Patricia Llana

Preliminary Development of Locomotive Crashworthy Components

The Federal Railroad Administration (FRA) and the Volpe Center are continuing to evaluate new technologies for increasing the safety of passengers and operators in rail equipment. In recognition of the importance of override prevention in train-to-train collisions in which one of the vehicles is a locomotive, and in light of the success of crash energy management technologies in cab car-led passenger trains, the Volpe Center seeks to evaluate the effectiveness of components that could be integrated into the end structure of a locomotive that are specifically designed to mitigate the effects of a collision and, in particular, to prevent override of one of the lead vehicles onto the other. This paper provides preliminary results of a research program that aims to develop, fabricate and test two crashworthy components for the forward end of a locomotive: (1) a deformable anti-climber, and (2) a push-back coupler.

Analysis of colliding vehicle interactions for the passenger rail train-to-train impact test

A full-scale train-to-train impact test was performed in which a cab car-led passenger train traveling at 30 mph collided with a standing locomotive-led train. During the test, the lead cab car overrode the cab of the standing locomotive, sustaining approximately 20 feet of crush, while the cab of the locomotive remained essentially intact. In this study, a finite element-based analysis of the collision was performed. The first 0.5 seconds of the collision was simulated. Results of the analysis were compared with accelerometer and video test data. Specific comparisons are made between test data and model predictions for: motions of the cab car and the standing locomotive; longitudinal forces arising between the cab car and the standing locomotive and between the respective lead and trailing vehicles; and the mode of deformation of the cab car and the locomotive. The results of the study indicate that the model captures pertinent features of the first 0.3 seconds of the collision, particularly with respect to longitudinal vehicle motions and collision forces. After 0.3 seconds, agreement between model predictions and test data becomes progressively worse. This is attributable to the models inability to capture the massive fracture that occurs at the front of the cab car.

Preliminary Finite Element Analysis of Locomotive Crashworthy Components

The Office of Research and Development of the Federal Railroad Administration (FRA) and the Volpe Center are continuing to evaluate new technologies for increasing the safety of passengers and operators in rail equipment. In recognition of the importance of override prevention in train-to-train collisions in which one of the vehicles is a locomotive, and in light of the success of crash energy management technologies in cab car-led passenger trains, the Volpe Center seeks to evaluate the effectiveness of components that could be integrated into the end structure of a locomotive that are specifically designed to mitigate the effects of a collision and, in particular, to prevent override of one of the lead vehicles onto the other. A research program is being conducted that aims to develop, fabricate and test two crashworthy components for the forward end of a locomotive: (1) a deformable anti-climber, and (2) a push-back coupler. Preliminary designs for these components have been developed. This paper provides details on the finite element models of the crashworthy components and how the component designs behave in the finite element analyses. The component designs will be evaluated to determine if the requirements have been met, such as the energy absorption capability, deformation modes, and force/crush characteristics.Copyright

Finite element analysis and full-scale testing of locomotive crashworthy components

The Office of Research and Development of the Federal Railroad Administration (FRA) and the Volpe Center are continuing to evaluate new technologies for increasing the safety of passengers and operators in rail equipment. In recognition of the importance of override prevention in train-to-train collisions in which one of the vehicles is a locomotive, and in light of the success of crash energy management technologies in cab car-led passenger trains, the Volpe Center seeks to evaluate the effectiveness of components that could be integrated into the end structure of a locomotive that are specifically designed to mitigate the effects of a collision and, in particular, to prevent override of one of the lead vehicles onto the other. A research program has been conducted to develop, fabricate and test two crashworthy components for the forward end of a locomotive: (1) a deformable anti-climber, and (2) a push-back coupler. Detailed designs for these components were developed, and the performance of each design was evaluated through large deformation dynamic finite element analysis (FEA). Designs for two test articles that could be used to verify the performance of the component designs in full-scale tests were also developed. The two test articles were fabricated and dynamically tested by means of rail car impact in order to verify certain performance characteristics of the two components relative to specific requirements. The tests were successful in demonstrating the effectiveness of the two design concepts. Test results were consistent with finite element model predictions in terms of energy absorption capability, force-displacement behavior and modes of deformation.Copyright

