A data-driven dynamics simulation framework for railway vehicles

The finite element (FE) method is essential for simulating vehicle dynamics with fine details, especially for train crash simulations. However, factors such as the complexity of meshes and the distortion involved in a large deformation would undermine its calculation efficiency. An alternative method, the multi-body (MB) dynamics simulation provides satisfying time efficiency but limited accuracy when highly nonlinear dynamic process is involved. To maintain the advantages of both methods, this paper proposes a data-driven simulation framework for dynamics simulation of railway vehicles. This framework uses machine learning techniques to extract nonlinear features from training data generated by FE simulations so that specific mesh structures can be formulated by a surrogate element (or surrogate elements) to replace the original mechanical elements, and the dynamics simulation can be implemented by co-simulation with the surrogate element(s) embedded into a MB model. This framework consists of a series of techniques including data collection, feature extraction, training data sampling, surrogate element building, and model evaluation and selection. To verify the feasibility of this framework, we present two case studies, a vertical dynamics simulation and a longitudinal dynamics simulation, based on co-simulation with MATLAB/Simulink and Simpack, and a further comparison with a popular data-driven model (the Kriging model) is provided. The simulation result shows that using the legendre polynomial regression model in building surrogate elements can largely cut down the simulation time without sacrifice in accuracy.     

Modelling,simulation and applications of longitudinal train dynamics

ABSTRACT

Significant developments in longitudinal train simulation and an overview of the approaches to train models and modelling vehicle force inputs are firstly presented. The most important modelling task, that of the wagon connection, consisting of energy absorption devices such as draft gears and buffers, draw gear stiffness, coupler slack and structural stiffness is then presented. Detailed attention is given to the modelling approaches for friction wedge damped and polymer draft gears. A significant issue in longitudinal train dynamics is the modelling and calculation of the input forces – the co-dimensional problem. The need to push traction performances higher has led to research and improvement in the accuracy of traction modelling which is discussed. A co-simulation method that combines longitudinal train simulation, locomotive traction control and locomotive vehicle dynamics is presented. The modelling of other forces, braking propulsion resistance, curve drag and grade forces are also discussed. As extensions to conventional longitudinal train dynamics, lateral forces and coupler impacts are examined in regards to interaction with wagon lateral and vertical dynamics. Various applications of longitudinal train dynamics are then presented. As an alternative to the tradition single wagon mass approach to longitudinal train dynamics, an example incorporating fully detailed wagon dynamics is presented for a crash analysis problem. Further applications of starting traction, air braking, distributed power, energy analysis and tippler operation are also presented.     

Development and validation of side-impact crash and sled testing finite-element models

Side-impact collisions are the second leading cause of death and injury in the traffic accidents after frontal crashes. Side-impact airbags, side door bars and other protection techniques have been developed to provide occupant protection. To confirm the effectiveness of protection equipment installed in vehicles, studying the degree of impact is fundamental to understand the effect of automobile collisions on the human body. Therefore, the dynamic response of the human body to traffic accidents should be analyzed to reduce the level of occupant injuries. Generally, the experimental method is complex and expensive. Recently, numerical crash simulations have provided a valuable tool for automotive engineers. This work presents full-scale and sled side-impact test finite-element (FE) models - based on the Federal Motor Vehicle Safety Standard No. 214 - that simulate a side-impact accident. The crash simulations utilized the LS-DYNA finite-element code. The human body's dynamic response to crashes is discussed herein. Additionally, occupant injuries were measured. To verify the accuracy of the proposed crash test and sled test FE models, simulation results are compared with those obtained from experimental tests. The comparison results indicate that the proposed crash test and sled test FE models have considerable potential for assessing a vehicle's crash safety performance and assisting future development of safety technologies.     

