Mechatronic Modeling of Real-Time Wheel-Rail Contact

126 Pages·2013·4.813 MB·English

by  Nicola Bosso, Maksym Spiryagin, Antonio Gugliotta, Aurelio Somà (auth.)

Nicola Bosso · Maksym Spiryagin
Antonio Gugliotta · Aurelio Somà
Mechatronic
Modeling
of Real-Time
Wheel-Rail Contact
Mechatronic Modeling of Real-Time
Wheel-Rail Contact
Nicola Bosso Maksym Spiryagin
•
Antonio Gugliotta Aurelio Somà
•
Mechatronic Modeling of
Real-Time Wheel-Rail
Contact
123
Nicola Bosso MaksymSpiryagin
Antonio Gugliotta Centre forRailway Engineering
Aurelio Somà Central QueenslandUniversity
IngegneriaMeccanica eAerospaziale Rockhampton
Politecnico diTorino Australia
Turin
Italy
ISBN 978-3-642-36245-3 ISBN 978-3-642-36246-0 (eBook)
DOI 10.1007/978-3-642-36246-0
SpringerHeidelbergNewYorkDordrechtLondon
LibraryofCongressControlNumber:2013931750
(cid:2)Springer-VerlagBerlinHeidelberg2013
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Preface
Real-time simulations of the behaviour of a rail vehicle require realistic solutions
of the wheel-rail contact problem which can work in a real-time mode. Examples
ofsuchsolutionsfortheonlinemodehavebeenwellknownandareimplemented
within standard and commercial tools for the simulation codes for rail vehicle
dynamics.
Theoverallaimofthisinvestigationistodevelopareal-timewheel-railcontact
model accounting for wheel and rail geometry, the behaviour of a solid wheelset,
frictionparametersandloadcharacteristics.Thebehaviourofawheelsetislimited
to the motions in the lateral and vertical directions, and an angular movement
around the longitudinal axis.
Themodeldesignapproachbasicallyusescombinationsoftheassembliesfrom
the well-known theories, which have been developed using the rules of the
‘‘MISRA-C’’ coding standard and the requirements of real-time applications with
dSpacesystems.Additionalimprovementshavebeenmadetodelineatethecontact
pointsbetweenthewheelandrailsurfacesandthecalculationofcreepagesforthe
classicalwheel-railcontact,andthecontactbetweenwheelsandrollersinthecase
of the test rig application. Furthermore, the improvements also include the
determination of adhesion forces based on the introduction of variable friction
coefficientdependantontherollingvelocityandthelongitudinalcreepage,instead
of a standard model of creep forces with a constant static friction coefficient.
This book presents work on the project for the development of a real-time
wheel-railcontactmodelandprovidesthesimulationresultsobtainedwithdSpace
real-time hardware. Besides this, the implementation of the contact model for the
developmentofareal-timemodelforthecomplexmechatronicsystemofascaled
testrigispresentedinthisbookandmaybeusefulforthefurthervalidationofthe
real-time contact model with experiments on a full scale test rig.
v
Acknowledgments
TheauthorswouldliketothankTimMcSweeneyforthecarefulproofreadingand
valuable comments on this book.
vii
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Background. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Structure of the Book. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Review of Wheel-Rail Contact Models . . . . . . . . . . . . . . . . . . . . . 5
2.1 Statement of the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.1 Rigid Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.2 Elastic Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.3 Quasi-Elastic Contact. . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Tangential Problem: Evolution of Theories. . . . . . . . . . . . . . . 9
2.3 Non-Hertzian Contact Methods . . . . . . . . . . . . . . . . . . . . . . . 16
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Roller Rigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Application of Roller Rig to Railway Testing . . . . . . . . . . . . . 21
3.2 Pascal’s Similitude. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Iwnicki’s Similitude. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4 Jaschinski’s Similitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Design of Scaled Roller Rigs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Roller Rig Developed at the Politecnico di Torino. . . . . . . . . . 37
4.2 Bogie Prototype. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3 Single Wheelset Prototype . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.4 Motorisation of the Roller Rig. . . . . . . . . . . . . . . . . . . . . . . . 48
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5 Contact Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1 Statement of the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 Wheelset and its Coordinate System. . . . . . . . . . . . . . . . . . . . 56
5.3 Algorithm for the Wheel-Rail Contact Model . . . . . . . . . . . . . 56
5.4 Simulation Software and Requirements. . . . . . . . . . . . . . . . . . 57
ix
x Contents
5.5 Integration Approach for the Real-Time Realisation
of the Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.6 Initial Data for the Contact Model. . . . . . . . . . . . . . . . . . . . . 58
5.6.1 Parameterisation of Wheel and Rail Geometries . . . . . 59
