Vehicle Dynamics Competition Mark Benton, Lead Project Manager 24 March 2016 Agenda 14.00 Competition Introduction/ Outline - Mark Benton, RSSB 14.15 A Train Operator’s (TOC) perspective - John Hawkins, GWR 14.25 Vehicle dynamics & the importance of the wheel-rail interface - Hugh O’Neill, RSSB 14.45 Use of VTISM to assess ‘track friendliness’ of rail vehicles - Dr Gareth Tucker, RSSB 15.00 VTAC - Dr Mark Burstow, Network Rail 15.15 Q & A 15.30 Coffee Break 15.40 Elevator Pitches - Russ Noble, IXC (facilitating) 16.00 - 17.30 Networking (drinks reception) 2 Future Railway 04 April 2016 Competition Scope The objectives of this competition are as follows: Primary objectives: – Reduction of the costs associated with track damage – Reduction of suspension and wheelset maintenance costs Secondary objectives: – Enable vehicles to transition between main-line and branch line running more easily Projects should be at Technology Readiness Level 4-6 3 Future Railway 04 April 2016 Funding £4.5m to fund demonstrator projects that meet the competition scope Duration 18-24 months (up to 30 months with justification) Co-funded proposals (subject to state aid requirements) Individual projects expected to be £2-5m including co-funding 4 Future Railway 04 April 2016 Submission Applications must be on the form provided and be no more than 20 pages in total. One additional document may be provided - Gantt Chart (.pdf) Submit to: Vehicle.Dynamics@RSSB.co.uk 5 Future Railway 04 April 2016 Evaluation Criterion Description Weight Technical How does the proposal meet the brief 50% and how innovative and feasible is the proposal to lead to a marketable product? How effectively will the project be Project 20% managed, are the skills and capabilities of the consortia appropriate? Finances How appropriate is the proposal 30% financially? Is the overall budget realistic and justified in terms of the aims and methods proposed, and complies with state aid funding requirements? 6 Future Railway 04 April 2016 Indicative Key Dates Question Deadline 5.00pm, 6 May 2016 Final Answers to questions 5.00pm, 19 May 2015 Entry submission date 5.00pm, 2 June 2016 Presentations to the evaluation panel 19 or 20 July 2016 Applicants informed of outcome w/c 25 July 2016 Grant Award by 29 August 2016 7 Future Railway 04 April 2016 Registration Competition pages can be found at: – http://www.rssb.co.uk/future-railway-programme/funding-opportunities Or – http://www.cvent.com/d/vfqq1r 8 Future Railway 04 April 2016 A Train Operator’s (TOC’s) Perspective John Hawkins First Group A Train Operator’s (TOC’s) Perspective • Key TOC consideration for new trains designs: • • • • • Performance specification Leasing costs Operating costs Safety and Reliability Customer experience 10 Train Performance Specification A fundamental requirement is that the train should be capable of the performance specified for its intended operation. This includes: • • • • Maximum speed Acceleration Capacity Passenger facilities A “deliverability” review is required to assess the prospects for the design proposed achieving the specification. 11 Train Leasing Costs • Financiers / Rolling Stock Leasing companies will set train leasing charges based on the following considerations: • Capital cost • Expected life • Residual value, based on: ‒ ‒ ‒ ‒ ‒ Assessed future requirements for type of train Cost of maintenance Track access charges Reliability Ability to deploy on other routes 12 Train Operating Costs • In addition to leasing charges, TOCs must budget for the following operating costs: • Useable availability ‒ Maintenance requirements ‒ Deployment flexibility (routes / train length) • • • Variable Track Access Charge (VTAC) Based on a modelled assessment of track wear and tear caused by the vehicle design (stated as a cost per vehicle mile). Linked to suspension characteristics, overall vehicle mass and unsprung mass. The key assessment tool is VTISM - to be explained in more detail in a later presentation. Train maintenance cost Linked to complexity, inherent reliability and maintainability. Energy cost Linked to energy efficiency of traction system, vehicle mass and ability to regenerate when braking. 