Andrea Rindi

A railway vehicle multibody model for real-time applications

Hardware in the loop (HIL) techniques are widely used for fast prototyping of control systems, electronic and mechatronic devices. In the railway field, several mechatronic on board subsystems are often tested and calibrated following the HIL approach. The accuracy of HIL tests depends on how the simulated virtual environment approximates the physical conditions. As the computational power available on real-time hardware grows, the demand for more complex and realistic models of railway vehicles for real-time application increases. In past research activities, the authors worked on the implementation of simplified real-time models for several applications and in particular for an HIL test rig devoted to the type approval of wheel slide protection systems. The activity has then been focused on the development of a three-dimensional model of the dynamics of a railway vehicle for more complex applications. The paper summarises the features and the results of the study.

Evaluation of odometry algorithm performances using a railway vehicle dynamic model

In modern railway Automatic Train Protection and Automatic Train Control systems, odometry is a safety relevant on-board subsystem which estimates the instantaneous speed and the travelled distance of the train; a high reliability of the odometry estimate is fundamental, since an error on the train position may lead to a potentially dangerous overestimation of the distance available for braking. To improve the odometry estimate accuracy, data fusion of different inputs coming from a redundant sensor layout may be used. Simplified two-dimensional models of railway vehicles have been usually used for Hardware in the Loop test rig testing of conventional odometry algorithms and of on-board safety relevant subsystems (like the Wheel Slide Protection braking system) in which the train speed is estimated from the measures of the wheel angular speed. Two-dimensional models are not suitable to develop solutions like the inertial type localisation algorithms (using 3D accelerometers and 3D gyroscopes) and the introduction of Global Positioning System (or similar) or the magnetometer. In order to test these algorithms correctly and increase odometry performances, a three-dimensional multibody model of a railway vehicle has been developed, using Matlab-Simulink™, including an efficient contact model which can simulate degraded adhesion conditions (the development and prototyping of odometry algorithms involve the simulation of realistic environmental conditions). In this paper, the authors show how a 3D railway vehicle model, able to simulate the complex interactions arising between different on-board subsystems, can be useful to evaluate the odometry algorithm and safety relevant to on-board subsystem performances.

Development and validation of a wear model for the analysis of the wheel profile evolution in railway vehicles

The numerical wheel wear prediction in railway applications is of great importance for different aspects, such as the safety against vehicle instability and derailment, the planning of wheelset maintenance interventions and the design of an optimal wheel profile from the wear point of view. For these reasons, this paper presents a complete model aimed at the evaluation of the wheel wear and the wheel profile evolution by means of dynamic simulations, organised in two parts which interact with each other mutually: a vehicles dynamic model and a model for the wear estimation. The first is a 3D multibody model of a railway vehicle implemented in SIMPACK™, a commercial software for the analysis of mechanical systems, where the wheel–rail interaction is entrusted to a C/C++user routine external to SIMPACK, in which the global contact model is implemented. In this regard, the research on the contact points between the wheel and the rail is based on an innovative algorithm developed by the authors in previous works, while normal and tangential forces in the contact patches are calculated according to Hertzs theory and Kalkers global theory, respectively. Due to the numerical efficiency of the global contact model, the multibody vehicle and the contact model interact directly online during the dynamic simulations. The second is the wear model, written in the MATLAB® environment, mainly based on an experimental relationship between the frictional power developed at the wheel–rail interface and the amount of material removed by wear. Starting from a few outputs of the multibody simulations (position of contact points, contact forces and rigid creepages), it evaluates the local variables, such as the contact pressures and local creepages, using a local contact model (Kalkers FASTSIM algorithm). These data are then passed to another subsystem which evaluates, by means of the considered experimental relationship, both the material to be removed and its distribution along the wheel profile, obtaining the correspondent worn wheel geometry. The wheel wear evolution is reproduced by dividing the overall chosen mileage to be simulated in discrete spatial steps: at each step, the dynamic simulations are performed by means of the 3D multibody model keeping the wheel profile constant, while the wheel geometry is updated through the wear model only at the end of the discrete step. Thus, the two parts of the whole model work alternately until the completion of the whole established mileage. Clearly, the choice of an appropriate step length is one of the most important aspects of the procedure and it directly affects the result accuracy and the required computational time to complete the analysis. The whole model has been validated using experimental data relative to tests performed with the ALn 501 ‘Minuetto’ vehicle in service on the Aosta–Pre Saint Didier track; this work has been carried out thanks to a collaboration with Trenitalia S.p.A and Rete Ferroviaria Italiana, which have provided the necessary technical data and experimental results.

