Transportation
Systems
Trains
Using SIMPACK
at Siemens TS Trains
Uerdingen, November 2004
Roger Gansekow
Vehicle Dynamics
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 1 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Trains
Business Field
ICE® 3 High-Speed Train and
ICE T® Intercity Tilting Train
Electric Multiple Unit
Desiro® UK
- Commuter- and
Regional Trains
- High-Speed and
InterCity Trains
Diesel-Mechanical Multiple Unit
Desiro® Classic
- Passenger Coaches
& Push-Pull-Trains
Passenger Coaches
(single deck / double deck)
Venturio® –
The Intercity Train Concept
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 2 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Trains
Overview
Simulation methods are key points in the design of
railway vehicles as development cycles are very short
today. Customer demands and manufacturer‘s design
sophistication are growing in parallel. Optimization by
tests is more and more supported and replaced by
calculations. Examples of our analysis:
• Structural Dynamics
• Simulation toolkit for E&M-simulation
• Dynamics of diesel drivetrain
• Gauging UK
• Cross Wind Stability
• Vehicle Acceptance
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 3 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Structural Dynamics
Purpose
Trains
Standards
¾
¾
¾
Limits according to UIC 518 and GM/RT2160
Design target according to UIC513
UK: Ride Comparator Test
Calculation scenario
¾
¾
¾
¾
¾
Running on straight line and in curve
Maximum Speed
Maximum Cant Deficiency
Typical track irregularities / Maintenance limits
UK: Typical operational condition
Limit values
¾
¾
¾
Stand: November 2004
Simpack_user_meeting_2004
Rms-y.. < 0.2 m/s²
Rms-z.. < 0.2 m/s²
UK: Max-y../z.. and Rms-y../z.. better than the ride comparator
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 4 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Structural Dynamics
Method
Trains
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 5 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Structural Dynamics
Results
Trains
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 6 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Structural Dynamics
Results
Trains
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 7 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Structural Dynamics
Results
Trains
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 8 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Structural Dynamics
Results
Trains
Vertical bending mode
of the raw body shell
calculation
16.2 Hz
measurement
16.8 Hz
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 9 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Structural Dynamics
Results
Trains
Torsional bending mode
of the raw body shell
calculation
19.6 Hz
measurement
19.9 Hz
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 10 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Structural Dynamics
Results
n
tio
a
t
l
en
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m
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e
C
tio
ur
a
t
l
s
en
ea
lcu
m
e
a
M
i
e
C
g
ur
bo
as
e
r M
nt e
ce
Trains
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 11 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Simulation Toolkit
Trains
Motivation
•Drive train vibrations
•Specific vehicle vibrations
•Instable behaviour of controllers
S
TS
R&D Project
GT E
Electrical
components
Based on the interaction of
Electrics ⇔ Mechanics ⇔ Controller
LM MT TR BG
Toolkit for Simulation of Railway
Vehicles as Mechatronical Systems
Mechanical components
Mechanics
(SIMPACK)
Electrics
(SIMULINK)
Co-Simulation
Export of Linear System Matrices
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 12 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Simulation Toolkit - Applications
Trains
Longitudinal Vehicle Vibrations
Drive Train Vibrations
torque (engine)
Controller reduces set value
Vibration:
Engine (1,2) ⇔ (3,4) at f = 6Hz
torque (wheelset)
Start of torsional vibrations
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 13 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Dynamics of diesel drivetrain
Longitudinal coupling of cardan shafts
Trains
Standards
¾ UIC 518 / GMRT 2160
Calculation scenario
¾ investigated on diesel hydraulic multiple unit
¾ at high speed with low traction
Limit values
¾ According to standards
Modeling features
¾ mechanical behaviour similar to a stiff ptp spring with low damping
¾ structural modes of car body can be excited
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 14 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Trains
Dynamics of diesel drivetrain
Method - Modeling (1) – MBS
¾ MBS model of a one car unit
¾ one powered bogie
¾ underfloor equipment mounted elastically
¾ cardan shafts connecting
¾ motor – power transmission
¾ power transmission – axle gear
¾ elastic car body
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 15 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Trains
Dynamics of diesel drivetrain
Method - Modeling (2) – elastic car body
¾ model of the body shell (ANSYS)
¾ distribution of mass -> car body without underfloor equipment
¾ definition of coupling points
¾ underfloor equipment
¾ bogies
¾ reduction of dof -> SIDFEM -> SIMPACK import
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 16 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Trains
Dynamics of diesel drivetrain
Results – ride comfort (vertical)
¾ linear model with el. car body, track irregularities DB-high
¾ wheel / rail, P8 / BR113a
¾ incline 1:20, v=160 km/h
ISO-RMS-z [m/s²]
structural mode
Trailer bogie, le
Trailer bogie, mi
without cardan shaft
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Powered bogie, le
Powered bogie, mi
with cardan shaft, 0.5e8 N/m
Seite 17 von 32
Car body, le
Car body, mi
with cardan shaft, 1e8 N/m
Roger Gansekow, TS TR EN 02
Transportation