FUEL TANK INTEGRITY RESEARCH: FUEL TANK ANALYSES AND TEST PLANS

The Federal Railroad Administration’s Office of Research and Development is conducting research into fuel tank crashworthiness. Fuel tank research is being performed to determine strategies for increasing the fuel tank impact resistance to mitigate the threat of a post-collision or postderailment fire. In accidents, fuel tanks are subjected to dynamic loading, often including a blunt or raking impact from various components of the rolling stock or trackbed. Current design practice requires that fuel tanks have minimum properties adequate to sustain a prescribed set of static load conditions. Current research is intended to increase understanding of the impact response of fuel tanks under dynamic loading. Utilizing an approach that has been effective in increasing the structural crashworthiness of railcars, improved strategies can be developed that will address the types of loading conditions which have been observed to occur in a collision or derailment event. U.S. rail accident surveys reveal the types of threats fuel tanks are exposed to during collisions, derailments and other events. These include blunt impacts and raking impacts to any exposed side of the tank. This research focuses on evaluating dynamic impact conditions for fuel tanks and investigating how fuel tank design features affect the collision performance of the tank. Research activities will include analytical modeling of fuel tanks under dynamic loading conditions, dynamic impact testing of fuel tank articles, and recommendations for improved fuel tank protection strategies. This paper describes detailed finite element analyses that have been developed to estimate the behavior of three different fuel tanks under a blunt impact. These analyses are being used to understand the deformation behavior of different tanks and prepare for planned testing of two of these tanks. Observations are made on the influence of stiffeners, baffles, and other design details relative to the distance from impact. This paper subsequently describes the preliminary test plans for the first set of tests on conventional passenger locomotive fuel tanks. The first set of tests is designed to measure the deformation behavior of the fuel tanks with a blunt impact of the bottom face of the tanks. The test articles are fuel tanks from two retired EMD F-40 locomotives. A blunt impact will be conducted by securing the test articles to a crash wall and impacting them with an indenter extending from a test cart. This set of tests is targeted for late summer 2013 at the Transportation Technology Center (TTC) in Pueblo, Colorado. Both blunt and raking impact conditions will be evaluated in future research. Tests are also being planned for DMU fuel tanks under dynamic loads.

Dynamic and Quasi-Static Grade Crossing Collision Tests

To support the development of a proposed rule [1], a fullscale dynamic test and two full-scale quasi-static tests have been performed on the posts of a state-of-the-art (SOA) end frame. These tests were designed to evaluate the dynamic and quasi-static methods for demonstrating energy absorption of the collision and corner posts. The tests focused on the collision and corner posts individually because of their critical positions in protecting the operator and passengers in a collision where only the superstructure, not the underframe, is loaded. There are many examples of collisions where only the superstructure is loaded. For the dynamic test, a 14,000-lb cart impacted a standing cab car at a speed of 18.7 mph. The cart had a rigid striking surface in the shape of a coil mounted on the leading end that concentrated the impact load on the collision post. During the dynamic test the collision post deformed approximately 7.5 inches, and absorbed approximately 137,000 ft-lbs of energy. The SOA collision post was successful in preserving space for the operators and the passengers. For the quasi-static test of the collision post, the collision post was loaded in the same location and with the same fixture as the dynamic test. The post absorbed approximately 110,000 ft-lb of energy in 10 inches of permanent, longitudinal deformation. For the quasi-static test of the corner post, the post was loaded at the same height as the collision post, with the same fixture. The corner post absorbed 136,000 ft-lb of energy in 10 inches of permanent, longitudinal deformation. The series of tests was designed to compare the dynamic and quasi-static methods for measuring collision energy absorption during structural deformation as a measure of crashworthiness. When properly implemented, either a dynamic or quasi-static test can demonstrate the crashworthiness of an end frame.

STRUCTURAL CRASHWORTHINESS STANDARDS COMPARISON: GRADE-CROSSING COLLISION SCENARIOS

In support of the Federal Railroad Administration’s (FRA) Railroad Equipment Safety Program, American and European grade-crossing collision scenarios were evaluated and compared. Finite element analyses (FEA) were employed to subject an FRA-compliant passenger car to grade-crossing collision scenarios defined in both the proposed FRA Code of Federal Regulations (CFR) and European Standard (EN) 15227. The proposed FRA collision scenario involved a single car impacted by a cart. The cart had a punch mounted to it to hit a specific post of the end frame of the car. The EN 15227 collision scenario involved a complete train consist impacting a large deformable obstacle that approximates a lorry. The analyses show that these collision scenarios, while both grade-crossing scenarios, are very different not only in terms of the impact object and the amount of initial kinetic energy involved, but also in terms of how the car is loaded and deformed during impact. The FRA scenario is shown to be easier to analyze as well as easier to test than the EN 15227 scenario. Additionally, the FRA scenario is safer to test because of the levels of initial energy involved. The FRA scenario also provides clearer metrics of success. The FRA-compliant car utilized in the analyses and test conducted for this paper passed both FRA and EN 15227 grade-crossing collision scenarios according to the requirements for each respective standard. However, the analyses show that despite both scenarios providing for energy absorption in a grade-crossing collision, because the manner in which the car is loaded and deformed (concentrated vs. distributed) is different, the FRA performance standard and EN 15227 grade-crossing collision scenarios are not equivalent and mutual compliance is not guaranteed.