Experimental and numerical investigation of the effect of rail corrugation on the behaviour of rail fastenings

This paper presents the results of a detailed investigation of the effects of rail corrugation on the dynamic behaviour of metro rail fastenings, obtained from extensive experiments conducted on site and from simulations of train–track dynamics. The results of tests conducted with a metro train operating on corrugated tracks are presented and discussed first. A three-dimensional (3D) model of the metro train and a slab track was developed using multi-body dynamics modelling and the finite element method to simulate the effect of rail corrugation on the dynamic behaviour of rail fastenings. In the model, the metro train is modelled as a multi-rigid body system, and the slab track is modelled as a discrete elastic support system consisting of two Timoshenko beams for the rails, a 3D solid finite element (FE) model for the slabs, periodic discrete viscoelastic elements for the rail fastenings that connect the rails to the slabs, and uniformly viscoelastic elements for the subgrade beneath the slabs. The proposed train–track model was used to investigate the effects of rail corrugation on the dynamic behaviour of the metro track system and fastenings. An FE model for the rail fastenings was also developed and was used to calculate the stresses in the clips, some of which rupture under the excitation of rail corrugation. The results of the field experiments and dynamics simulations provide an insight into the root causes of the fracture of the clips, and several remedies are suggested for mitigating strong vibrations and failure of metro rail fastening systems.     

Three-dimensional override analysis of crashed railway multiple units

Override simulations of two train units in frontal collision have been carried out using multi-body dynamics. The aim of this paper is to investigate the possible factors influencing the overriding behaviour throughout frontal collisions. In addition to the initial vertical offset defined in the standard EN 15227, the pitching motion of vehicles has a great effect on the overriding phenomenon. It depends on several factors, such as collision mass, pitching frequency, height of the centre of mass above the rail level. In this paper, it has been shown that the overriding phenomenon is more sensitive to variations in pitching frequency and height of the centre of mass, compared with the factor of the collision mass. Moreover, it has been demonstrated from simulation results that a 200-kN vertical force is required for the combined anti-climber devices (100 kN for each side anti-climber) to constrain the vertical relative motion between crashed train units.     

汽车正撞时后排座椅安全性的CAE分析与改进设计

构建了带假人和安全带等约束系统的汽车后排座椅骨架的多刚体和有限元耦合计算模型,根据欧洲座椅法规ECER17的规定,模拟正面碰撞后排座椅安全性台车试验,对座椅骨架冲击强度和假人动态响应等进行了CAE分析.根据分析结果提出改进方案,并进行相应的仿真和试验验证.     

燃料电池汽车正面碰撞安全性研究

燃料电池汽车在结构上有别于传统汽车,其碰撞安全性尤应关注.文中重点对燃料电池汽车结构特点进行研究,建立燃料电池汽车正面碰撞有限元模型,运用LS-DYNA仿真确定车辆安全性能设计方案.同时根据燃料电池汽车的特点阐述了对其碰撞试验方法的思考.通过实车正面碰撞试验,验证了车辆结构改进设计的效果.     

轻型载货汽车驾驶室正面摆锤碰撞的动态响应模拟

以某轻型载货汽车驾驶室为研究对象,阐述了驾驶室正面碰撞有限元模型的建立和在LS-DYNA软件中求解碰撞仿真结果的方法及步骤,对驾驶室正面碰撞动态响应结果进行了分析,研究了驾驶室壳体结构碰撞后的变形及应力和位移的变化规律。     

Dynamic model for automotive side impact crashes

A rigid body model to represent a side impact crash is constructed using five degrees-of-freedom (dof) for the vehicle and three dof for each occupant in the vehicle. Nonlinear stiffness and damping elements and the presence of physical gaps between several components make the model highly nonlinear. The model is validated using experimental crash test data from a National Highway Traffic Safety Administration (NHTSA) database. To simplify the parameter identification process and reduce the number of parameters to be identified at each stage, a two-step process is adopted in which the vehicle is first assumed to be unaffected by the presence of the occupants, and its model parameters are identified. Subsequently, the parameters in the occupant models are identified.

The active set method with a performance index that includes both the L₂ and L_∞ norms is used for parameter identification. A challenge is posed by the fact that the optimisation problem involved is non-convex. To overcome this challenge, a large set of random initial values of parameter estimates is generated and the optimisation method is applied with all these initial conditions. The values of parameters that provide the minimal performance index from the entire set of initial conditions are then chosen as the best parameter values. The optimal parameters values thus identified are shown to significantly improve the match between the model responses and the experimentally measured sensor signals from the NHTSA crash test.     