13 Train Safety and Reliability • The suspension system is one of the most safety critical elements of a train design. Many of the components have the potential to become single sources of failure. • The system design (suspension and track) is unique to rail • It is vital to demonstrate how the suspension system design manages risks associated with component failure – faults must be detectable in time to prevent catastrophic failures • Train delays and cancellations create an adverse impact for customers and a significant financial cost for TOCs through the performance regime with Network Rail • Designs should ensure that failures cause the minimum of impact on the rail network – consideration of graceful degradation and degraded modes of operation is essential 14 Customer Experience • Comfort, in terms of noise and vibration, is a key consideration in creating the right customer experience. Rail will inevitably be compared with other competing modes, such as cars and coaches/buses. Also, expectation is to be able to walk around safely whilst trains are moving. • Any potential to reliably reduce journey times is beneficial. • Need to consider accelerations experienced by passengers in all three planes. • May be a potential to deliver similar ride quality to that experienced today on track with poorer alignment – reducing track maintenance costs. • Ability to travel more quickly on existing track, without adverse impact on safety or comfort? 15 Rail Vehicle Dynamics: The importance of the wheel rail interface Hugh O‘Neill Professional Head of Rolling Stock RSSB Topics for today • The wheel-rail interface – why its management matters • Cyclic top instability – imprinting risk • Instability and hunting • Wear and rolling contact fatigue • Ballast settlement • An example of an innovative solution 17 Rail Vehicle Dynamics 30 March 2016 Why does it matter? 18 Rail Vehicle Dynamics 30 March 2016 The wheel rail interface – an introduction Highest contact stress in engineering 19 Rail Vehicle Dynamics 30 March 2016 Effect of track wavelength Railway track contains a wide range of wavelengths Vehicles respond differently to different wavelengths Wavelength =2L Wavelength =L 20 Rail Vehicle Dynamics 30 March 2016 Wavelengths in GB track Standard rail length in UK jointed track = 60ft (18.3m) 21 Rail Vehicle Dynamics 30 March 2016 Derailment due to vertical resonance • Coal Wagon - Short wheelbase and closely spaced bounce and pitch modes • Track input – case 1 - Wavelength = 11.24m - Speed = 45mph - Frequency = 1.8 Hz • Track input – case 2 - Wavelength = 11.24m - Speed = 51mph - Frequency = 2 Hz • Cyclic top derailment - Add a 500m radius curve 22 Rail Vehicle Dynamics 30 March 2016 Cyclic top derailment PCA wagon 10769 that derailed at Heworth 23 Rail Vehicle Dynamics 30 March 2016 Cyclic top derailment CCTV image of a derailed freight train at Heworth, near Newcastle upon Tyne 24 Rail Vehicle Dynamics 30 March 2016 Ballast Settlement 25 Rail Vehicle Dynamics 30 March 2016 Ballast Settlement 26 Rail Vehicle Dynamics 30 March 2016 Conicity depends on both wheelset & track MiniProf for Windows Version 2.4.63 Page 1 of 1 Date: 07 September 2009 Time: 10:35:21 50 • Wheel profile - Increasing wear - Increasing conicity (usually) 40 30 increasing conicity 20 MiniProf for Windows Version 2.4.63 Page 1 of 1 20 10 • Track gauge - Tight gauge - high conicity 0 10 -10 0 -20 • Wheelset back-back - Wide back-to-back – higher conicity -10 10 20 30 40 50 60 70 80 90 100 110 120 130 Copyright(c) 1997-2005, Greenwood Engineering -20 old 113A new 113A -30 • Rail profile - Flatter rail head – higher conicity - New 113A rail reduced conicity -40 -50 -60 