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TRANSCRIPT
Vehicle-Track-Interaction-System
23.11.2016, Dr. T. Moshammer, MO MLT BG EN SSV
siemens.com/mobility Open to Public © Siemens AG 2016
Open to Public © Siemens AG 2016
23.11.2016 Seite 2 Dr. T. Moshammer / MO MLT BG EN SSV Mobility Division / Mainline Transport
Dr. Thomas Moshammer: Vehicle-Track-Interaction-System
Contents
CONTENTS:
• The history in the development of the SIEMENS Vehicle-
Track-Interaction System…
• Why is a Track-Vehicle-Interaction so important?
• What is a Vehicle-Track-Interaction Monitoring System?
• Why might it be interesting to have a Track Monitoring
System on a Train?
• What are the restrictions of such a Monitoring System?
• Summary
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23.11.2016 Seite 3 Dr. T. Moshammer / MO MLT BG EN SSV Mobility Division / Mainline Transport
There is a long History in Development of Bogie Monitoring &
Diagnostics Systems at SIEMENS! We are ready to use this Expertise!
ICE 2, ICE 3 Roller
Dynamometer
RUBIN Nürnberg
(driverless Metro operation)
Electronic Derailment Detection
Electronic Obstacle Detection
(SIL 3)
In operation since 2005
First Functional
Prototype in ICE
between 2001 - 2004.
2 bogies equipped with
sensors.
Data transfer with GSM
ÖBB 1116 (Taurus)
In operation 2008 - 2013 Velaro RUS
2010-today
Velaro D
Metro Munich C2
Metro Warshaw Metro Klang Valley
Metro Riyadh
Velaro Eurostar* Icx* RRX
Metro Munich C1
PKP
PC based System Generation 0.5 Generation 1.0 Generation 2.0
*Pre-Installation *Pre-Installation1.0 5 trains,
4 bogies 1 bogie
4 bogies all bogies GOA4
GOA4
4 bogies
All bogies
All bogies
Charger Locomotive
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Why is the Vehicle-Track-Interaction so important?
Why is the Vehicle-Track-Interaction so
important?
• The vehicle-track system has to be maintained
that save operation is possible and guaranteed
• Unsave in this context means high forces, high
wheel unloading, high strike angles, high
slippage in the wheel-rail contact
• Essential is the wheel-rail-interaction because it
determines the height of the interacting terms
(forces, slippage, accelerations, etc.)
• That makes measurements of the interaction of
vehicle and track essential for maintenance
• Diagnostics of the vehicle track interaction would
help to make an accurate prediction of the
development of this interaction behavior possible
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The Traditional Approach
• Testing for the acceptance of running characteristics
of railway vehicles according to EN14363
• Periodical Maintenance Intervals according to the
maintenance handbook
• Visual Inspection of parts
• Measuring of wearing parts (e.g. wheel) and crack
detection
• Exchange of Components according to the
maintenance plan or after measuring
• Test drives after maintenance works
• ...
Vehicles are assessed separately…
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• Visual Inspections of tracks
• Observations by the train driver and the train crew
• Measurements of track geometry with track
recording cars
• Measuring of wear of the track, switchings, etc.
• Crack detection of components of the track...
The Traditional Approach
…Tracks are assessed separately
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The Traditional Approach
…Tracks are assessed separately Vehicles are assessed separately …
Rarely consideration of the interaction between vehicle and track,
rarely permanent diagnostics
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The traditional way of diagnosis of the interaction between train and
track shows the opportunity of improvement
• The two subsystems vehicle and track are
considered stand alone
• Diagnosis is not performed continuously but in
periodically defined time schedules
• Not the interaction itself is considered but
quantities which are assumed to affect the
interaction between vehicle and track
• It would be perfect to have a permanent
diagnosis of the interaction between vehicle
and track.
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There are several possibilities to diagnose several aspects of the
interaction permanently
The SIEMENS Bogie Diagnostics
System (SBDS) is a sensoric system
for the identification of the behavior of
the system bogie and the vehicle track
interaction
R = f (ax, ay, az, ωx, ωy, ωy, n, .....)
State Predictions,
Maintenance Instructions
„It would be perfect to have a permanent diagnosis of the
interaction between vehicle and track.”
Approach: Bogie Diagnostics and Vehicle Track Interaction System
• Bogies with sensors which measure significant movement
quantities and thus capture the impacts of the interaction between
vehicle and track.