Energy and wear optimisation of train longitudinal dynamics and of traction and braking systems

Traction and braking systems deeply affect longitudinal train dynamics, especially when an extensive blending phase among different pneumatic, electric and magnetic devices is required. The energy and wear optimisation of longitudinal vehicle dynamics has a crucial economic impact and involves several engineering problems such as wear of braking friction components, energy efficiency, thermal load on components, level of safety under degraded or adhesion conditions (often constrained by the current regulation in force on signalling or other safety-related subsystem). In fact, the application of energy storage systems can lead to an efficiency improvement of at least 10% while, as regards the wear reduction, the improvement due to distributed traction systems and to optimised traction devices can be quantified in about 50%. In this work, an innovative integrated procedure is proposed by the authors to optimise longitudinal train dynamics and traction and braking manoeuvres in terms of both energy and wear. The new approach has been applied to existing test cases and validated with experimental data provided by Breda and, for some components and their homologation process, the results of experimental activities derive from cooperation performed with relevant industrial partners such as Trenitalia and Italcertifer. In particular, simulation results are referred to the simulation tests performed on a high-speed train (Ansaldo Breda Emu V250) and on a tram (Ansaldo Breda Sirio Tram). The proposed approach is based on a modular simulation platform in which the sub-models corresponding to different subsystems can be easily customised, depending on the considered application, on the availability of technical data and on the homologation process of different components.

A Tool for the Simulation of Turbo-Machine Auxiliary Lubrication Plants

The reliability and safety of large turbo-machinery systems used in the oil and gas industries are heavily affected by the efficiency of the lubrication plant. In particular, hazard and operability (HAZOP) analyses are often performed using piping and instrumentation diagrams (P&ID; according to regulations in force, ISO 14617). Usually, these analyses are time-consuming and affected by potentially dangerous errors. In this work, a tool for the mono-dimensional simulation of thermal hydraulic plants is presented and applied to the analysis of safety-relevant components of compressor and pumping units, such as the lubrication circuits. Compared to known commercial products, the proposed tool is optimised for fixed step solvers in order to make real-time (RT) integration easier. The proposed tool defines a general approach, and can be used as a SimScape-Simulink library of thermal-hydraulic components (designed according to the P&ID definitions). Another interesting feature of the tool is the automatic scheme generation, where the Simulink model can be automatically generated by P&ID schemes.

A numerical model of a HIL scaled roller rig for simulation of wheel–rail degraded adhesion condition

Scaled roller rigs used for railway applications play a fundamental role in the development of new technologies and new devices, combining the hardware in the loop (HIL) benefits with the reduction of the economic investments. The main problem of the scaled roller rig with respect to the full scale ones is the improved complexity due to the scaling factors. For this reason, before building the test rig, the development of a software model of the HIL system can be useful to analyse the system behaviour in different operative conditions. One has to consider the multi-body behaviour of the scaled roller rig, the controller and the model of the virtual vehicle, whose dynamics has to be reproduced on the rig. The main purpose of this work is the development of a complete model that satisfies the previous requirements and in particular the performance analysis of the controller and of the dynamical behaviour of the scaled roller rig when some disturbances are simulated with low adhesion conditions. Since the scaled roller rig will be used to simulate degraded adhesion conditions, accurate and realistic wheel–roller contact model also has to be included in the model. The contact model consists of two parts: the contact point detection and the adhesion model. The first part is based on a numerical method described in some previous studies for the wheel–rail case and modified to simulate the three-dimensional contact between revolute surfaces (wheel–roller). The second part consists in the evaluation of the contact forces by means of the Hertz theory for the normal problem and the Kalker theory for the tangential problem. Some numerical tests were performed, in particular low adhesion conditions were simulated, and bogie hunting and dynamical imbalance of the wheelsets were introduced. The tests were devoted to verify the robustness of control system with respect to some of the more frequent disturbances that may influence the roller rig dynamics. In particular we verified that the wheelset imbalance could significantly influence system performance, and to reduce the effect of this disturbance a multistate filter was designed.

A localization algorithm for railway vehicles based on sensor fusion between tachometers and inertial measurement units

The availability of a reliable speed and travelled distance estimation is relevant for the efficiency and safety of automatic train protection and control systems. This paper investigates the main features of an innovative localization algorithm that integrates tachometers and inertial measurement units. Nowadays, the estimation is performed by an odometry algorithm that relies on wheel angular speed sensors. The objective is to increase the accuracy of the odometric estimation, especially in critical adhesion conditions, through sensor fusion techniques based on Kalman filter theory. The Italian company ECM S.p.A. has supported the project, providing a custom inertial measurement unit based on micro electro-mechanical system sensors for the on-track testing of the algorithm. The preliminary results show a significant improvement of the position and speed estimation performances compared to those obtained with SCMT (Italian acronym for ‘Sistema Controllo Marcia Treno’) algorithms, currently in use on the Italian railway network. A wide set of simulated test results, showing the improvement of the estimation process, is presented and discussed. An accurate train navigation that scarcely relies on information from the infrastructure will open a road map for the development of a more and more effective and efficient exploitation of the railway infrastructure.

