A numerical method for the simulation of freight train emergency braking operations based on the UIC braked weight percentage

The present paper shows the development of a strategy for the calculation of the air brake forces of European freight trains. The model is built to upgrade the existing Politecnico di Torino longitudinal train dynamics(LTD) code LTDPoliTo, which was originally unable to account for air brake forces. The proposed model uses an empirical exponential function to calculate the air brake forces during the simulation, while the maximum normal force on the brake friction elements is calculated according to the indication of the vehicle braked weight percentage.Hence, the model does not require to simulate in detail the fluid dynamics in the brake pipe nor to precisely know the main parameters of the braking system mounted on each vehicle. The model parameters are tuned to minimize the difference between the braking distance computed by the LTDPoliTo code and the value prescribed by the UIC544-1 leaflet in emergency braking operations. Simulations are run for different configurations of freight train compositions including a variable number of Shimmns wagons trailed by an E402B locomotive at the head of the train, as suggested in a reference literature paper. The results of the proposed method are in good agreement with the target braking distances calculated according to the international rules.

Blended Regenerative Anti-Lock Braking System and Electronic Wedge Brake Coordinate Control Ensuring Maximal Energy Recovery and Stability of All-Wheel-Motor-Drive Electric Vehicles

ABS is an active safety system which showed a valuable contribution to vehicle safety and stability since it was first introduced. Recently, EVs with in-wheel-motors have drawn increasing attention owing to their greatest advantages. Wheels torques are precisely and swiftly controlled thanks to electric motors and their advanced driving techniques. In this paper, a regenerative-ABS control RABS is proposed for all-in-wheel-motors-drive EVs. The RABS is realized as a pure electronic braking system called brake-by-wire. A coordination strategy is suggested to control RABS compromising three layers. First, wheels slip control takes place, and braking torque is calculated in the higher layer. In the coordinate interlayer, torque is allocated between actuators ensuring maximal energy recovery and vehicle stability. While in the lower layer, actuator control is performed. The RABS effectiveness is validated on a 3-DOF EVSimulink model through two straight-line braking manoeuvres with low and high initial speeds of 50 km/h and 150 km/h, respectively. Both regular and emergency braking manoeuvres are considered with ABS enabled and disabled for comparison. Simulation results showed the high performance of the proposed RABS control in terms of vehicle stability, brake response, stopping distance, and battery re-charging.

Thermal fatigue and wear of compacted graphite iron brake discs with various thermomechanical properties

The increase in payload capacity of trucks has heightened the demand for cost-effective yet high performance brake discs.In this work,the thermal fatigue and wear of compacted graphite iron brake discs were investigated,aiming to provide an experimental foundation for achieving a balance between their thermal and mechanical properties.Compacted graphite iron brake discs with different tensile strengths,macrohardnesses,specific heat capacities and thermal diffusion coefficients were produced by changing the proportion and strength of ferrite.The peak temperature,pressure load and friction coefficient of compacted graphite iron brake discs were analyzed through inertia friction tests.The morphology of thermal cracks and 3D profiles of the worn surfaces were also discussed.It is found that the thermal fatigue of compacted graphite iron discs is determined by their thermal properties.A compacted graphite iron with the highest specific heat capacity and thermal diffusion coefficient exhibits optimal thermal fatigue resistance.Oxidization of the matrix at low temperatures significantly weakens the function of alloy strengthening in hindering the propagation of thermal cracks.Despite the reduced hardness,increasing the ferrite proportion can mitigate wear loss resulting from low disc temperatures and the absence of abrasive wear.

Sustainable Biocomposites Materials for Automotive Brake Pad Application:An Overview

Research into converting waste into viable eco-friendly products has gained global concern.Using natural fibres and pulverized metallic waste becomes necessary to reduce noxious environmental emissions due to indiscriminately occupying the land.This study reviews the literature in the broad area of green composites in search of materials that can be used in automotive brake pads.Materials made by biocomposite,rather than fossil fuels,will be favoured.A database containing the tribo-mechanical performance of numerous potential components for the future green composite was established using the technical details of bio-polymers and natural reinforcements.The development of materials with diverse compositions and varying proportions is now conceivable,and these materials can be permanently connected in fully regulated processes.This explanation demonstrates that all of these variables affect friction coefficient,resistance to wear from friction and high temperatures,and the operating life of brake pads to varying degrees.In this study,renewable materials for the matrix and reinforcement are screened to determine which have sufficient strength,coefficient of friction,wear resistance properties,and reasonable costs,making them a feasible option for a green composite.The most significant,intriguing,and unusual materials used in manufacturing brake pads are gathered in this review,which also analyzes how they affect the tribological characteristics of the pads.

