a toolkit for simulating mechatronics in railway vehicles · a toolkit for simulating mechatronics...

A Toolkit for Simulating Mechatronics in Railway Vehicles

Heinz-Peter KotzSiemens TS HR BG EN

Copyright (C) Siemens AG 2003. All Rights Reserved.

Siemens TS Development Centers

Software & Electrical components

UerdingenTS LRTS TR

ErlangenTS GT E

MünchenTS LM

GrazTS HR BG

GT EMarkus GaudenzAchim DegenhardtWolfgang Fetter

Simulation & Mechanical components

HR BG Andreas HaigermoserChristian BrandstätterHeinz-Peter Kotz

LMWerner BreuerYu MinyiTim Weigel

LRHelmut NetterMichael Seibert

TRRoger GansekowKaspar Schröder


Motivation

Old approach: Designing electrics & mechanics independently

•Drive train vibrations•Vehicle vibrations•Instable behaviour of controllers

non-optimal system design

New approach I: Simulating complete railway vehicles

•Full mechanical SIMPACK-model (200 DOFs)•Low-level implementation of controller-software•Emulation of controller-hardware

too complex, problems withusability & maintainability

New approach II: User friendly toolkit

•Providing building blocks of different complexity•Building electrical components in MATLAB/SIMULINK•Providing various simulation-methods•Comfortable simulation-environment•Automatic creation of simulation-models •Automatic simulation & post-processing


Aims

1. Validated know-how on simulation methods for• Drive train vibrations < 100 Hz

• Vehicle vibrations caused by interaction of mechanics & electrics

• Longitudinal dynamics caused by interaction of mechanics & electrics

• Partitioning of Power & Torque within groups of engines

2. Development of tools• Extended friction laws

• Models for gear units

• Models for metal-rubber-elements

• Models for tachometer generators

3. User-interface

• High usability & maintainability

• Automatisation of standard simulation scenarios


Structure of the Toolkit

SubsystemMechanics

Incr

easi

ng C

ompl

exity

Subsystem Electrics

Incr

easi

ng C

ompl

exity

Co-Simulation

Optimization

Assessment & Evaluation

Post-Processing


Building blocks: Mechanics

Platform:

Wheelset

•Frame with 1DOF•Drive train as rotator chain•Primary suspension & guidance

Bogie

•Frame with 6 DOF•Drive trains as rotator chains•Primary suspension & guidance

Vehicle

•All configurations up to 4 motors


Building blocks: Electrics

Platform:

Level I – Traction control unit• Set values (traction force, wheel slip, intermediate circuit voltage)• Slip and acceleration control (PI-controller)• Direct feed-through of torque set value

Level II - Level I + motor dynamics• Differential equations for induction machine (4th order ODEs)• Up to four induction machines in parallel at one converter• Magnetic flux and torque control (field orientation)

Level III - Level II + tachometer generator dynamics• Simulation of incremental encoder with toothed wheel• Sample rate of measurement increasing with rotational speed


Coupling Electrics & Mechanics

SIMPACK stand-alone

SIMULINK stand-alone

•User routines

•Control loop

•Import of system-matrices

•Import of SIMULINK „symbolic code“

•Simple mechanics

•Import of system-matrices

•Import of SIMPACK „symbolic code“

LinearSystemAnalysis

Co-Simulation•SIMAT

•MATSIM

Nonlineartime domaincalculations


Coupling: Co-Simulation

efficient modelling both in SIMPACK & SIMULINK

calculations in time domain

loss of performance

no linear system analysis


Coupling: Linear System Analysis

efficient modelling both in SIMPACK & SIMULINK

powerful tools for linear system analysis

DuCxyBuAxx

+=+=&

changing the model requires re-export of matrices

automation not (yet) possible


Extended Friction-LawsExtended Friction-Laws

-1 0 1 2 3 4 5 6 7 8-0.05

0

0.05

0.1

0.15

0.2

0.25

0.3

Friction-law from measurements:

µ decreases with increasing slip

Extensions needed In Kalker‘s theory (SIMPACK): No decrease of µ

Physical model

based on Haese und Menth [eb 5/96]

-25000.00

-20000.00

-15000.00

-10000.00

-5000.00

0.00

5000.00

10000.00

15000.00

20000.00

25000.00

-2.00 -1.50 -1.00 -0.50 0.00 0.50 1.00 1.50 2.00

s

Tx [N

]

37

1115

1923

12

34

5

0

0.1

0.2

0.3

0.4

vZug [m/s]

vg [m/s]

f(vg,

v Zug)

•Consideration of layer between wheel and rail

•Model is determined by the layer‘s physical properties

•State variables: Temperature, viscosity,...

•Extension: Dynamics (hysteresis)

reasing part

pirical parameters

r‘s theory

ν

f(ν)

•Correct description of the inc

•Decrease of µ covered by 2 em

Empirical extension of Kalke


Simulation Environment

Requirements & Features

•Automatic model-generation from symbolic description

•Choice of different complexity levels for electrics & mechanics

•Definition of interfaces between Mechanics-Electrics

•Reproduceable simulations

•Automatic post-processing

Input (model description) Output (SIMULINK model)


Simulation Methods

Linear system analysis

•Eigenvalues & eigenfrequencies

•Root locii & stability analysis

•Response plots

Non-linear time integration

•Acceleration scenarios

•Tracks: different topologies & irregularities

•Crossings & twists

•Different friction models

Variation of parameters

•Wheel-Rail-Contact

•Mechanical properties

•Controller settings


Summary

Within a R&D-project Siemens TS developed a toolkit for simulating the effects based on

interactions between electrics & mechanics of railway vehicles with the following features:

Mechanics in SIMPACK

Hierarchy of objects: drive train – bogie – vehicle - train

Electrics in SIMULINK

Traction control unit + motor dynamics + tachometer generator dynamics

Coupling the systems

Co-Simulation SIMPACK – MATLAB (nonlinear time domain)

Export of ABCD-Matrices from SIMPACK (LTI analysis)

Additional Models

Extended friction laws, models for coupling elements (gear unit, metal-rubber-elements)

Simulation Environment

User-friendly interface, generates models for the needed level of complexity, automatic simulation & postprocessing

a toolkit for simulating mechatronics in railway vehicles · a toolkit for simulating mechatronics...

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