Dynamic analysis of axle box bearings on the high-speed train caused by wheel-rail excitation

To explore the impact of wheel-rail excitation on the dynamic performance of axle box bearings,a dynamic model of the high-speed train including axle box bearings is developed.Subsequently,the dynamic response characteristics of the axle box bearing are examined.The investigation focuses on the acceleration characteristics of bearing vibration under excitation of track irregularities and wheel flats.In addition,experiments on both normal and faulty bearings are conducted separately,and the correctness of the model and some conclusions are verified.According to the research,track irregularity is unfavorable for bearing fault detection based on resonance demodulation.Under the same speed conditions,the acceleration peak of bearing is inversely proportional to the length of the wheel flat and directly proportional to its depth.The paper will contribute to a deeper understanding of the dynamic performance of axle box bearings.

Electromagnetic Tomography System for Defect Detection of High-Speed Rail Wheel

A novel electromagnetic tomography(EMT)system for defect detection of high-speed rail wheel is proposed,which differs from traditional electromagnetic tomography systems in its spatial arrangements of coils.A U-shaped sensor array was designed,and then a simulation model was built with the low frequency electromagnetic simulation software.Three different algorithms were applied to perform image reconstruction,therefore the defects can be detected from the reconstructed images.Based on the simulation results,an experimental system was built and image reconstruction were performed with the measured data.The reconstructed images obtained both from numerical simulation and experimental system indicated the locations of the defects of the wheel,which verified the feasibility of the EMT system and revealed its good application prospect in the future.

Deep learning-based fault diagnostic network of high-speed train secondary suspension systems for immunity to track irregularities and wheel wear

Fault detection and isolation of high-speed train suspension systems is of critical importance to guarantee train running safety. Firstly, the existing methods concerning fault detection or isolation of train suspension systems are briefly reviewed and divided into two categories, i.e., model-based and data-driven approaches. The advantages and disadvantages of these two categories of approaches are briefly summarized. Secondly, a 1D convolution network-based fault diagnostic method for highspeed train suspension systems is designed. To improve the robustness of the method, a Gaussian white noise strategy(GWN-strategy) for immunity to track irregularities and an edge sample training strategy(EST-strategy) for immunity to wheel wear are proposed. The whole network is called GWN-EST-1 DCNN method. Thirdly, to show the performance of this method, a multibody dynamics simulation model of a high-speed train is built to generate the lateral acceleration of a bogie frame corresponding to different track irregularities, wheel profiles, and secondary suspension faults. The simulated signals are then inputted into the diagnostic network, and the results show the correctness and superiority of the GWN-EST-1DCNN method. Finally,the 1DCNN method is further validated using tracking data of a CRH3 train running on a high-speed railway line.

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.

Minimum Curve Radii for High-Speed Trains, Including the Gyroscopic Moments of the Wheels

This paper studies the title problem including an analysis of the gyroscopic effects of the wheels of a rail-car travelling at high-speed around a level, horizontal curve. The analysis is based upon the fundamental principles of dynamics. The result is a design formula for the minimum curve radius needed to prevent derailment. Aside from the rail car geometric and physical properties, the minimum curve radius depends upon the square the train speed. An illustrative example shows that the wheel gyroscopic effect is destabilizing and additive to the centrifugal force derailment tendency. From a track design perspective, however, the gyroscopic effect is relatively small compared with the centrifugal force effect.

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.

Wheel Setting Error Modeling and Compensation for Arc Envelope Grinding of Large-Aperture Aspherical Optics

Precision grinding is a key process for realizing the use of large-aperture aspherical optical elements in laser nuclear fusion devices,large-aperture astronomical telescopes,and high-resolution space cameras.In this study,the arc envelope grinding process of large-aperture aspherical optics is investigated using a CM1500 precision grinding machine with a maximum machinable diameter ofΦ1500 mm.The form error of the aspherical workpiece induced by wheel setting errors is analytically modeled for both parallel and cross grinding.Results show that the form error is more sensitive to the wheel setting error along the feed direction than that along the lateral direction.It is a bilinear function of the feed-direction wheel setting error and the distance to the optical axis.Based on the error function above,a method to determine the wheel setting error is proposed.Subsequently,grinding tests are performed with the wheels aligned accurately.Using a newly proposed partial error compensation method with an appropriate compensation factor,a form error of 3.4μm peak-to-valley(PV)for aΦ400 mm elliptical K9 glass surface is achieved.

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.