Dynamic Response Impact of Vehicle Braking on Simply Supported Beam Bridges with Corrugated Steel Webs Based on Vehicle-Bridge Coupled Vibration Analysis

A novel approach for analyzing coupled vibrations between vehicles and bridges is presented,taking into account spatiotemporal effects and mechanical phenomena resulting fromvehicle braking.Efficient modeling and solution of bridge vibrations induced by vehicle deceleration are realized using this method.The method’s validity and reliability are substantiated through numerical examples.A simply supported beam bridge with a corrugated steel web is taken as an example and the effects of parameters such as the initial vehicle speed,braking acceleration,braking location,and road surface roughness on the mid-span displacement and impact factor of the bridge are analyzed.The results show that vehicle braking significantly amplifies mid-span displacement and impact factor responses in comparison to uniform vehicular motion across the bridge.Notably,the influence of wheelto-bridge friction forces is of particular significance and cannot be overlooked.When the vehicle initiates braking near the middle of the span,both the mid-span displacement and impact factor of the bridge exhibit substantial increases,further escalating with higher braking acceleration.Under favorable road surface conditions,the midspan displacement and the impact factor during vehicle braking may exceed the design values stipulated by codes.It is important to note that road surface roughness exerts a more pronounced effect on the impact factor of the bridge in comparison to the effects of vehicle braking.

Integrated Active Suspension and Anti-Lock Braking Control for Four-Wheel-Independent-Drive Electric Vehicles

This paper presents an integrated control scheme for enhancing the ride comfort and handling performance of a four-wheel-independent-drive electric vehicle through the coordination of active suspension system(ASS)and anti-lock braking system(ABS).First,a longitudinal-vertical coupled vehicle dynamics model is established by integrating a road input model.Then the coupling mechanisms between longitudinal and vertical vehicle dynamics are analyzed.An ASS-ABS integrated control system is proposed,utilizing an H∞controller for ASS to optimize load transfer effect and a neural network sliding mode control for ABS implementation.Finally,the effectiveness of the proposed control scheme is evaluated through comprehensive tests conducted on a hardware-in-loop(HIL)test platform.The HIL test results demonstrate that the proposed control scheme can significantly improve the braking performance and ride comfort compared to conventional ABS control methods.

ISO releases a standard on braking systems of railway vehicles

ISO 24221:2024, Railway applications-Braking system-General requirements, the first of its kind, was recently released. With the leading efforts of National Railway Administration of China, China has made new breakthrough in railway international standardization by the development of the international standard.

Electronic Brake-Force Distribution Control Methods of ABS-Equipped Vehicles During Cornering Braking

Based on the dynamics of ABS-equipped vehicles during cornering braking, the electronic brake- force distribution （EBD） control methods of ABS-equipped vehicles during cornering braking are proposed. According to the dynamics and the tire model under tire adhesion limit, the stability acceptance criteria of vehicles during cornering braking are proposed. According to the stability acceptance criteria and the ABS control, the EBD control methods of ABS-equipped vehicles during cornering braking are implemented by adjusting the threshold values of tires slip independently. The vehicle states during cornering braking at two typical initial velocities of the vehicle are analyzed by the EBD control methods, whose results indicate the EBD control methods can improve the braking performances of the vehicle during cornering braking comparing with the ABS control.

Dynamic mechanical characteristics of NdFeB in electromagnetic brake

With the continuous development of artillery,the disadvantages of hydraulic recoil brakes gradually appear.At the same time,the appearance of high-performance Nd Fe B permanent magnet makes it possible to apply electromagnetic braking technology to recoil mechanism.In this paper,prototype tests of a certain artillery were carried out to verify the feasibility of the electromagnetic brake(EMB)and obtain the electromagnetic braking force.Due to the brittleness of Nd Fe B,in order to eliminate the worry about the safety of EMB,SHPB experiments of Nd Fe B were carried out.Then,based on the assumption of uniform crack distribution,the law of crack propagation and damage accumulation was described theoretically,and the damage constitutive model suitable for brittle materials was proposed by combining the Zhu-Wang-Tang(ZWT)equation.Finally,the numerical simulation model of the artillery prototype was established and through calculation,the dynamic mechanical characteristics of Nd Fe B in the prototype were analyzed.The calculation results show that the strength of Nd Fe B can meet the requirements of the use in the working process.From the perspective of damage factor,the damage value of the permanent magnet on the far right is larger,and the damage value of the inner ring gradually decreases to the outer ring.

