Rail Vehicle Technology PDF
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Joachim Ihme Rail Vehicle Technology Rail Vehicle Technology Joachim Ihme Rail Vehicle Technology JoachimIhme OstfaliaHaW Wolfenbüttel,Germany ISBN978-3-658-36968-2 ISBN978-3-658-36969-9 (eBook) https://doi.org/10.1007/978-3-658-36969-9 ThisbookisatranslationoftheoriginalGermanedition„Schienenfahrzeugtechnik“byIhme,Joachim,published by Springer Fachmedien Wiesbaden GmbH in 2019. The translation was done with the help of artificial intelligence(machinetranslationbytheserviceDeepL.com).Asubsequenthumanrevisionwasdoneprimarily intermsofcontent,sothatthebookwillreadstylisticallydifferentlyfromaconventionaltranslation.Springer Natureworkscontinuouslytofurtherthedevelopmentoftoolsfortheproductionofbooksandontherelated technologiestosupporttheauthors. #TheEditor(s)(ifapplicable)andTheAuthor(s),underexclusivelicensetoSpringerFachmedienWiesbaden GmbH,partofSpringerNature2022 Thisworkissubjecttocopyright.AllrightsaresolelyandexclusivelylicensedbythePublisher,whetherthe wholeorpartofthematerialisconcerned,specificallytherightsoftranslation,reprinting,reuseofillustrations, recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,andtransmissionorinformation storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now knownorhereafterdeveloped. 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Theregisteredcompanyaddressis:Abraham-Lincoln-Str.46,65189Wiesbaden,Germany Preface ThisbookoriginatedfromlecturesonrailvehicletechnologythatIhaveheldsince1990at theOstfaliaUniversityofAppliedSciencesinWolfenbüttelandWolfsburgforstudentsof mechanicalengineering,automotiveengineeringandelectricalengineering. Unfortunately,overthelast30years,theteachingofrailvehicletechnologyandrailway engineeringhasbeencutbackattechnicaluniversitiesanduniversitiesofappliedsciences, althoughGermanystillhasimportantlocationsfortherailvehicleandsupplyindustry.In addition, theinterest inrailwaysandrail vehiclesamong first-year students is rather low, since model railways have essentially become a collector’s item for older gentlemen and railwayshavewithdrawnfrommanyregions. This is why the German rail vehicle industry and rail operators are finding fewer and fewerengineersspeciallytrainedforthem.Accordingtoreports,thereisthereforeaneedto provide new employees with the necessary basic knowledge and special skills in the company. This book aims to make an introductory contribution to this in the field of rail vehicletechnology.Apartfrombeingusedasalecturematerial,itisalsosuitableforself- study. However, not all aspects of rail vehicle technology and rail transport can be dealt withanddeepenedhere. Attherequestofthereadership,anewchapteron“Engineeringinrailvehicleconstruc- tion”hasbeenincludedinthesecondedition. The target group for this book are students at colleges and universities after the basic studiesofmechanicalorvehicleengineering.Alsotheinterestedlayman,e.g.therailway enthusiast, can expand his knowledge in this book. However, he will largely miss steam locomotivesandlandscapephotographsofrailwaytrains. I would like to thank all the companies and institutions that supported me with informationandpicturematerial,especiallythecompaniesAlstom,Bombardier,Siemens, Voith and Vossloh. I would also like to thank Springer Vieweg Verlag and Dipl.-Ing. ThomasZipsnerforthepleasantcooperation.Lastbutnotleast,Iwouldliketothankmy dear wife, who had to forego many joint activities with me during the preparation of the manuscript. v vi Preface All unmarked illustrations and photos are by the author. I am grateful for suggestions fromreadersandforinformationonerrors. Braunschweig inOctober2021 Wolfenbüttel,Niedersachsen,Germany JoachimIhme Contents 1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 RunningResistancesofRailVehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2.1 RunningResistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 2.2 AirResistance. . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . 33 2.3 AdditionalResistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2.4 LineResistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.5 AccelerationResistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.6 AirResistanceAccordingtotheHanoverFormula. . . . . . . . . . . . . . . . . 40 2.7 TotalResistanceandWheelPower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 2.8 ExamplesandTasksforChap.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 3 DrivingMachines,PowerTransmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3.1 SteamEngine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 3.2 ElectricMotor. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . 58 3.2.1 DCMotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 3.2.2 Single-PhaseACMotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 3.2.3 Three-PhaseMotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 3.2.4 MechanicalPartoftheElectricDrives. . . . . . . . . . . . . . . . . . . . . 74 3.3 InternalCombustionEngine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 3.3.1 MechanicalPowerTransmission. . . . . . . . . . . . . . . . . . . . . . . . . 83 3.3.2 HydrodynamicPowerTransmission. . .. . . . . . .. . . . . . . .. . . . . 85 3.3.3 ElectricalPowerTransmission. . .. . . . . .. . . . . . .. . . . . . .. . . . 