动车组轮对故障模式分析及风险评估

动车组转向架的检修质量直接关乎行车安全,轮对是转向架重点部件,为提高其检修品质,将轮对装配结构的可靠性进行分解研究,根据实车故障数据分析制定轮对故障先验模式,再结合三维仿真分析和实车数据完善轮对故障后验模式,同时推导出轮对故障风险顺序数RPN的计算权重,将实车故障数据按故障模式和RPN进行归纳整理,得出轮对装配结构中车轮故障发生频次高且危害大的结论,针对性地分析了车轮检修的重点部位和操作工序,优化了轮对的维修策略,提高了检修品质。

动车组轮对故障模式分析及风险评估

动车组转向架的检修质量直接关乎行车安全,轮对是转向架重点部件,为提高其检修品质,将轮对装配结构的可靠性进行分解研究,根据实车故障数据分析制定轮对故障先验模式,再结合三维仿真分析和实车数据完善轮对故障后验模式,同时推导出轮对故障风险顺序数RPN的计算权重,将实车故障数据按故障模式和RPN进行归纳整理,得出轮对装配结构中车轮故障发生频次高且危害大的结论,针对性地分析了车轮检修的重点部位和操作工序,优化了轮对的维修策略,提高了检修品质。

基于实测数据的车辆轮对磨耗模型研究

[目的]基于上海轨道交通17号线列车轮对实测数据,研究轮对磨耗规律,建立轮对轮缘厚度和轮径磨耗模型,以提高城市轨道交通车辆的安全性和维护效率。[方法]对轮对实测数据进行预处理,消除数据误差;采用曲线拟合和误差分析方法建立轮缘厚度和轮径的磨耗模型,并以磨耗速率拟合标准差,以及真实值与误差拟合曲线之间误差值的拟合标准差作为该模型的评价指标,评估轮缘厚度及轮径磨耗模型的准确性;分别针对1701次和1721次列车进行轮对磨耗模型验证。[结果及结论]1701次和1721次列车轮对轮缘厚度磨耗速率4次拟合曲线的拟合标准差,以及真实值与误差拟合曲线之间误差值的6次拟合曲线的拟合标准差均接近于零,验证了该车辆轮对磨耗模型的准确性,能够精确预测上海轨道交通17号线同一车型不同列车及同一列车不同位置的轮对磨耗情况。

Influence of ground effect on flow field structure and aerodynamic noise of high-speed trains

The simulation of the ground effect has always been a technical difficulty in wind tunnel tests of high-speed trains.In this paper,large eddy simulation and the curl acoustic integral equation were used to simulate the flow-acoustic field results of high-speed trains under four ground simulation systems(GSSs):“moving ground+rotating wheel”,“stationary ground+rotating wheel”,“moving ground+stationary wheel”,and“stationary ground+stationary wheel”.By comparing the fluid-acoustic field results of the four GSSs,the influence laws of different GSSs on the flow field structure,aero-acoustic source,and far-field radiation noise characteristics were investigated,providing guidance for the acoustic wind tunnel testing of high-speed trains.The calculation results of the aerodynamic noise of a 350 km/h high-speed train show that the moving ground and rotating wheel affect mainly the aero-acoustic performance under the train bottom.The influence of the rotating wheel on the equivalent sound source power of the whole vehicle was not more than 5%,but that of the moving ground slip was more than 15%.The average influence of the rotating wheel on the sound pressure level radiated by the whole vehicle was 0.3 dBA,while that of the moving ground was 1.8 dBA.

复杂多变工况下高铁轮对轴承故障识别研究

为提升复杂多变工况下轴承故障识别精度,研究了高铁轮对轴承故障识别方法。复杂多变工况下的轮对轴承振动信号经集合经验模态分解后,获得多个IMF分量及剩余分量,计算各分量的排列熵,以此为初始特征集,将朴素贝叶斯算法和最大均值差异(FSBD)方法相结合筛选有效特征,进行源域深度迁移自编码器训练,将输出参数作为目标域深度迁移自编码器的初始参数,检测目标域特征子集,输出故障识别结果。实验结果表明:该方法可实现轮对轴承振动信号的分解,完成初始特征FSI值的计算,选取特征数为150时,轮对轴承故障识别效果最突出,识别精度达到98.5%。

全控器件大型水轮发电机组自动励磁系统设计

为保证大型水轮发电机组稳定运行,设计了基于全控器件的大型水轮发电机组自动励磁系统,通过全控器件实现发电机组自动励磁控制。以电压源型脉冲宽度调制变换器为全控器件,采用基于直接电流控制方法的电压源型脉冲宽度调制变换器控制方案并补充阻尼,避免其直流侧电压异常波动,优化了励磁系统电流质量。制定基于占空比调节的斩波器控制方案,调节励磁电压的占空比,避免发电机组励磁电流异常变化,完成大型水轮发电机组自动励磁控制。实验结果表明,该系统有较好的控制效果,可在1 s内实现大型水轮发电机组的稳定。

Numerical study of wheel–rail adhesion performance of new-concept high-speed trains with aerodynamic wings

Wheel–rail adhesion is a complex tribological problem of wheel–rail rolling contact and is closely related to the operational safety of high-speed trains.A new design concept of high-speed trains was recently proposed with an expectation of a reduction of equivalent weight and total energy consumption by installing aerodynamic wings(aero-wings)on the roof,but it was accompanied by the disadvantage of deteriorating wheel–rail adhesion performance.In this study,a comprehensive multibody dynamics(MBD)model of the high-speed train with predesigned aero-wings is established using the commercial software SIMPACK,in which the real aerodynamic characteristics of the train are taken into account.The available adhesion and adhesion margin are employed to evaluate the wheel–rail adhesion performance.The influences of aero-wing lift,train speed,and contact conditions on the wheel–rail adhesion level are discussed.The results show that the load transfer caused by the action of aerodynamic load and braking torque was the main reason for the inconsistent adhesion condition of four wheelsets.The influences of aero-wing lift and train speed on the wheel–rail adhesion performance are coupled;the available adhesion of both motor car and trailer is negatively correlated with aero-wing lift and train speed under all contact conditions,while the variation law of adhesion margin with train speed shows differences under different contact conditions.When the wheel–rail interface was polluted by a‘third-body medium’such as water and oil,the wheel–rail adhesion performance was dramatically reduced and the wheelset tended to reach adhesion saturation and slide.However,track irregularity had little effect on the adhesion performance and could be ignored to save calculation time.These results are of positive significance for reducing the wheel idling or sliding phenomenon and to ensure the safe operation of high-speed trains with aero-wings.

