘-块界面的Stribeck摩擦参数,揭示了摩擦块形状、摩擦系数和盘-块界面黏滑振动之间的关系.进一步,建立了考虑盘-块摩擦、轮-轨黏着及轮-盘扭转的高速列车制动系统动力学模型,并将辨识的Stribeck摩擦参数集成到该动力学模型中,构建了盘-块界面摩擦特征与制动系统动态响应之间的关联.基于此,研究了摩擦块形状对高速列车制动系统黏滑振动的影响.结果表明,摩擦块形状通过改变盘-块界面摩擦特征,影响制动系统的黏滑振动响应及稳定性.此外,相比五边形摩擦块,采用六边形摩擦块制动系统的黏滑振动强度更低.

高速列车盘形制动器热-结构耦合方法研究

盘形制动器热负荷计算是高速列车制动盘研发设计的关键环节,其计算结果是列车运行参数配置的依据。开发合适的计算方法建立计算精度高、工况适用性广的热-结构耦合计算模型是盘形制动器热负荷计算的关键问题。针对动车组用轴装制动盘制动过程,充分考虑制动闸片和制动盘的几何特性、运动特性和载荷工况,提出位移梯度循环法,基于ABAQUS软件建立盘形制动器摩擦副三维瞬态传热有限元模型,运用位移梯度循环法推导出热流加载式,用以计算制动过程中产生的摩擦热流,解决摩擦作用沿制动盘周向差异造成的耦合结果偏差。运用位移梯度循环法对制动盘进行热-结构耦合分析,并将仿真结果与试验数据、现场调研成果进行对比,通过仿真与试验结果的峰值温度误差率、相关性系数等统计学指标及现场调研观测结果评定该模型的计算精度及工况适用性。研究结果表明:基于位移梯度循环法的热-结构耦合模型可有效模拟制动盘在制动过程中温度变化规律且具有良好的重复性与稳定性,结构场分析出的制动盘热裂纹失效易发位置与该型号制动盘装车运用情况相符。研究成果可有效模拟高速列车在制动时制动盘的热-结构耦合过程,尤其在大轴重下的持续制动或间隔制动工况下,制动时间越长,计算精度越高。

轮装制动盘螺栓载荷测试及有限元分析

制动盘螺栓对于确保高速动车组制动可靠性和运行安全性非常重要。本研究使用高速动车组制动盘螺栓载荷测试技术,对中国客运专线的轮装制动盘螺栓载荷进行线路测试,获得制动盘螺栓载荷动态时间历程。螺栓载荷包括拉伸载荷、径向弯矩和周向弯矩。通过建立轮装制动盘车轮结构有限元模型,模拟仿真在有轮轨接触下车轮高速旋转过程中螺栓受载情况,并与试验结果进行对照。结果表明,拉伸载荷、径向弯矩和周向弯矩与列车运行速度密切相关。运行速度越大,螺栓载荷的变化越大,且这些载荷随着车轮转动呈周期性变化。同时,各载荷信号上还存在由轮轨激扰引起的小波形。有限元仿真结果表明螺栓杆上各个截面的径向弯矩大小和方向并不一致。车轮内外结构的不对称性将导致螺栓杆上左侧截面的弯矩大于右侧截面的弯矩。

风阻制动板外形参数对高速列车气动特性影响分析

随着高速列车运营速度的不断提升,应对更高速列车安全制动及紧急停车问题日益凸显。针对这一问题,就流线型头部及等截面车身位置布置风阻制动板,采用基于SSTk-ω湍流模型的RANS方法研究了风阻制动板高度、开口设计及开口制动板位置、高度与开口协同等因素对列车气动特性的影响,并通过风阻制动列车风洞试验验证了数值模拟方法的正确性。结果表明风阻制动板影响了列车表面压力分布特性,诱发气流强分离现象。此外,风阻制动板增强了整车压差阻力,进而增强列车气动阻力。增高的风阻制动板会扩大压力分布范围,导致板后回流区分布范围增加,其所受气动阻力得到增加。风阻制动板的开口设计及开口制动板位置的变化带来的影响并不显著,但开口设计能够强化后方增高的风阻制动板所受气动阻力。合理增高制动板对于整车的气动增阻效果最为明显,最大增阻效果为原始高速列车所受气动阻力的422.91%。相比于单纯的开口设计及开口制动板位置的变化,采用开口设计与增高协同布置能够具有较好的气动增阻表现,增阻效果为420.67%。