A preliminary study of thermal hydraulic models for virtual hazard and operability analysis and model-based design of rotating machine packages

Hazard and operability analysis is a decisive factor to evaluate safety and reliability of plants considering the propagated effects due to consecutive failures of known critical components. A good design and analysis practice increases the robustness of the considered system in different operating conditions; however, in the plant design process, the use of a model-based design approach is fundamental to increase speed, efficiency and reliability. In this work, a tool for the 1-D simulation of thermal hydraulic plants is presented and applied to the analysis of critical system for compressor and gas turbine units, e.g. the lubrication circuits. Different from known commercial products, the proposed tool is implemented to work in cooperation with PidXP™ (the GE Nuovo Pignone P&ID definition tool), and it is optimized for fixed step solvers in order to easily include the rotating machine control logics within the simulation environment (essential prerequisite for hazard and operability evaluations). All the above makes it suitable for the fast prototyping of real time code. Moreover, the proposed tool represents a general tool in the model-based approach, and it can be used as a Simulink™ library of components that have been optimized and specifically designed in order to make easier the automatic generation of simulation models from P&Id schemes and technical documentation, reducing errors associated to data transcription and operator misbehaviour. In this work, proposed approach and test bench on experimental data for validation purposes are shown.

Development of a wear model for the wheel profile optimisation on railway vehicles

The modelling and the reduction of wear due to wheel–rail interaction is a fundamental aspect in the railway field, mainly correlated to safety, maintenance interventions and costs. In this work, the authors present two innovative wheel profiles, specifically designed with the aim of improving the wear and stability behaviour of the standard ORE S1002 wheel profile matched with the UIC60 rail profile canted at 1/20 rad, which represents the wheel–rail combination adopted in the Italian railway line. The two wheel profiles, conventionally named CD1 and DR2, have been developed by the authors in collaboration with Trenitalia S.p.A. The CD1 profile has been designed with the purpose of spreading the contact points in the flange zone on a larger area in order to reduce wear phenomena and having a constant equivalent conicity for small lateral displacements of the wheelset with respect to the centred position in the track. The DR2 wheel profile is instead designed to guarantee the same kinematic characteristics of the matching formed by ORE S1002 wheel profile and UIC60 rail profile with laying angle α p equal to 1/40 rad, widely common in European railways and characterised by good performances in both wear and kinematic behaviour. The evolution of wheel profiles due to wear has been evaluated through a wear model developed and validated by the authors in previous works. The wear model comprises two mutually interactive units: a vehicle model for the dynamic simulations and a model for the wear assessment. The whole model is based on a discrete process: each discrete step consists in one dynamic simulation and one profile update by means of the wear model while, within the discrete step, the profiles are supposed to be constant. The choice of an appropriate step is crucial in terms of precision and computational effort: the particular strategy adopted in the current work has been chosen for its capacity in representing the nonlinear wear evolution and for the low computational time required. In the present research, the investigated trainset is the passenger vehicle ALSTOM ALn 501 ‘Minuetto’, which is usually equipped with the standard ORE S1002 wheel profile in Italian railways. The entire model has been simulated on a virtual track specifically developed to represent a statistical description of the whole Italian line. The data necessary to build the virtual track and the vehicle model were provided by Trenitalia S.p.A. and Rete Ferroviaria Italiana. The CD1 and DR2 wheel profiles, matched to the UIC60 rail with cant 1/20 rad, have shown a good behaviour in terms of wear resistance if compared with the old ORE S1002 wheel profile, consequently assuring a more uniform distribution of the removed material and a prolongation of the mean time between two subsequent re-profiling interventions.

Preliminary Field Testing Of A Servoactuated Pantograph

One of the main problems concerning high speed running on Italian railways is the current pick up. The contact force between the pantograph and the overhead contact line increases its amplitude and frequency as the speed increases. The frequent detachments generated by this situation cause not only the temporary interruption of power transmission and wire and contact shoe erosion and produce electromagnetic pollution. A frequent method to reduce detachments is based on the progressive increase of uplift force with the increasing speed. This solution can^t be used in high speed running as the excessive contact force necessary to avoid detachments causes a very quick erosion of contact shoes. Furthermore, operating in the above mentioned condition, the amplitude of contact shoe oscillations may cause impact with the suspension devices of overhead line. An alternative approach to solve these problems is the use of a servo actuated pantograph able to maintain the contact force at a given value. In order to obtain the above mentioned result a FS pantograph was modified applying a brushless servomotor connected by a wire to the contact strip. This actuator, adding its force to the effect of the traditional air bellow, is able to properly regulate the contact force. In the paper the preliminary experimental results, obtained by a special test rig in a FS laboratory, are reported and discussed. Transactions on the Built Environment vol 34,