Establishment and verification of three-dimensional dynamic model for heavy-haul train–track coupled system

For the long heavy-haul train, the basic principles of the inter-vehicle interaction and train–track dynamic interaction are analysed firstly. Based on the theories of train longitudinal dynamics and vehicle–track coupled dynamics, a three-dimensional (3-D) dynamic model of the heavy-haul train–track coupled system is established through a modularised method. Specifically, this model includes the subsystems such as the train control, the vehicle, the wheel–rail relation and the line geometries. And for the calculation of the wheel–rail interaction force under the driving or braking conditions, the large creep phenomenon that may occur within the wheel–rail contact patch is considered. For the coupler and draft gear system, the coupler forces in three directions and the coupler lateral tilt angles in curves are calculated. Then, according to the characteristics of the long heavy-haul train, an efficient solving method is developed to improve the computational efficiency for such a large system. Some basic principles which should be followed in order to meet the requirement of calculation accuracy are determined. Finally, the 3-D train–track coupled model is verified by comparing the calculated results with the running test results. It is indicated that the proposed dynamic model could simulate the dynamic performance of the heavy-haul train well.     

薄壁梁碰撞仿真中时间步长问题的研究

车辆碰撞中对碰撞能量吸收起重要作用的典型截面的薄壁梁进行了碰撞性能的有限元仿真.并与试验结果进行了比较,验证了模型的准确性。然后用此有限元模型对碰撞仿真中时间步长问题进行了研究,有效提高了计算效率。     

车辆与弯道混凝土护栏碰撞的动态数值模拟及试验

对车辆与弯道混凝土护栏碰撞动态数值模拟结果和实车足尺碰撞试验结果进行对比分析，从车辆行驶轨迹、乘员冲击加速度以及车辆损伤形态3个方面，验证了动态数值模拟的准确性，并分析了弯道混凝土护栏曲线半径对乘员碰撞过程中所承受冲击加速度的影响；得到乘员风险的最不利护栏半径。结果表明：有限元仿真是进行汽车护栏碰撞研究的有效方法；弯道处护栏的形式对碰撞时乘员的安全有很大影响。     

不同类型偏置碰撞的驾驶员腿部伤害对比研究

为了探讨不同类型偏置碰撞下驾驶员腿部伤害的差异性,本文在对C-NCAP40%偏置碰撞及IIHS 25%小偏置碰撞两种不同类型偏置碰撞试验的试验工况、假人腿部评价指标进行介绍的基础上,对某乘用车车型在上述两种试验下驾驶员的腿部伤害指标进行了对比研究,并从碰撞力的传递路径对其结果进行了分析。结果表明:由于碰撞中车身与壁障重叠率的不同导致不同的碰撞力传递路径,最终导致车身变形的差异。其中,25%小偏置碰撞对车身的破坏程度极大,试验后驾驶员侧的A柱严重变形,车身结构大量侵入到车内生存空间,故其假人腿部伤害值大于另外两种正面碰撞,尤其是驾驶员左腿伤害值。优化车身前端结构,增加A柱强度,最大程度保证驾驶舱腿部生存空间,才能有效提高小偏置碰撞中乘员的安全性能。     

Non-linear modelling and control of semi-active suspensions with variable damping

Electro-hydraulic dampers can provide variable damping force that is modulated by varying the command current; furthermore, they offer advantages such as lower power, rapid response, lower cost, and simple hardware. However, accurate characterisation of non-linear f–v properties in pre-yield and force saturation in post-yield is still required. Meanwhile, traditional linear or quarter vehicle models contain various non-linearities. The development of a multi-body dynamics model is very complex, and therefore, SIMPACK was used with suitable improvements for model development and numerical simulations. A semi-active suspension was built based on a belief–desire–intention (BDI)-agent model framework. Vehicle handling dynamics were analysed, and a co-simulation analysis was conducted in SIMPACK and MATLAB to evaluate the BDI-agent controller. The design effectively improved ride comfort, handling stability, and driving safety. A rapid control prototype was built based on dSPACE to conduct a real vehicle test. The test and simulation results were consistent, which verified the simulation.     