91 3.4 GasTurbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 3.5 HybridVehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 4 BrakesforRailwayVehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 4.1 FrictionalBrakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 4.1.1 ThroughBrakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 4.1.2 MechanicalBrakeComponents. . . . . . . . . . . . . . . . . . . . . . . . . . 124 4.1.3 Electric(Regenerative)Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 127 4.1.4 HydrodynamicBrake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 vii viii Contents 4.2 BrakesIndependentofWheel-RailAdhesion. . . . . . . . . . . . . . . . . . . . . 129 4.3 CalculationofBrakingDistances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 4.4 BrakeWeight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 5 WheelsetGuidance,SuspensionandDamping. . . . . . . . . . . . . . . . . . . . . . . 143 5.1 VibrationPerceptionoftheHumanBeing. . . . . . . . . . . . . . . . . . . . . . . . 144 5.2 VehicleVibrationsDuetoTrackUnevenness. . . . . . . . . . . . . . . . . . . . . 145 5.3 TheoreticalPrinciplesofVibrationSimulation. . . . . . . . . . . . . . . . . . . . 148 5.3.1 SimulationintheFrequencyDomain. . . . . . . . . . . . . . . . . . . . . . 151 5.3.2 SimulationintheTimeDomain.. . . . . . . . . . . . . . . .. . . . . . . . . 157 5.4 InteractionBetweenVehicleandTrack. . . . . . . . . . . . . . . . . . . . . . . . . . 160 5.5 DynamicBehaviouroftheWheelset. . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 5.6 RunningGearsofRailVehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 5.6.1 BogiesforRailwayVehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 5.6.2 RunningGearofTramcars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 5.7 CurveEntryandExit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 5.8 AirSuspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 6 SupportingStructuresandSuperstructuresofRailwayVehicles. . . . . . . . . 215 6.1 StrengthRequirementsforRailVehicleBodies. . . . . . . . . . . . . . . . . . . . 216 6.1.1 StaticLoadAssumptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 6.1.2 DynamicLoadAssumptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 6.1.3 StaticTests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 6.1.4 CrashworthyDesign. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 6.2 HistoricalDevelopmentandCurrentStatusofRailwayPassenger Carriages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 6.3 Metro,LightRailandTramVehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . 247 6.4 Locomotives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 6.5 FreightWagons. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 258 6.6 BogiesandRunningGear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 7 EngineeringinRailVehicleConstruction. . . . . . . . . . . . . . . . . . . . . . . . . . 271 7.1 ProductCreationProcessinRailVehicleConstruction. . . . . . . . . . . . . . 273 7.2 Computer-AidedProductCreation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 References. . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . 297 Index. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . 301 Formula Symbols, Indices and Abbreviations Used Formula Symbols Used A[m2,cm2,mm2] Area A [m2] Transverseclampingsurface 1 A [m2] Trainsurface 2 B[N,kN] Brakingforce C[diverse] Integrationconstant D[–] DampingfactoraccordingtoLehr E[kWh] Energy F[N,kN] Forcegeneral F [N,kN] Brakingforce B F [N,kN] Weightforceonwheel/wheels GR F [N,kN] Brakingforceofthemagneticrailbrake MG F [N,kN] Rollingresistanceforceofawheel WR G[N,kN] Weightforce I[A] Current I[mm4] Secondmomentofanarea J[kgm2] Massmomentofinertia Im[–] Imaginarypartofacomplexnumber K [–] Ratioofaveragedragcoefficients W L[m] Length,trainlength L[m] Unevenwavelength M[Nm] Moment,torque M [Nm] Stalltorque(forthree-phasemotor) Kipp M [Nm] Bearingfrictionaltorque RL N[N,kN] Normalforce P[kW] Power P [kW] Hourlyoutput(forelectriclocomotives) 1h P [kW] Startingpower(forelectriclocomotives) Start P [kW] Continuouspower(forelectriclocomotives) Cont ix x FormulaSymbols,IndicesandAbbreviationsUsed P [kW] Powerloss V R[m] Radiusofthetrackcurve Re[–] Reynoldsnumber Re[–] Realpartofacomplexnumber S[N,kN] Lateralforce T[N,kN] Tangentialforce T[s] Time(point) U[V,kV] (Electr.)Voltage U[N,kN] Circumferentialforce U [V,kV] DCvoltageaverage gl V[m3] Volume W [N,kN] Drivingresistanceforce Drive W[cm3,mm3] Resistancetorque W [N,kN] Airresistancenoseandtail a W [N,kN] Accelerationresistance Acc W [N,kN] Airresistancetrainsurface(airfriction) b W [N,kN] Curveresistance Cur W [N,kN] Runningresistance Run W [N,kN] Airresistance Air W [N,kN] Rollingresistance R W [N,kN] Impactresistance Imp W [N,kN] Lineresistance Lin Z[N,kN] Tractionforce Z [N,kN] Maximumtractionforce max a[m,mm] Distance,wheelsetdistance a[m/s2] Brakingdeceleration b[m/s2] Acceleration c Coefficient(general) c[N/m] Springconstant c0 [N/m] Gravitationalstiffness(gravitationalspringstiffness) c [–] Coefficientforimpactresistance d c [–] Dragcoefficient W c0 ½(cid:2)(cid:3) Dragcoefficientforinclinedairflow W c [–] Dragcoefficientlocomotive W,L c [–] Dragcoefficientwagon W,W e[m,mm] Distance,eccentricity f[Hz] Frequency f [–] Rollingresistancecoefficient R g[m/s2] Accelerationduetogravity h[m,mm] Height;unevenness(amplitude) pffiffiffiffiffiffiffi i[–] ImaginaryUnit,i¼ (cid:2)1
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