27 Rail Vehicle Dynamics -50 -40 30 March 2016 Copyright(c) 1997-2005, Greenwood Engineering -30 -20 -10 0 10 20 30 40 5 Hunting instability • Bogie hunting - high-speed, high-conicity - high frequency ~7Hz - wheelsets move relative to bogie - body barely moves • Body hunting - low conicity - low frequency 0.5-1.5Hz - Wheelset and bogie move together - body moves 28 Rail Vehicle Dynamics 30 March 2016 Lateral Movement of Wheelset on Track • • • • Wheelset amplitude is limited by flange contact Can get high forces between wheel and rail Bad riding, passenger complaints Deterioration of track and vehicle, higher maintenance costs Decreasing speed 29 Rail Vehicle Dynamics 30 March 2016 Contact patch energy Y Z X 30 Rail Vehicle Dynamics 30 March 2016 The pressure in the wheel contact patch is equivalent to a weight of a double decker bus on a 5p coin Contact Patch Energy -Wear Wearrelationships 0.5 Wear (mm²/km) 0.4 0.3 0.2 0.1 0 0 100 200 300 TGamma (J/m) 31 Rail Vehicle Dynamics 30 March 2016 400 500 Contact patch energy • • • 32 Rail Vehicle Dynamics 30 March 2016 Wear • - traction direction on rails - braking direction on wheels Low energy (T) - no damage Moderate energy (T) - severe RCF - typically when wheelset steering High energy (T) - wear removes any cracks - typically in flange contact RCF more damaging RCF • Longitudinal forces in the contact patch cause Rolling Contact Fatigue Contact patch energy Rolling contact fatigue 33 Rail Vehicle Dynamics 30 March 2016 RCF consequences Multiple fractures: • Consequences may be catastrophic • UK Hatfield derailment October 2000 34 Rail Vehicle Dynamics 30 March 2016 Wheel effects Cracks in wheels generally don’t turn down like rails: • Wheels are bi-directional • Causes surface damage (spalling) • In extreme cases, wheel fracture 35 Rail Vehicle Dynamics 30 March 2016 Example of Innovative Solution: HALL Bush 36 Rail Vehicle Dynamics 30 March 2016 Summary • An understanding of vehicle dynamics does matter! - To manage safety - To minimise commercial risk to Railway Undertakings (RUs) and Infrastructure Managers (IMs) - To guarantee passenger comfort and avoid damage to freight payloads • Your innovative solutions are welcome 37 Rail Vehicle Dynamics 30 March 2016 Use of VTISM to assess ‘track friendliness’ of rail vehicles Dr Gareth Tucker FIMechE Background to VTISM • Vehicle Track Interaction System Model • VTISM is a tool to carry out route specific calculations of the cost track degradation due to the passing of rail vehicles • VTISM Phase 1 (T353) 2009 • VTSIM Core Module • Integration of: • Geogis • Actraff • WLRM • T-SPA • VTISM Phase 2 (T792) 2013 • Addition of WPDM & WMM • Updates to user interface • Addition of ride force coefficient calculation 39 VTISM 04 April 2016 Track degradation due to rail vehicle traffic 40 VTISM 04 April 2016 VTISM overview? 41 VTISM 04 April 2016 VTISM Track damage model 42 VTISM 04 April 2016 Vertical damage (T-SPA) Vertical axle load vs time • Ballast settlement • Sleeper degradation • Vertical rail stresses 43 VTISM 04 April 2016 Ride force coefficient calculations (forces <20Hz) 44 VTISM 04 April 2016 Rail surface damage (WLRM) • WLRM developed by RSSB project T115 (2003), developed further by project T775 (2011) 45 VTISM 04 April 2016 Example WLRM output over a 130 mile route 46 VTISM 04 April 2016 Example VTISM output 47 VTISM 04 April 2016 Example VTISM output 48 VTISM 04 April 2016 Using VTISM • License is available from RSSB (contact enquiries@rssb.co.uk) • Training and support is also available • User manual is provided 49 VTISM 04 April 2016 Presentation Title: View > Header & Footer Variable Track Access Charges (VTAC) and infrastructure damage Mark Burstow Principal Vehicle Track Dynamics Engineer 4-Apr-16 / 50 January 2014 Introduction ► Running trains causes wear and tear to the infrastructure • Variable usage charges (VUC) are levied to recover the costs of (some) of the