Influence of quick release valve on braking performance and coupler force of heavy haul train

We establish a simulation model based on the theory of air flow to analyze the accelerated release effect of the quick release valve inside the air brake control valve.In addition, the combined simulation system of train air brake system and longitudinal train dynamics is used to analyze how the parameters of the quick release valve in the 120/120–1 brake control valve affect the propagation characteristics of the train brake pipe pressure wave, the release action range of the accelerated brake, and the longitudinal coupler force for a 20,000-ton heavy haul train on the section of the Datong–Qinhuangdao Railway. The results show that the quick release valve can effectively accelerate the rising speed of the train brake pipe pressure during the initial release, as the accelerated release effect is evident before the train brake pipe pressure reaches582 k Pa. The quick release valve can effectively accelerate the release of the rear cars, reducing the longitudinal coupler force impact due to time delay of the release process. The quick release valve can effectively reduce the tensile coupler force in the train by as much as 20% in certain cases.

An approach for simulating the air brake system of long freight trains based on fluid dynamics

Air brake systems are critical equipment for railway trains, which affects the running safety of the trains significantly. To study air braking characteristics of long freight trains, an approach for simulating air brake systems based on fuid dynamics theory was proposed. The structures and working mechanisms of locomotive and wagon air brakes are introduced, and mathematical models of the pipes, brake valves, reservoirs or chambers, cylinders, etc., are presented.Besides, the dynamic motions of parts in the main valve are considered. The simulation model of the whole air brake system is then formulated, and the solving method based on the finite-difference method is used. New efficient pipe boundary conditions without iterations are developed for brake pipes and branch pipes, which can achieve higher computational efficiency. The proposed approach for simulating the air brake system is validated by comparing with published measured data. Simulation results of different train formations indicate that models that consider the dynamic behavior of brake pipes are recommended for predicting the characteristics of long trains under service braking conditions.

Thermomechanical Behavior of Brake Drums Under Extreme Braking Conditions

Braking efficiency is characterized by reduced braking time and distance,and therefore passenger safety depends on the design of the braking system.During the braking of a vehicle,the braking system must dissipate the kinetic energy by transforming it into heat energy.A too high temperature can lead to an almost total loss of braking efficiency.An excessive rise in brake temperature can also cause surface cracks extending to the outside edge of the drum friction surface.Heat transfer and temperature gradient,not to forget the vehicle’s travel environment(high speed,heavy load,and steeply sloping road conditions),must thus be the essential criteria for any brake system design.The aim of the present investigation is to analyze the thermal behavior of different brake drum designs during the single emergency braking of a heavy-duty vehicle on a steeply sloping road.The calculation of the temperature field is performed in transient mode using a three-dimensional finite element model assuming a constant coefficient of friction.In this study,the influence of geometrical brake drum configurations on the thermal behavior of brake drums with two different materials in grey cast iron FG200 and aluminum alloy 356.0 reinforced with silicon carbide(SiC)particles is analyzed under extreme vehicle braking conditions.The numerical simulation results obtained using FE software ANSYS are qualitatively compared with the results already published in the literature.

The effect of controllable train-tail devices on the longitudinal impulse of the combined trains under initial braking

The 20,000-ton combined train running has greatly promoted China’s heavy-haul railway transportation capability. The application of controllable train-tail devices could improve the braking wave of the train and braking synchronism, and alleviate longitudinal impulse.However, the characteristics of the controllable train-tail device such as exhaust area, exhaust duration and exhaust action time are not uniform in practice, and their effects on the longitudinal impulse of the train are not apparent,which is worth studying. In this work, according to the formation of the Datong-Qinhuangdao Railway, the train air brake and longitudinal dynamics simulation system(TABLDSS) is applied to establish a 20,000-ton combined train model with the controllable train-tail device, and the braking characteristics and the longitudinal impulse of the train are calculated synchronously with changing the air exhaust time, exhaust area, and action lag time under initial braking. The results show that the maximum coupler force of the combined train will decrease with the extension of the continuous exhaust time, while the total exhaust time of the controllable train-tail device remains unchanged;the maximum coupler force of the combined train reduces by32.5% with the exhaust area increasing from 70% to 140%;when the lag time between the controllable train-tail device and the master locomotive is more than 1.5 s, the maximum coupler force of the train increases along with the time difference enlargement.