A Dynamic Test of a Collision Post of a State-of-the-Art End Frame Design

In support of the Federal Railroad Administration’s (FRA) Railroad Equipment Safety Program, a full-scale dynamic test of a collision post of a state-of-the-art (SOA) end frame was conducted on April 16, 2008. The purpose of the test was to evaluate the dynamic method for demonstrating energy absorption and graceful deformation of a collision post. The post aims to protect the operators and passengers in the event of a collision where only the superstructure, not the underframe, is loaded. Methods for improving the performance of collision and corner posts were prompted by accidents such as the fatal collision in Portage, Indiana in 1998, where a coil of steel sheet metal penetrated the cab car through the collision post. The improvements made for the SOA end frame structure include more substantial corner and collision posts, robust post connections to the buffer beam and anti-telescoping (AT) beam, and corner and collision posts integrated with a shelf and bulkhead sheet. Full length side sills improved support for the end frame. This test focused on one collision post because of its critical position in protecting the operator and passengers in an impact with an object at a grade-crossing. For the test, a 14,000-lb cart impacted a standing cab car at a speed of 18.7 mph. The cart had a rigid coil shape mounted on the leading end that concentrated the impact load on the collision post. The requirements for protecting the operator’s space state that there will be no more than 10 inches of longitudinal crush and none of the attachments of any of the structural members separate. During the test, the collision post deformed approximately 7.4 inches and absorbed approximately 138,000 ft-lb of energy. The attachment between the post and the AT beam remained intact. The connection between the post and the buffer beam did not completely separate, however the forward flange and both side webs fractured. The post itself did not completely fail. There was material failure in the back and the sides of the post at the impact location. Overall, the end frame was successful in absorbing energy and preserving space for the operators and the passengers.© 2008 ASME

Conventional locomotive coupling tests

Research to develop new technologies for increasing the safety of passengers and crew in rail equipment is being directed by the Federal Railroad Administration’s (FRA’s) Office of Research, Development, and Technology. Crash energy management (CEM) components which can be integrated into the end structure of a locomotive have been developed: a push-back coupler and a deformable anti-climber. These components are designed to inhibit override in the event of a collision. The results of vehicle-to-vehicle override, where the strong underframe of one vehicle, typically a locomotive, impacts the weaker superstructure of the other vehicle, can be devastating. These components are designed to improve crashworthiness for equipped locomotives in a wide range of potential collisions, including collisions with conventional locomotives, conventional cab cars, and freight equipment.Concerns have been raised in discussions with industry that push-back couplers may trigger prematurely, and may require replacement due to unintentional activation as a result of service loads. Push-back couplers are designed with trigger loads meant to exceed the expected maximum service loads experienced by conventional couplers. Analytical models are typically used to determine these required trigger loads. Two sets of coupling tests are planned to demonstrate this, one with a conventional locomotive equipped with conventional draft gear and coupler, and another with a conventional locomotive equipped with a push-back coupler. These tests will allow a performance comparison of a conventional locomotive with a CEM-equipped locomotive during coupling. In addition to the two sets of coupling tests, car-to-car compatibility tests of CEM-equipped locomotives, as well as a train-to-train test are also planned. This arrangement of tests allows for evaluation of the CEM-equipped locomotive performance, as well as comparison of measured with simulated locomotive performance in the car-to-car and train-to-train tests.This paper describes the results of the coupling tests of conventional equipment. In this set of tests, a moving locomotive was coupled to a standing cab car. The coupling speed for the first test was 2 mph, the second test 4 mph, and the tests continued with the speed incrementing by 2 mph until the last test was conducted at 12 mph. The damage observed resulting from the coupling tests is described. The lowest coupling speed at which damage occurred was 6 mph. Prior to the tests, a one-dimensional lumped-mass model was developed for predicting the longitudinal forces acting on the equipment and couplers. The model predicted that damage would occur for coupling speeds between 6 and 8 mph. The results of these conventional coupling tests compare favorably with pre-test predictions. Next steps in the research program, including future full-scale dynamic tests, are discussed.

Locomotive Crash Energy Management Test Plans

The Office of Research, Development, and Technology of the Federal Railroad Administration (FRA) and the Volpe Center are continuing to evaluate new technologies for increasing the safety of passengers and operators in rail equipment. The results of vehicle-to-vehicle override, where the strong underframe of one vehicle, typically a locomotive, impacts the weaker superstructure of the other vehicle, can be devastating. Crashworthy components which can be integrated into the end structure of a locomotive have been developed to inhibit override in the event of collision. Recent research has resulted in the development of a design concept, including evaluation with finite-element analysis (FEA), fabrication, and component tests. The design concept developed incorporates two key components: a push-back coupler and a deformable anti-climber. Detailed designs for these components were developed and the performance of the designs was evaluated through large deformation dynamic FEA. This paper describes the tests that are planned to demonstrate the behavior of these components when they are integrated into the end structure of a locomotive. The tests will demonstrate the in-service and crashworthiness performance of the modified locomotives. This research program endeavors to advance locomotive crashworthiness technology and develop the technical basis for generating specifications for push-back couplers and deformable anti-climbers.