5.6.2 Definition of Wheel and Rail Surfaces
for the Contact Model . . . . . . . . . . . . . . . . . . . . . . . 59
5.6.3 Realisation of the Module. . . . . . . . . . . . . . . . . . . . . 59
5.7 Geometrical Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.7.1 Scenario of One Point Contact. . . . . . . . . . . . . . . . . . 61
5.7.2 Interpolation Algorithm . . . . . . . . . . . . . . . . . . . . . . 64
5.8 Hertz Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.9 Creepage Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.10 Module for the Calculation of Normal Forces . . . . . . . . . . . . . 67
5.10.1 Normal Contact Forces in Wheel-Rail Contact . . . . . . 67
5.10.2 Operation of the Module. . . . . . . . . . . . . . . . . . . . . . 68
5.11 Dynamic Friction Coefficient Module. . . . . . . . . . . . . . . . . . . 69
5.12 Creep Forces Calculation Model . . . . . . . . . . . . . . . . . . . . . . 70
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6 Real-Time Simulation of the Contact Model . . . . . . . . . . . . . . . . . 73
6.1 Integration with Simulink: Model Inputs and Outputs. . . . . . . . 73
6.2 Mechatronic System Model of Test Rig . . . . . . . . . . . . . . . . . 77
6.3 Multibody Model of Test Rig in Simpack. . . . . . . . . . . . . . . . 78
6.4 Control Algorithms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.5 Power Converter and Sensors . . . . . . . . . . . . . . . . . . . . . . . . 82
6.6 Simulation Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7 Example of Real-Time Application for Scaled Test Rig. . . . . . . . . 91
7.1 Structure of the Mechatronic Model. . . . . . . . . . . . . . . . . . . . 91
7.2 Multibody Model of Test Rig in SimMechanics . . . . . . . . . . . 92
7.3 Control Algorithms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.4 Integration with Simulink and SimMechanics . . . . . . . . . . . . . 96
7.5 Simulation Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
8 Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
About the Authors
Nicola Bosso was born in Vercelli in 1971. He
graduatedinMechanicalEngineeringin1996from
PolitecnicodiTorino.Heworkedasaconsultantin
railwaydynamicsandmultibodysimulationsatFiat
Ferroviaria from 1996 to 1998, and as a Research
FellowatPolitecnicodiTorinofrom1999to2002.
HehasbeenanAssistantProfessoratPolitecnicodi
Torino since 2002 and was awarded his Ph.D. in
Machine Design there in 2004.
Researchactivity:Simulationofrailwaydynamic,
wheel-railinteraction,designandexperimentationon
scaledprototypesfortherailwaysector.
Teaching activity: Technology and design of railway vehicles, multibody
simulation, machine design.
He has more than 40 scientific publications and 5 patents.
MaksymSpiryagin isaresearchfellowatCentral
Queensland University, where he works at the
Centre for Railway Engineering. His present
research interests are rail vehicle dynamics,
mechatronics and real-time and software-enabled
controlsystems.HewasborninLugansk(Ukraine)
in 1975. He graduated from the Department of
Transport at the East Ukrainian State University in
1998 with an M.Sc. degree in Railway Transport.
Also, he completed his Master’s degree in
ComputerEngineeringandNetworksin2003atthe
East UkrainianNational University.Hereceived hisPh.D.inthe field ofRailway
Transport in 2004 at the same university. After that, he got promotion there and
xi
xii AbouttheAuthors
continuedservingasanassociateprofessor.Inearly2007,hestartedworkingasa
research professor in the field of mechatronics and vehicle dynamics at Hanyang
University (Seoul, South Korea). At the end of 2008, he commenced work as a
foreign senior researcher at Politecnico di Torino (Turin, Italy). His research
focused on the development of real-time wheel-rail contact models and vehicle
mechatronicsystems.Hehasmorethan50scientificpublicationsand17patentsas
one of the inventors.
Antonio Gugliotta was born in Sava (Taranto,
Italy) in 1949. He graduated in Aeronautical
Engineering from the Politecnico di Torino in
1973, and an M.Sc. in Mechanical Engineering
from the Carleton University, Ottawa, Ontario,
Canada in 1978. He held positions as Assistant
Professor of Machine Design at the Politecnico of
Torino (1973–1977), Teaching Assistant at the
Faculty of Engineering, Carleton University,
Ontario, Canada (1977–1978), Associate Professor
of Machine Design at the Politecnico of Torino
(1983–1987) and since 1987 has been Professor of
Machine Design at the University of Roma
‘‘La Sapienza’’ (1987–1990) and at the Politecnico of Torino, Second Faculty of
Engineering(since1990).DeanoftheSecondFacultyofEngineering,Politecnico
di Torino (1993–2003). President of COREP (Consortium for Research and
Continuing Education). He has published more than 100 scientific papers.
Research activity: Applied mechanics, mechanical design, finite element
method,structuralanalysis,metalforming,crashworthiness,dynamicsandcontact
mechanics of railway vehicles, microstructures (MEMS), methodologies for
microstructures simulation and experimental characterisation.