Systems
Trains
Dynamics of diesel drivetrain – Wheel unloading
Standards
¾
ERRI B55, UIC 518
Calculation scenario
¾
Twist in narrow curves
Limit values
¾
¾
Stand: November 2004
Simpack_user_meeting_2004
Wheel unloading
Nadal‘s coefficient L/V
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 18 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Dynamics of diesel drivetrain – Wheel unloading
Trains
bevel gear stages
torque reaction
links
gear box
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
spur gear stage
Seite 19 von 32
gear box
Roger Gansekow, TS TR EN 02
Transportation
Systems
Dynamics of diesel drivetrain – Wheel unloading
Wheel unload under traction
of a dieselhydraulic multiple unit
10
10
9
5
8
0
7
-5
6
-10
5
-15
4
-20
3
-25
2
-30
1
-35
0
-40
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
wheel unload [%]
traction torque [kNm]
Trains
41
time [sec]
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 20 von 32
Roger Gansekow, TS TR EN 02
Gauging UK
Purpose
Transportation
Systems
Trains
Standards
¾
GM/RT2141 & GE/RT8029
Shadow
Gauging
Standard
Structure
Gauging
Standard
vehicle
Gauge
Absolute
Gauging
GAUGING STRATEGY
Standard Gauge
Shadow Gauging
Structure Gauging
Absolute Gauging
Laser Rail Clear Route
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 21 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Gauging UK
Method - Ptp Force element for moment proportioning
Trains
¾ translatoric stiffness, damping
¾ rotatoric stiffness terms based on behaviour of elastic beam
¾ moment proportioning by factor A
F = F +F
i
c ,i
d ,i
⎡c
M = r × F + ⎢⎢c
⎢⎣0
xx
*
i
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
j
i
yy
⎤
⎥[ϕ
⎥
⎥⎦
Seite 22 von 32
x
ϕ
y
ϕ
z
]
Roger Gansekow, TS TR EN 02
Transportation
Systems
Gauging UK
Method
Trains
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 23 von 32
Roger Gansekow, TS TR EN 02
Gauging UK
Results
Transportation
Systems
Trains
Results of SIMPACK gauging calculations
lateral way between car body and
bogie at bump stop height [mm]
70
60
50
80
60
40
40
20
30
0
track cant 30 mm
-20
20
track cant 300 mm
-40
-60
10
-80
0
0
0
50
100
1
2
150
3
4
5
200
6
7
8
250
9
10
11
12
300
13
14
15
350
track cant [mm]
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 24 von 32
Roger Gansekow, TS TR EN 02
Gauging UK
Results
Transportation
Systems
Trains
SIMPACK Locked in Movement (LIM) calculations
70000
lateral force [N]
60000
50000
track cant rising
from 0 - 298 mm
LIM
40000
30000
track cant releasing
from 298 -0 mm
20000
10000
0
0
10
20
30
40
50
60
70
lateral way between car body and bogie at bump stop height
Quelle:[mm]
Metalastik
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 25 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Gauging UK
Results
Trains
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 26 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Cross Wind Stability
Trains
side wind
windward wheel
wheel load Q0
_______ unloading through wind forces
________ unloading by sway dynamics
__________ unloading through curve acceleration
____________ Reserve Q0 - ∆Q = 10% Q0
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 27 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Cross Wind Stability
Purpose
Trains
Standards
¾
¾
¾
Ril 401 old version, see presentation of T. Weber, Logomotive, User-Meeting 2003
TSI/Ril 401 new version for class 1 vehicles, static scenario
TSI/Ril 401 new version for class 2 vehicles, dynamic scenario
Calculation scenario, class 1 vehicles
¾
¾
¾
¾
wind blows perpendicular from side
various sideward accelerations (curves)
various wind angles
embankment
Limit values
Stand: November 2004
Simpack_user_meeting_2004
¾
wheel unloading
Q
< 10%
Q0
¾
yields limit wind speed:
vw,lim (vF )
Copyright (C) Siemens AG 2004. All Rights Reserved.
Q
= 10%
Q0
Seite 28 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Cross Wind Stability
Method
Trains
Determination of limit wind speed
vw,lim (vF )
Q
= 10%
Q0
i.e. solve static equilibrium for parameter wind speed
in SIMPACK
¾
¾
module „static equilibrium“ (Newtons Method)
calculate Error
¾
add further state equations for:
E=
∂
¾ ⇒
Stand: November 2004
Simpack_user_meeting_2004
solve for parameter
Copyright (C) Siemens AG 2004. All Rights Reserved.
Q
− 0.1
Q0
vw,lim
vw,lim
∂t
= k p E + kI ∫ E
automatically
Seite 29 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Cross Wind Stability
Method
Trains
in particular:
Q
− 0.1
Q0
¾
E=
¾
plus further PT1-element for E
¾
controller equation
modeled in „SIMPACK-Control“
∂
vw,lim
∂t
= k p E + kI ∫ E
modeled in User-Routine for side-wind
(thanks to Dr. R. Naumann from Deutsche Bahn for
original version and models)
Equilibrium without wind
Equilibrium with windforce
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 30 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Cross Wind Stability
Results
Trains
in SIMPACK ParVar, Static Equilibrium:
Stand: November 2004
Simpack_user_meeting_2004
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 31 von 32
Roger Gansekow, TS TR EN 02
Transportation
Systems
Trains
Vehicle Design & Acceptance
Vehicle design
¾
¾
¾
Short delivery time requires improved engineering, testing and optimization methods
Design optimization by simulation has a high importance
But: Service conditions have to be known to designer
Acceptance criteria
¾
¾
¾
¾
¾
¾
¾
Resistance against Derailment
Wheel/rail-forces
Bogie stability
Ride quality
Gauging
Pantograph sway
Cross Wind stability
Vehicle qualification
¾
¾
¾
UIC requires 1:1 testing
But: Cross wind safety only by model testing+calculation
RGS allows testing and calculation
Results
¾
¾
Stand: November 2004
Simpack_user_meeting_2004
Precise predictions of compliance with acceptance criteria
No further optimization of the vehicles necessary
Copyright (C) Siemens AG 2004. All Rights Reserved.
Seite 32 von 32
Roger Gansekow, TS TR EN 02