damage caused • The VUC for each vehicle is in inverse proportion to its ‘track friendliness’ - Vehicles which cause more damage will carry a higher charge - VUC can be used as a measure of ‘track friendliness’ ► What costs are recovered through the VUC? ► How are these costs calculated and turned into charges? ► What factors determine the level of a vehicles charge? • Limitations/assumptions The CP5 variable usage charge (VUC) / 51 What costs does the VUC recover? •The VUC recovers operating, maintenance and renewal costs that vary with traffic Signalling (5%) Civils (10%) Includes maintenance costs and points renewal costs Includes costs associated with underbridges, embankments and culverts Track (85%) January 2014 The CP5 variable usage charge (VUC) Includes maintenance and renewals costs, 70% of costs related to vertical rail forces and 30% of costs relate to horizontal rail forces / 52 January 2014 How are VUC costs turned into charges? Network-wide VUC costs •The VUC is not a measure of the full ‘damage’ caused by each vehicle VUC vehicle rate (passenger) Signalling (£12m) VUC vehicle rate (passenger) Civils (£26m) VUC vehicle rate (passenger) •But is meant to be cost reflective Assessment of vehicles ‘track friendliness’ Efficient average VUC rate X Network-wide traffic = VUC vehicle rate (passenger) VUC vehicle rate (Freight) Track (£215m) VUC vehicle rate (Freight) VUC vehicle rate (Freight) VUC vehicle rate (Freight) The CP5 variable usage charge (VUC) / 53 January 2014 How do we assess ‘track friendliness’ – key variables The VUC for any vehicle type is determined by its ‘track friendliness’ ► VUC rates are designed to be cost reflective For each vehicle type a ‘track friendliness score’ is calculated and used to apportion costs The four key vehicle characteristics that inform the ‘track friendliness score’ are: ► Axle load ► Operating speed ► Un-sprung mass ► Bogie primary yaw stiffness (indicative of its curving ability) The CP5 variable usage charge (VUC) / 54 Presentation Title: View > Header & Footer VUC calculator VUC calculator model is available from the Network Rail website 4-Apr-16 / 55 How do we assess ‘track friendliness’ – formulae VUC cost category Formula used to calculate ‘track friendliness’ score Track (Vertical) Ct * ( 0.473e^(0.133A) + 0.015 SU - 0.009 S - 0.284 U - 0.442) * GTM * axles Track (Horizontal) Allocated using the ‘curving class’ methodology Civils Ct.A3.00.S1.52 (per tonne.mile).GTM Signalling 50% of costs assumed to be load-related allocated using Track (Vertical) formula, above, and 50% of costs assumed to be non-load-related allocated based on vehicle miles Where: Ct = 0.89 for loco-hauled passenger stock and multiple units, 1 for all others (vertical track costs equation) Ct = 1.2 for 2-axle freight wagons, 1 for all others (civils costs equation) A = axle load (tonnes) S= operating speed (miles/hour) U = unsprung mass (tonne/axle) GTM = gross tonne miles January 2014 The CP5 variable usage charge (VUC) / 56 January 2014 Track (vertical forces)‘wear and tear’ relationship VTISM was used to determine variation in track damage (vertical) for a range of vehicle parameters (not ‘real’ vehicles) ► Speeds: 25 – 100mph ► Axleloads: 5 – 25t ► Unsprung mass= 1000 – 3000kg Fit a continuous relationship between these damage costs Calibrate this against agreed NR recoverable total track costs to determine VTAC The CP5 variable usage charge (VUC) / 57 January 2014 ‘Vertical’ damage relationships Damage found to be strongly influenced by axleload Axleload Speed Unsprung mass The CP5 variable usage charge (VUC) / 58 January 2014 Track surface damage methodology Horizontal track damage covers rail wear and rolling contact fatigue ► Derived from models developed to predict RCF RCF/wear damage depends on wheel/rail forces (often quantified through the contact patch energy, Tgamma or T) T depends on ► ► Vehicle suspension type and bogie design