• With this Vehicle-Track-Interaction-System abnormal behavior is
detected.
• Changes in the behavior of bogie components are detected as
well.
Main benefits:
• Condition-based maintenance of bogies becomes possible.
• Corrective maintenance measures become predictable.
• Components can be used for a longer period (utilization of the
individual service life)
Side Effect: Interaction-relevant condition of the driveway is recorded!
Digitizing
Algorithms
Statistics
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The development of efficient diagnostics Systems is complex and
challenging
In the development of an effective diagnostics system a set of
interdisciplinary competences are necessary:
Development of “rail-operation-resistent” Sensors and
Electronics
Modern methods of signal processing and anomality/fault
detection
Knowledge of the system behavior of rail vehicles
Knowledge of the operational necessities and technical
possibilities for the optimization of maintenance processes
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Bogie-Diagnostics
OnBoard Diagnostic Systems Diagnostics Infrastructure Maintenance Process Optimization
Trend Analysis/Prognostics models
Maintenance Orders/Maintenance Measures
Fleet Analysis/Diagnostics Reports
BMD
RDA
Internet
WebAccess Alerts
Vehicle-Track-Interaction Data Transfer to Landside
Landside IT Infrastructure
Human Machine Interface for Diagnostics Personal
The way from OnBoard Diagnostics to Maintenance Process
Optimization needs a full IT-Integration of the Diagnostic Data in the
Maintenance System
Cellular Infrastructure
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Siemens Bogie Diagnostics including the Vehicle Track Interaction
System provides a wide range of functions
ID Code Function
YDD Yaw Damper Diagnostics
ARDD Anti Rolling Device Diagnostics
WSGD Wheelset Guidance Diagnostics
ID Code Function
ABD Axle Bearing Diagnostics
WD Wheel Diagnostics
ID Code Function
BFP Bogie Finger Print
RCD Ride & Comfort Diagnostics
EID Early Instability Detection
BHC Bogie Health Check
TCI Track Condition Indicator
GOAx Supervision
WAD Wheel & Axle Diagnostics
ACD Advanced Component Diagnostics APF Advanced Prediction Functions
FOD Field Operation Diagnostics GMD Gear & Motor Diagnostics
ID Code Function
TCI Track Condition Indicator
ID Code Function
EDD Electronic Derailment Detection
EOD Electronic Obstacle Detection
ID Code Function
GBD Gear Box Diagnostics
MBD Motor Bearing Diagnostics
ID Code Function
FOD Field Operation Diagnostics
ID Code Function
BWP Brake Wear Prognostics
WPP Wheel Profile Prognostics
RLP Rubber Lifetime Prognostics
LoCCo Load Cycle Counter
Landside Diagnostics systems
ID Code
TDS Train Diagnostics System
CM Configuration Management System
BDES Bogie Diagnostics Expert System
TCIS Track Conditon Indication System
GID Gravel Impact Detection
ID Code Function
GID Gravel Impact Detection
ID Code Function
HBD Hot Box Detection
WMS Wheel Monitoring System
URD Unstable Running Detection
TSI Supervision
Siemens Bogie Diagnostics including the Vehicle Track Interaction System provides a wide range of functions
OnBoard and Landside Solutions are needed!
SIEMENS Bogie Diagnostics and Vehicle Track Interaction System Functions
Open to Public © Siemens AG 2016
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5 Categories of Functions have to be distinguished
Diagnosis of Components
• Algorithms detect defects of components
• Examples: Axle Bearing Diagnostics, Wheel Flats, Polygonization of
wheels, ...
Diagnosis of the System Behavior
• Algorithms analyze the dynamic behavior of the vehicle
• Examples: Bogie Finger Print, Early Instability Detection, ...
Prognostic Models
• The wear influencing and component damaging quantities are
measured and with models the remaining service life are estimated.
• Examples: Brake Wear, Wheel Wear, …
Vehicle-Track-Interaction Diagnosis
• Accelerations in 3 Vehicle Levels (unsprung, primary spring,
secondary spring level) are recorded and analyzed, high levels are
transferred with GPS position to the landside
Supervision Functions
• TSI / GOA4 / Gravel Impact Detection
3 levels of acceleration:
Unsprung masses: The area of the wheelset
including the axle bearing box as the contact to the rail
is the area of highest impacts to any bogie (~100 g).