升力翼高速列车曲线通过时的轮轨黏着性能研究

建立考虑轮轨关系、升力翼及流场耦合特性等因素的车辆系统动力学模型,分析升力翼高速列车曲线通过时的运动姿态和轮轨接触特性响应,研究列车在曲线轨道运行的轮轨黏着性能,探讨轨道不平顺、曲线半径、运行速度及轮轨接触条件对轮轨黏着性能的影响。研究结果表明:气动升力通过改变列车运行动态响应和轮轨接触特性导致内、外侧轮轨垂向力和纵向蠕滑力重新分配,促使内侧轮更易失去黏着;气动升力和运行速度的增大均会劣化轮轨黏着性能,但曲线半径的增大将显著提升轮轨黏着水平;轨道不平顺削弱了轮轨黏着性能,干态、湿态、油态条件下的轮轨黏着性能依次恶化。列车牵引运行时,干态、湿态、油态条件下的轮轨均能满足牵引力安全限值要求,但制动运行时,湿态和油态条件下的轮轨均不能满足制动力安全限值要求。研究结果可为超高速列车的安全运行与节能设计提供技术支持。

横风下风阻制动板对高速列车气动性能影响的仿真分析

[目的]随着列车运行速度的提高,采用多种制动方式成为高速列车紧急安全制动的有力保障,风阻制动作为轮轨黏着制动的补充而广受关注。风阻制动板安装后,将影响列车的流线型,在横风条件下甚至会影响列车运行安全。为保证列车在大风环境下的行车安全和制动性能,需要对横风下不同制动板形式对列车气动性能的影响规律进行深入研究。[方法]采用三维、定常、不可压缩N-S方程和k-ε两方程湍流模型,开展有无横风和不同制动板高度对高速列车流场规律和气动力的影响研究。[结果及结论]仿真研究结果表明,横风下列车车身和制动板的气动阻力沿车身方向递增,横向力则递减,当制动板高度从0.5 m提高到1.0 m时,制动板阻力占总阻力的比例从54.89%提高到69.92%,最高达到56 kN;制动板横向力占整体横向力的比例小于1%,不同高度制动板对列车整体横向力的影响较小;制动板对来流有一定的滞止作用,距离较近的制动板存在流场相互干扰;制动板对于横向力的影响较小。通过制动板的前期设计,风阻制动足以成为列车制动的有效方案,且对列车的运行稳定性影响较小。

面向3min追踪间隔的400 km/h高速列车追踪过程仿真分析

将高速铁路运营速度提高至400km/h有利于提升旅行速度和旅客运输效率。但速度提高会影响追踪间隔,导致能力降低。在梳理高速铁路列车追踪间隔影响因素的基础上,构建了基于距离步长的高速铁路列车追踪运行多智能体仿真模型。通过仿真实验,计算了不同目标速度下的追踪间隔,并分析了各种追踪间隔随目标速度变化的趋势,以及出发及到达追踪间隔对列车牵引制动性能提升的响应情况。实验结果表明,在目标速度400km/h和采用中国标准动车组为基础模拟的牵引制动性能的仿真场景下,列车的区间追踪间隔在3min以内,而出发追踪间隔和到达追踪间隔均大于3min;若提升列车牵引加速度与制动减速度,则可以使列车出发及到达追踪间隔控制在3min以内。

考虑不同制动工况的制动盘力承载边界研究

随着列车速度的进一步提高,轨道激扰对车体振动的影响也更为明显。因此,在高速运行时,列车更容易受到制动系统动态特性的影响,对车辆运行的安全性构成威胁。为了研究车辆振动对高速列车制动系统力承载边界的影响,首先建立了具备制动系统的高速列车整车动力学模型,并进行了仿真计算。其次,研究了制动初速度、减速度、轴重以及线路不平顺幅值对制动盘压力波动的影响。研究结果表明,受到线路激扰的影响,位于轮对上的制动盘与位于转向架构架上的制动夹钳之间产生相对振动,导致制动压力在额定压力附近波动(约为±5%)。此外,制动初速度和线路不平顺的增大、减速度的降低均会加大制动压力的波动。因此,在分析评估高速列车制动系统温度和振动特性时,特别是在高干扰线路条件下,需要考虑车辆振动环境的影响。

永磁线性涡流制动的性能分析与试验研究

为弥补电磁涡流制动系统在重量和发热方面的不足,文中设计了一种永磁式线性涡流制动装置样机,基于等效磁路法推导制动力及吸力解析公式,并用于指导设计参数初始值的选取。通过有限元仿真,对比分析了永磁涡流制动与电磁涡流制动的制动力及吸力特性。搭建永磁涡流制动试验装置,测试不同速度、不同气隙的涡流制动特性,并与解析法及有限元法的计算结果进行对比和误差分析。结果表明:在与原电磁涡流制动装置长度相同的前提下,设计的永磁涡流制动装置样机可以达到与其相当的制动力水平,且在200~400 km/h区间永磁涡流制动力更稳定,吸力更低;解析计算和有限元仿真结果均与试验曲线变化趋势一致,有限元仿真精度更高;当气隙达到70 mm时,制动力和吸力均趋于0,此缓解高度与原电磁涡流制动装置的缓解高度一致。从制动力及吸力特性的角度分析,永磁线性涡流制动适合高速列车应用。