Curve radius Cant deficiency (speed & installed cant) PYS8 180 PYS8, calculated PYS8, v5.0 160 PYS16 140 T /J/m ► 200 PYS16, calculated 120 PYS16, v5.0 100 PYS32 PYS32, calculated 80 PYS32, v5.0 60 40 20 Assessment is done over a range of curves 0 0 500 1000 1500 2000 2500 Curve radius/m 3000 3500 4000 The CP5 variable usage charge (VUC) / 59 January 2014 Methodology T can only be evaluated using detailed vehicle dynamics simulations ► The existing VUC formulation allows users to either • ‘look-up’ pre-calculated values for a range of vehicle characteristics (the ‘vehicle curving class’), or • do the simulations for the required vehicle and enter the values into the VTAC spreadsheet to determine the horizontal damage cost - A guidance document exists to specify how to do the simulations: wheel/rail profiles, friction conditions, curve & cant deficiency, required outputs etc. The CP5 variable usage charge (VUC) / 60 January 2014 Horizontal VUC component For a wide range of suspension stiffnesses/vehicle weights the VUC component has already been determined For new/modified vehicles it is possible to use a precalculated rate…. ….or use vehicle dynamics simulations to calculate a new rate ► ► To recognise the good curving performance of a novel suspension design Where axle spacing is shorter than on other vehicles Loco2_50 Loco3_50 Class_60 Class_66 Pacer_10 Coach_8 Coach_12_30 Coach_12_35 Coach_12_40 Coach_12_50 Coach_12_60 Coach_16_30 Coach_16_35 Coach_16_40 Coach_16_50 Coach_17_30 Coach_17_40 Coach_23_30 Coach_23_40 Coach_23_50 Coach_24_30 Coach_24_35 Coach_24_40 Coach_24_50 Coach_24_60 Coach_26_50 Coach_35_50 Coach_48_40 Coach_48_50 Coach_48_60 Coach_50_40 Coach_50_50 Coach_50_60 Coach_60_50 Coach_64_30 Coach_64_35 Coach_64_40 Coach_64_50 Coach_64_60 Coach_80_30 Coach_80_40 Coach_80_50 Coach_100_40 Coach_128_30 Coach_128_35 Coach_128_40 Coach_128_50 Tilting_50_50 Artic2_80 Artic3 Y25_loaded Y25_empty NACO_loaded NACO_empty 3Piece_empty 3Piece_loaded 2axle_empty 2axle_loaded TF25_empty TF25_loaded Coach_15_30 Coach_15_40 Coach_15_60 Shunter Coach_HB_40 Coach_HB_50 Coach_HB_60 Coach_HB_Cl221 Class_68 PPM_2axle The CP5 variable usage charge (VUC) / 61 Example VUC surface damage reduction Improve vehicle curving class Reduce ‘primary yaw stiffness’ ► Use of variable rate (HALL) radial arm bushes • Provide reduced yaw stiffness on curves (less wear & RCF) but high stiffness at high frequency oscillation, so maintains stability and ride ► 6 40t 50t Surface damage VUC/p/vm 5 60t HALL bush 4 3 2 1 0 0 20 40 60 80 100 Primary yaw stiffness/MNm/rad / Presentation Title: View > Header & Footer Summary Variable Usage Charge is a ‘proxy’ for track damage Does not give the actual costs of damage, but relative charges ► Driven by: • Axleload • Unsprung mass • Wheelset curving characteristics • Speed ► Not an ‘absolute’ measure of vehicle/track interaction • Not able to consider benefits of (e.g.) active suspensions and other enhancements • But useful to indicate what factors are important ► Where can I find the calculator….? 4-Apr-16 / 63 Presentation Title: View > Header & Footer Further information http://www.networkrail.co.uk/using-our-network/cp5-access-charges/ 4-Apr-16 / 64 Q&A Elevator pitches Elevator Pitches Running order: Rebeka Sellick Justin Hawley Roger Lewis Andrea Bracciali Russell Crow Brian Scales Mark Bush Lewis Lesley David Buckley Christopher Ward We offer experienced market entry and technology transfer into the railway industry, through our bid-winning, satisfaction-delivering innovations, engineering and business consultancy service: looking to partner with credible ideas people, wherever they come from, we can help them roll forward smoothly! • Company: • Contact: • Email: SellickRail Ltd Rebeka Sellick, Director Rebeka@SellickRail.com SET is developing an innovative traction and active steering system with the modelled capability to dramatically reduce rail wear and