整车多体动力学模型的建立、验证及仿真分析

利用多体动力学方法建立了某轿车的整车非线性多体动力学模型,模型中考虑了前后悬架、转向系统的详细几何结构参数,以及连接处的橡胶衬套、阻尼器的非线性特性,轮胎采用M agic Formu la模型。对所建模型进行了多种试验验证,并分析了该样车的操纵稳定性等相关特性,仿真结果表明所建整车多体模型有较高的精度。     

Dynamic performance of high-speed train passing windbreak breach under unsteady crosswind

Field test and computational fluid dynamics (CFD) method are conducted to investigate the safety of high-speed train under unsteady crosswind. Wheel–rail forces of high-speed train passing a breach between two windbreaks under strong crosswind are measured in a field test. The derailment coefficient of first wheelset of front car at the windward side reaches the allowable value. Meanwhile, the left and right of lateral wheel–rail force are in the opposite direction. This kind of phenomenon has not been tested before. Therefore, CFD and multi-body simulations are performed in order to study the phenomena. Good agreement is obtained between the simulation results and the experimental data. It is concluded that the sudden increase of transient aerodynamic loads, when the train passing the breach, is the root of this phenomenon; after running along the same direction as carbody and bogie run along the opposite direction during the high-speed train passing the windbreak breach; larger opposite longitudinal creeping forces of first wheelset compel the first wheelset to yaw toward the windward side; meanwhile, larger lateral wheel–rail forces compel the first wheelset to run toward the windward side rail; the left and right lateral wheel–rail forces become opposite because the right wheel impacts the windward side rail.     

Seatbelt and seatback control for occupant protection in frontal automotive collisions

This paper investigates the potential benefits of an imminent collision prediction system for improving occupant protection in a frontal automotive crash. Knowledge of an impending unavoidable crash is assumed to be known 100 ms before the crash occurs. A three dof human occupant model is developed using a Lagrangian approach to represent occupant translation with respect to seat, torso rotation and neck rotation. The performance of traditional elastic seat belts is compared with that of an analytically calculated seat belt law in which the force values are calculated in real-time so as to just prevent collision with car interior. Simulations verify that the analytical seat belt force calculation results in less force on occupant for the same level of safety. Furthermore, results show that knowledge of a future collision can be used to pre-tension seat belts but can provide no additional benefits, if seat belts are the only means for active occupant protection. However, if seat tilt-back can be deployed using an on–off mechanism, such predictive knowledge of a future collision can provide significantly improved occupant protection in terms of preventing occupant collision with car interior.     

基于Ls-Dyna和Hyperstudy的汽车吸能盒优化分析

基于Ls-Dyna和Altair Hyperstudy软件,以汽车吸能盒的板材厚度和形状为设计变量,吸能盒质量和刚性墙反力为约束条件,最大化内能为优化目标,对吸能盒进行尺寸和形状优化。优化结果显示,吸能盒质量和碰撞反力基本保持不变,而吸能效果提高了约10%。     

基于实物的汽车后碰仿真中移动小车有限元模型研究

基于上海机动车检测中心的实物建立了后碰撞移动小车CAE模型,针对某型轿车进行了后碰撞有限元仿真,分析了移动刚性墙模型和移动小车模型对后碰撞仿真结果的影响,以及移动小车模型对仿真结果准确性的重要作用.通过对比分析主要零部件的溃缩变形量可知,移动刚性墙模型与移动小车模型的计算结果差别较大;刚性材料移动小车模型和弹性材料移动小车模型的计算结果差别较小.     

Dynamic simulation of train–truck collision at level crossings

Trains crashing onto heavy road vehicles stuck across rail tracks are more likely occurrences at level crossings due to ongoing increase in the registration of heavy vehicles and these long heavy vehicles getting caught in traffic after partly crossing the boom gate; these incidents lead to significant financial losses and societal costs. This paper presents an investigation of the dynamic responses of trains under frontal collision on road trucks obliquely stuck on rail tracks at level crossings. This study builds a nonlinear three-dimensional multi-body dynamic model of a passenger train colliding with an obliquely stuck road truck on a ballasted track. The model is first benchmarked against several train dynamics packages and its predictions of the dynamic response and derailment potential are shown rational. A geometry-based derailment assessment criterion is applied to evaluate the derailment behaviour of the frontal obliquely impacted trains under different conditions. Sensitivities of several key influencing parameters, such as the train impact speed, the truck mass, the friction at truck tyres, the train–truck impact angle, the contact friction at the collision zone, the wheel/rail friction and the train suspension are reported.