Real-time catenary models for the hardware-in-the-loop simulation of the pantograph–catenary interaction

Hardware-in-the-loop (HIL) simulation is a promising technique to study the pantograph–catenary interaction problems by realising the interaction of a physical pantograph with a mathematical model of the overhead equipment (catenary). However, the computing power presently available on real-time CPUs only allows to run simplified models of the overhead equipment. Therefore, it is important to define catenary models that are suitable for real-time simulation and at the same time capable of accurately representing the dynamic behaviour of the catenary. In this paper, the use of a catenary model based on modal superposition is considered, and the effect of changing the number of modelled spans and the number of modal components allocated to the contact and messenger wires is investigated in view of finding the best model compatible with real-time simulation. Comparisons between HIL simulation results and line measurements are presented, to quantify the accuracy of the hybrid simulation method developed.     

Active control strategy on a catenary–pantograph validated model

Dynamic simulation methods have become essential in the design process and control of the catenary–pantograph system, overall since high-speed trains and interoperability criteria are getting very trendy. This paper presents an original hardware-in-the-loop (HIL) strategy aimed at integrating a multicriteria active control within the catenary–pantograph dynamic interaction. The relevance of HIL control systems applied in the frame of the pantograph is undoubtedly increasing due to the recent and more demanding requirements for high-speed railway systems. Since the loss of contact between the catenary and the pantograph leads to arcing and electrical wear, and too high contact forces cause mechanical wear of both the catenary wires and the strips of the pantograph, not only prescribed but also economic and performance criteria ratify such a relevance. Different configurations of the proportional-integral-derivative (PID) controller are proposed and applied to two different plant systems. Since this paper is mainly focused on the control strategy, both plant systems are simulation models though the methodology is suitable for a laboratory bench. The strategy of control involves a multicriteria optimisation of the contact force and the consumption of the energy supplied by the control force, a genetic algorithm has been applied for this purpose. Thus, the PID controller is fitted according to these conflicting objectives and tested within a nonlinear lumped model and a nonlinear finite element model, being the last one validated against the European Standard EN 50318. Finally, certain tests have been accomplished in order to analyse the robustness of the control strategy. Particularly, the relevance or the plant simulation, the running speed and the instrumentation time delay are studied in this paper.     

Implementation and verification of adaptive longitudinal traction control

Human in the loop (HIL) simulation has experienced a significant increase in popularity in recent years. In this work, a novel approach to traction control is developed and implemented in a HIL environment, exploiting the significant advantages of framing the problem in a manner that more closely matches how a human expert drives a vehicle. An adaptive gradient ascent algorithm is at the heart of the proposed solution to longitudinal traction control. A real-time implementation of the gradient ascent algorithm is developed using linear operator techniques, even though the tyre–ground interface is highly non-linear. The adaptive traction control algorithm is based on two separate, but related, estimation algorithms that estimate both the instantaneous traction force and a unique predictive traction force model. This adaptive control algorithm, the necessary estimation algorithms and their real-time implementation are described in this work. The results, when implemented as a driver assist application on a 6-DOF motion platform, with a HIL, are also presented. This work demonstrates the utility of a 6-DOF motion platform in developing and verifying vehicle control algorithms with a HIL.     

Active yaw damper for the improvement of railway vehicle stability and curving performances: simulations and experimental results

To further increase passenger train comfort and handling performances, a mechatronic approach to the design of railway vehicles is necessary. In fact, active systems on board a railway vehicle allow to push design barriers beyond those encountered with just passive systems. The article deals with the development of an electro-mechanical actuator to improve the running behaviour of a railway vehicle, both in straight track and curve. The main components of the active system are a brushless motor and a mechanical transmission, used to apply a longitudinal force between the carbody and the bogie of the vehicle. The actuator is operated in force control. Different control strategies were developed for straight track running, where the aim is to increase the vehicle critical speed, and for curve negotiation, where the goal is to reduce the maximum values of track shift forces. A mathematical model of the railway vehicle incorporating the active control device has been developed and used to optimise control strategies and hardware set-up of the active device and to estimate the increase in operating performances with respect to a conventional passive vehicle. The active control device has then been mounted on an ETR470 railway vehicle, and its performances have been evaluated during in-line tests in both straight and curved tracks.     