Primary spring: The frame and all frame mounted
parts still have high accelerations (~5 g).
Secondary spring: The carbody has low
accelerations (~2 g)
Processing the measured data to messages
(based on adjustable low/high levels) let the
bogie „talk“.
Acceleration and rotational speed sensors let the
bogie „feel“
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US Locomotive: Simple Vehicle Track Interaction System
Sensors
BMD
BMD Bogie Monitoring & Diagnostics Electronics
RDA
RDA Global Positioning & Data Provider System
Cellular Infrastructure
Landside: Vehicle-Track-Interaction-System
Internet
WebAccess
Track Condition
Alerts
OnBoard: Vehicle-Track-Interaction-System
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US Locomotive Charger: Simple Vehicle Track Interaction System
Vehicle-Track-Interaction-System Functions?
• Certain acceleration limits (Level Low / Level
High) can be set individually for
• Car Body vertical
• Car Body lateral
• Truck Frame lateral
• Axle vertical left side
• Axle vertical right side
• If this limit is reached in one of the positions this is
sent to the landside system including additional
data (raw data, velocity, GPS position, etc.)
• On the landside system filter functions help to
visualize this information on a map or look on
certain events.
• Additionally the time history is important to
optimize track maintenance efforts Landside: Vehicle-Track-Interaction-System (example)
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Statistical Vehicle Values give Additional Information Analyzing the Track
Metro Operation: Vertical Error and Statistical Vehicle Values give
valuable additional information analyzing the track
15 mm
14 mm
13 mm
12 mm
11 mm
10 mm
9 mm
8 mm
7 mm
6 mm
5 mm
4 mm
4 mm
3 mm
2 mm
1 mm
0 mm
Distance
Maximal Speed
Mean Speed
Track Quality
NMV
NMV y
NMV z
Sta
tio
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Sta
tio
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tio
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tio
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tio
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tio
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Ve
rtic
al E
rro
r (1
0 m
Win
do
w) Where are high vertical errors on the track?
How does the track quality develop in certain track sections?
How are these track sections concerning comfort in the vehicle?
Are there any instabilities, high vibrations of the bogie in certain track sections?
Vertical track error (left side)
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Metro Operation: Corrugation Characteristics can be determined and
Grinding Results are rated
Corrugations: shorter wavelengths Grinding Result
Corrugation
Development
After Grinding
Before Grinding
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Russian High Speed Train: Track Geometry Analysis according to
Russian Track Maintenance Rules (Vertical Error)
Typical Results from Track Analysis:
• The acceleration signals of the axle bearing
housing are double integrated and the vertical
track error is calculated with this procedure.
• These vertical errors are analyzed according to
the Russian chord measurement method and
are rated according to normative regulations
concerning track maintenance limits.
• Visualization of track positions where the
maintenance limits are exceeded.
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Russian High Speed Train: Track Geometry Analysis according to
Russian Track Maintenance Rules (Vertical Error)
Track Geometry Analysis: Vertical Error on a Sleeper Track
RUS_Fehler_M906_Ch767_Ch770.mat
0
5
10
15
20
25
30
35
40
45
50
mm
, mm
Grenzwertueberschreitungen der Gleislage / Bm1_20T18L_VelRus_SF520 / G029_S_B2_Moskau - St. Petersburg_Einweg1
0 1 2 3 4 5 6 7
x 105
0
50
100
150
200
250
300
d [m]
km/h
zl Sehne 6m-Fenster
zr Sehne 6m-Fenster
Grenzwert
Geschwindigkeit
Ueberschreitungen:72 links, 73 rechts
High Speed Track in Russia zl chord (6m window)
zr chord (6m window)
treshholds
300 km/h
250 km/h
200 km/h
150 km/h
100 km/h
50km/h
50 mm
45 mm
40 mm
35 mm
30 mm
25 mm
20 mm
15 mm
10 mm
5 mm
0 mm
0 km 100 km 200 km 300 km 400 km 500 km 600 km 700 km
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Track Geometry Analysis: Vertical Error on a Slab Track
RUS_Fehler_M1754_Ch312_Ch313.mat
0
5
10
15
20
25
30
35
mm, m
m
Grenzwertueberschreitungen der Gleislage / Bm1_15T14L_VelD_SF500 / G029_L_Frankfurt-Koeln_for_Tag3
0 2 4 6 8 10 12 14 16 18
x 104
0
50
100
150
200
250
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d [m]
km/h