Braking distance prediction for vehicle consist in low-speed on-sight operation:a Monte Carlo approach

The first and last mile of a railway journey, in both freight and transit applications, constitutes a high effort and is either non-productive(e.g. in the case of depot operations) or highly inefficient(e.g. in industrial railways). These parts are typically managed on-sight, i.e. with no signalling and train protection systems ensuring the freedom of movement. This is possible due to the rather short braking distances of individual vehicles and shunting consists. The present article analyses the braking behaviour of such shunting units. For this purpose, a dedicated model is developed. It is calibrated on published results of brake tests and validated against a high-definition model for lowspeed applications. Based on this model, multiple simulations are executed to obtain a Monte Carlo simulation of the resulting braking distances. Based on the distribution properties and established safety levels, the risk of exceeding certain braking distances is evaluated and maximum braking distances are derived. Together with certain parameters of the system, these can serve in the design and safety assessment of driver assistance systems and automation of these processes.

A simplified pneumatic model for air brake of passenger trains

Braking system performance is relevant for both railway safety and network optimization. Most trains employ air brake systems;air brake systems of freight trains mostly cannot achieve a synchronous application of brake forces, which is usually customary for passenger trains. The paper generalizes a previous air brake pneumatic model to passenger trains and describes the needed modifications. Among them, the way the pressure reduces in the brake pipe is generalized. Moreover, this paper reports an analytical bi-dimensional function for calculating the nozzle diameter equivalent to the electro-pneumatic(EP) or the electronically controlled pneumatic(ECP)brake valve as a function of the wagon length and the time to vent the brake pipe locally. The numerical results of the new model are compared against several experimental tests of high-speed passenger trains of Trenitalia, namely ETR500 and ETR1000. The model is suitable to be integrated into the UIC software TrainDy, aiming to extend its computational field to passenger trains and to simulate the safety of trains during a recovery.

Assessment of Asbestos Exposure Associated with a Brake Grinder

The wear patterns for drum-style automotive brakes tend to enlarge internal drum diameters. Such enlargement is most profound when used brake drums are machined to restore the metal friction surfaces. Specialized arc grinding machinery has been used to match replacement shoe-style brake friction materials to enlarged drums. The process of arc grinding removes friction material, thereby producing dust. When organic-style friction materials contained asbestos, use of arc grinding machinery posed an asbestos fiber exposure risk to operators and proximate personnel. The manufacturers of arc grinding machinery have incorporated local exhaust ventilation systems designed to capture and remove this dust at the point of grinding contact and propel this dust into collection bags or other systems. This research was designed to evaluate the dust capture and retention characteristics of a specific arc grinder product, when used to custom grind asbestos-containing brake friction materials. A Bear Model 1420 automotive brake shoe arc grinder was the subject of this study. During two separate but consecutive test sessions, newly relined sets of shoe-style automobile brake friction materials were precision ground. Both area and personal air samples were collected throughout each testing session. This work took place within a closed and unventilated metal building, with total interior volume of 2500 m3. Collected air samples were analyzed using phase contrast microscopy (PCM) and transmission electron microscopy (TEM). The results of analysis using PCM for personal samples (n = 6) ranged from <0.044 to 0.055 fibers per cc (f/cc) (mean 0.05). Follow-up analysis of these personal samples using TEM indicated asbestos-adjusted PCM exposures ranging from <0.0074 to 0.055 f/cc (mean ≤ 0.041). Area air samples, taken at distances ranging from 1.5 to 9 meters from the arc grinder (n = 12), showed asbestos-adjusted PCM concentrations ranging from <0.0075 to 0.041 f/cc (mean ≤ 0.017). The process of custom arc grinding shoe-style, asbestos-containing brake friction materials can cause exposure to airborne asbestos fibers. However, when done using properly equipped arc grinding machines, such exposures are not expected to exceed the current occupational exposure limits for asbestos of 0.1 f/cc 8-hour time-weighted average (TWA) or 1.0 f/cc 30-minute average.