A dynamic simulation of the wheel–rail impact caused by a wheel flat using a 3D rolling contact model

A three-dimensional （3-D） wheel-rail rolling contact model with a wheel fiat was built using commercial software Hypermesh, and the dynamic finite element simulation was conducted using LS-DYNA 3D/explicit code. Influences of the train speed, flat length and axle load on the vertical wheel-rail impact response were discussed, respectively. The results show that the maximum vertical wheel-rail impact force induced by the wheel flat is higher than that generated by the perfect wheel, and these two dynamic impact forces are much greater than the static axle load. Besides, the maximum von Mises equivalent stress and maximum equivalent plastic strain are observed on the wheel-rail contact surface, and both of them as well as the maximum wheel-rail impact force are sensitive to train speed, fiat length and axle load.

CRH2动车组轮对与轴箱弹簧的强度分析

高速列车运行超过蛇行稳定性临界速度时会出现安全隐患。为了解决这一隐患需对CRH2型动车组转向架进行数学建模。首先通过对轴箱体的简化处理及受力分析,在Pro/E软件中整体建模,并导入到Mechanica模块;然后对CRH2车轴建立刚性节点和弹性节点;最后进行静强度分析。结果表明,简化后的CRH2型转向架模型在临界速度上较初始模型有了一些改善,并且各个动力学参数均满足行业标准要求。

基于WPT-ESCDE的电气设备运输车轮对轴承故障特征提取方法

变压器等电气设备的吊装、转运环节是疏于监控的薄弱环节,极易发生机械冲击引起的二次损伤,而轨道运输车的轮对承载特性及轮对轴承运行状态关乎运输安全。综合考虑轨道运输车轮对轴承运输环境,分析振动信号中存在的主要成分及特征,提出一种基于小波包-包络谱相关散布熵(WPT-ESCDE)的故障特征提取方法。首先,对振动信号的离散时间序列进行小波包分解,并对小波包子带系数进行重构;其次,对每个小波包子带计算平方包络谱,得到离散频率序列,将得到的小波包子带包络谱离散序列看作广义时间序列进行相关分析,得到包络谱相关函数;最后,计算包络谱相关函数的散布熵,筛选最优小波包子带序列进行特征提取。通过仿真分析和QPZZ-Ⅱ旋转机械故障模拟实验台实测信号验证了所提方法的有效性。

考虑波磨激励的城市轨道车辆轮对吸振器减振方法

以抑制钢轨波浪形磨耗导致的城市轨道车辆振动为目的,提出一种新颖的适用于城市轨道车辆的轮对吸振器减振方法,建立包含轮对吸振器的车辆-轨道系统耦合模型。通过对轨道不平顺和钢轨波磨综合激扰源的构建,分析钢轨波磨激励对车辆系统动态响应的影响;针对轨道车辆的轮对振动特性,讨论轮对吸振器在不同工况下的减振效果。结果表明:钢轨波浪形磨耗会引起车辆系统各部件振动加剧,对轮对振动影响最为严重。在不同波长、不同波深波磨作用下,安装轮对吸振器的轨道车辆轮对振动都被很好抑制,轮对吸振器在不同速度以及不同载重工况下均有较好减振效果。轮对吸振器能够有效降低轮对的垂向振动,特别适合用于提升城市轨道车辆舒适性。研究工作为提高城市轨道车辆运行平稳性提供参考依据。

基于中点弦测法的车载式车轮不圆度测量

列车车轮不圆度是影响列车运行平稳性的重要因素,目前静态检测设备均需抬轮的准备工作,极大降低了检测效率,接触式传感器测量易发生损耗,导致测量发生误差,为提高检测效率以及避免检测误差,采用中点弦测法结合逆滤波器实现对车轮不圆度的车载式测量。检测时列车以低速运行,通过激光位移传感器实现非接触式测量,并同时利用3个激光位移传感器的具体位置关系和测量值得到弦测值作为逆滤波器的输入,构造逆滤波器的频率响应函数使一定波长范围内的不圆度数据得到还原,最后再构造低通滤波器以及进行离散傅里叶变换该车轮各个阶次多边形磨耗的粗糙度等级。通过实验测量数据验证,采用中点弦测法测得的车轮不圆度数据与真实不圆度数值的误差较小,可以实现车轮不圆度数据的车载式测量,各个阶次的粗糙度等级也可反映被测车轮目前的磨损状态。