zl Sehne 6m-Fenster
zr Sehne 6m-Fenster
Grenzwert
Geschwindigkeit
Ueberschreitungen:10 links, 10 rechts
German High Speed Train: Track Geometry Analysis according to
Russian Track Maintenance Rules (Vertical Error)
High Speed Track in Germany zl chord (6m window)
zr chord (6m window)
treshholds
300 km/h
250 km/h
200 km/h
150 km/h
100 km/h
50km/h
35 mm
30 mm
25 mm
20 mm
15 mm
10 mm
5 mm
0 km 100 km 200 km
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Vertical Track error according to the chord measurement
Bm1_20T18L_VelRus_SF520
-10
-5
0
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kN, k
N, k
N, k
N
Mf: 76:78
76 7778
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-10
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, mm
76 7778
41.08 41.1 41.12 41.14 41.16 41.1860
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d [km]
km/h
76 7778
81: F.z_20T.FmF1
82: F.z_20T.FmF2
83: F.z_20T.FmF3
84: F.z_20T.FmF4
239: v_Fzg_red
d.z_20T.Rs1
d.z_20T.Rs4
zl sehne
zr sehne
zl sehne 6m-Fenster
zr sehne 6m-Fenster
The acceleration signals of the axle bearing housing are double integrated and the vertical track error is calculated with
this procedure. The error is the maximal value minus the minimal value in a 6 m window. The normative rating of the verticla
error is speed-dependend defined and is 18 mm above a vehicle speed of 160 km/h.
Forces on components
Vertical Track Error
Velocity
High vertical track errors
High Speed Train: Track Geometry Analysis according to Forces on
Components
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High Speed Train: Track Geometry Analysis according to Forces on
Components
Vertical Track Error > 10mm High Forces on Component > 15 kN
Not all high vertical track errors produce high forces on the leaf springs
wave length dependency
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Vehicle Reaction: Lateral Acceleration (1 year observation period)
High Speed Train: The Vehicle Reaction on the Track changes
red means high lateral movement blue means stable running behavior
It is obvious that certain track sections induce high lateral movements on the bogie
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What are the restrictions of the Vehicle-Track-Interaction Monitoring
System?
Restrictions:
• Unstable running behavior is not only dependent on the track
geometry, it is also influenced from
• the wheel profile,
• the wheel guidance system and
• the yaw damper functionality
• Therefore additional bogie diagnostics is essential to separate:
• which reaction is coming from the worn bogie components
• Which reaction is coming from the track irregularities
• Different vehicles might show different reactions on certain
track defects (when should track maintenance efforts be started?)
• The SIEMENS Vehicle-Track-Interaction Monitoring System is
not able to measure lateral track defects or track profiles but it
measures the reactions of the vehicle on such defects which is
essential for a save operation
Track Irregularities Conicities
Yaw Damper, Wheel Profile,
Wheel Guidance System
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Dr. Thomas Moshammer: Vehicle-Track-Interaction-System
Summary
Summary:
• SIEMENS has developed a Bogie Diagnostics System in order to analyze the behavior of the bogie
over its lifetime in order to optimize bogie maintenance efforts.
• The same System is used to analyze the vehicle track interaction.
• Some characteristic parameters of the track such as longitudinal track levels are determined.
• In addition track faults e.g. corrugations are discovered.
• The difference of the vehicle track interaction system from track recording cars is that the vehicle
reactions induced by the track are measured and rated.
• Analyzing the vehicle reactions over time in combination with the exact track position might lead to track
maintenance works where the vehicle reactions are unfavourable (high forces and accelerations,
instabilities, corrugations, worn switches).
• The main goal of the vehicle-track-interaction monitoring system is not to replace track recording
cars but to give additional information about track sections where unfavourable vehicle reactions occur
and thus might help to optimize track maintenance efforts.
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Contact!
Dr. Thomas Moshammer Head of Department Structure, Simulation, Validation
Bogie Engineering
Siemens AG Österreich
Eggenberger Strasse 31
8020 Graz
Tel.: +43 (51 707) 60 259
Mobile: +43 (664) 88 55 45 79
E-Mail: [email protected]
siemens.com