RCF. • Company: Stored Energy Technology Ltd • Contact: Neil Cooney • Email: Innovation@set.gb.com • Web: www.set.gb.com Apparently Independently Rotating wheel set The competition is primarily interested in pushing solutions up the Technology Readiness Level scale through demonstrator projects and onward development plans. Wheels connected via a torque limiter: lower maintenance, lower TACs, less wheel/rail damage, better dynamics, safer. Fully passive. Proven design and technology. Applicable to virtually any kind of rolling stock. Driving and trailer versions available. Fully engineered and documented: ready for prototype manufacturing. • Company: AB Consulting di Andrea Bracciali & C. • Contact: Andrea Bracciali + 39 347 2429240 • Email: andrea.bracciali@unifi.it • Web: www.andreabracciali.it Wear/damage test apparatus – small-scale to full-scale • Company: The University of Sheffield • Email: roger.lewis@sheffield.ac.uk High resolution wear maps; RCF and squat damage models RE SEVE 800 600 RESEVE ROPHIC ST CATA SITION TRAN Contact Pressure (MPa) 1200 1000 60 kN 80 kN Local contact models and interface measurement Test methods for wear, RCF, lubrication friction modifiers • Web: http://merail.group.shef.ac.uk/ 40 kN CATASTROPHIC 437.5 -- 500.0 375.0 -- 437.5 312.5 -- 375.0 250.0 -- 312.5 187.5 -- 250.0 125.0 -- 187.5 62.50 -- 125.0 0 -- 62.50 Design tools integrating wear and damage predictions with MBD simulations -440 -445 -450 Z [mm] • Contact: Prof Roger Lewis 20 kN Contact Pressure (MPa) Wheel/rail tribology – experiment, model, validation, implementation -455 -460 -465 MILD -470 400 0.00 0.05 0.10 0.15 Sliding Speed (m/s) 0.20 New Profile Vehicle 1 - Left Wheel Vehicle 2 - Left Wheel -475 -820 -800 -780 -740 -760 Y [mm] -720 -700 -680 Design, Analysis, Prototyping, Test & Manufacture of vehicle suspension components How can we help you? • Company: Tinsley Bridge • Contact: Russell Crow • Email: russell.crow@tinsleybridge.co.uk • Web: www.tinsleybridge.co.uk Forging Welding Shot peening Heat treatment Mechanical testing Environmental testing Electrophoretic painting On-site metallurgy laboratory Design of radial bogies that provide major reduction in lateral force on curves and reduced wheel wear. • Company: Brian Scales – Transportation Engineer • Contact: Dr Brian Scales, P.E., F.I.Mech.E. • Email: brianscales@msn.com • Web Mark Bush Mark.Bush@TfL.gov.uk www.tfl.gov.uk We are seeking to join innovative technology proposals that aims to reduce rolling contact fatigue, and wheelset maintenance costs across our rail networks to form a well balanced consortium. We offer: • Transport authority intelligence – how we run our services and future opportunities for suppliers/authorities • Access to our rolling stock, infrastructure and engineers to faster move through TRLs • Business case development capability including assessing new operation and maintenance processes • Dissemination capability through our wider organisation both internally and externally to TfL • Proven track record in InnovateUK, EU and transport innovation projects Summary – we would like to provide the “pull” to your “push” for demonstrator concepts as the ultimate end user Developing economic high performance operational systems from Trampower’s low track force bogie. • Company: Tram Power Ltd. • Contact: Lewis Lesley • Email: lewis.lesley@trampower.co.uk • Web www.trampower.co.uk Vampire Dynamic Simulations and Vehicle Modelling Consultancy Services • Company: Balfour Beatty Rail • Contact: David Buckley • Email: d.buckley@bbrail.com • Web: www.balfourbeatty.com/capabilities/rail-engineering/assetmanagement/gauging/ Long established expertise in mechatronic vehicles: concepts, modelling and control systems design. Looking to partner: vehicle manufacturers, owners and operators • Company: Loughborough University • Contact: Dr Christopher Ward • Email: c.p.ward@lboro.ac.uk • Web: lboro.ac.uk Thank you