Analysis of a Cashew Shell and Fly Ash Rich Brake Liner Composite Material

Hybrid materials collected from organic and inorganic sources,which are traditionally used as brake lining materials,generally include fly ash,cashew shell powder,phenolic resins,aluminium wool,barites,lime powder,carbon powder and copper powder.The present research focuses on the specific effects produced by fly ash and aims to provide useful indications for the replacement of asbestos due to the health hazards caused by the related fibers.Furthermore,the financial implications related to the use of large-volume use of fly ash,lime stone and cashew shell powder,readily available in most countries in the world,are also discussed.It is shown that many manufacturing and automotive industries,which are currently experiencing difficulties in meeting the increasing demand for brake lining material,may take advantage from the proposed solution.

A trailer car dynamics model considering brake rigging of a high-speed train and its application

Brake systems are essential for the speed regulation or braking of a high-speed train.The vehicle dynamic performance under braking condition is complex and directly affects the reliability and running safety.To reveal the vehicle dynamic behaviour in braking process,a comprehensive trailer car dynamics model(TCDM)considering brake systems is established in this paper.The dynamic interactions between the brake system and the other connected components are achieved using the brake disc-pad frictions,brake suspension systems,and wheel-rail interactions.The force and motion transmission from the brake system to the wheel-rail interface is performed by the proposed TCDM excited by track irregularity.In addition,the validity of TCDM is verified by experimental test results.On this basis,the dynamic behaviour of the coupled system is simulated and discussed.The findings indicate that the braking force significantly affects vehicle dynamic behaviour including the wheel-rail forces,suspension forces,wheelset torsional vibration,etc.The dynamic interactions within the brake system are also significantly affected by the vehicle vibration due to track irregularity.Besides,the developed TCDM can be further employed to the dynamic assessment of such a coupled mechanical system under different braking conditions.

Typical faults and safety analysis of brake controller for AC locomotive

Purpose–The brake controller is a key component of the locomotive brake system.It is essential to study its safety.Design/methodology/approach–This paper summarizes and analyzes typical faults of the brake controller,and proposes four categories of faults:position sensor faults,microswitch faults,mechanical faults and communication faults.Suggestions and methods for improving the safety of the brake controller are also presented.Findings–In this paper,a self-judgment and self-learning dynamic calibration method is proposed,which integrates the linear error of the sensor and the manufacturing and assembly errors of the brake controller to solve the output drift.This paper also proposes a logic for diagnosing and handling microswitch faults.Suggestions are proposed for other faults of brake controller.Originality/value–The methods proposed in this paper can greatly improve the usability of the brake controller and reduce the failure rate.

Energy model based sensorless estimation method for operational temperature of braking resistor onboard metro vehicles

Purpose–This study aims to improve the availability of regenerative braking for urban metro vehicles by introducing a sensorless operational temperature estimation method for the braking resistor(BR)onboard the vehicle,which overcomes the vulnerability of having conventional temperature sensor.Design/methodology/approach–In this study,the energy model based sensorless estimation method is developed.By analyzing the structure and the convection dissipation process of the BR onboard the vehicle,the energy-based operational temperature model of the BR and its cooling domain is established.By adopting Newton’s law of cooling and the law of conservation of energy,the energy and temperature dynamic of the BR can be stated.To minimize the use of all kinds of sensors(including both thermal and electrical),a novel regenerative braking power calculation method is proposed,which involves only the voltage of DC traction network and the duty cycle of the chopping circuit;both of them are available for the traction control unit(TCU)of the vehicle.By utilizing a real-time iterative calculation and updating the parameter of the energy model,the operational temperature of the BR can be obtained and monitored in a sensorless manner.Findings–In this study,a sensorless estimation/monitoring method of the operational temperature of BR is proposed.The results show that it is possible to utilize the existing electrical sensors that is mandatory for the traction unit’s operation to estimate the operational temperature of BR,instead of adding dedicated thermal sensors.The results also validate the effectiveness of the proposal is acceptable for the engineering practical.Originality/value–The proposal of this study provides novel concepts for the sensorless operational temperature monitoring of BR onboard rolling stocks.The proposed method only involves quasi-global electrical variable and the internal control signal within the TCU.