Active yaw damper for the improvement of railway vehicle stability and curving performances: simulations and experimental results

To further increase passenger train comfort and handling performances, a mechatronic approach to the design of railway vehicles is necessary. In fact, active systems on board a railway vehicle allow to push design barriers beyond those encountered with just passive systems. The article deals with the development of an electro-mechanical actuator to improve the running behaviour of a railway vehicle, both in straight track and curve. The main components of the active system are a brushless motor and a mechanical transmission, used to apply a longitudinal force between the carbody and the bogie of the vehicle. The actuator is operated in force control. Different control strategies were developed for straight track running, where the aim is to increase the vehicle critical speed, and for curve negotiation, where the goal is to reduce the maximum values of track shift forces. A mathematical model of the railway vehicle incorporating the active control device has been developed and used to optimise control strategies and hardware set-up of the active device and to estimate the increase in operating performances with respect to a conventional passive vehicle. The active control device has then been mounted on an ETR470 railway vehicle, and its performances have been evaluated during in-line tests in both straight and curved tracks.     

Design and validation of an electro-hydraulic brake system using hardware-in-the-loop real-time simulation

This paper presents a novel electric booster (E-booster) that exibits superior performance advantages over traditional vacuum boosters. The proposed E-booster, consisting of an electric motor and a ball screw assembly, is designed for electro-hydraulic brake (EHB) systems to meet relevant requirements for electric vehicles and active safety technologies. A mathematical model for an EHB system is generated to determine the desired values of the parameters for the E-booster prototype using numerical simulation in MATLAB. Simulation results of the EHB system with the virtual E-booster demonstrate the feasibility and effectiveness of the innovative technique. Built upon the results derived from the numerical simualtions, an integrated algorithm based on the Kalman filter and a sliding mode control technique is designed to control the E-booster motor and to implement the brake booster function. A hardware-in-the-loop (HIL) real-time simulation system equipped with the E-booster prototype is developed. HIL real-time simulations are conducted to evaluate the proposed algorithm. The HIL real-time simulation results demonstrate that the proposed algorithm generates booster brake forces fast, and forces the ball nut to track the push rod well to ensure comfortable brake pedal feel.     

Influence of AC system design on the realisation of tractive efforts by high adhesion locomotives

The main task for heavy haul railway operators is to reduce the cost of exported minerals and enhance the long-term viability of rail transport operations through increasing productivity by running longer and heavier trains. The common opinion is that this is achievable by means of implementation of high adhesion locomotives with advanced AC traction technologies. Modern AC high adhesion locomotives are very complex mechatronic systems and can be designed with two alternative traction topologies of either bogie or individual axle controls. This paper describes a modelling approach for these two types of AC traction systems with the application of an advanced co-simulation methodology, where an electrical system and a traction algorithm are modelled in Matlab/Simulink, and a mechanical system is modelled in a multibody software package. Although the paper concentrates on the analysis of the functioning for these two types of traction control systems, the choice of reference slip values also has an influence on the performance of both systems. All these design variations and issues have been simulated for various adhesion conditions at the wheel–rail interface and their influence on the high traction performance of a locomotive equipped with two three-axle bogies has been discussed.     

An innovative localisation algorithm for railway vehicles

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. The aim of this work has been developing an innovative localisation algorithm for railway vehicles able to enhance the performances, in terms of speed and position estimation accuracy, of the classical odometry algorithms, such as the Italian Sistema Controllo Marcia Treno (SCMT). The proposed strategy consists of a sensor fusion between the information coming from a tachometer and an Inertial Measurements Unit (IMU). The sensor outputs have been simulated through a 3D multibody model of a railway vehicle. The work has provided the development of a custom IMU, designed by ECM S.p.a, in order to meet their industrial and business requirements. The industrial requirements have to be compliant with the European Train Control System (ETCS) standards: the European Rail Traffic Management System (ERTMS), a project developed by the European Union to improve the interoperability among different countries, in particular as regards the train control and command systems, fixes some standard values for the odometric (ODO) performance, in terms of speed and travelled distance estimation. The reliability of the ODO estimation has to be taken into account basing on the allowed speed profiles. The results of the currently used ODO algorithms can be improved, especially in case of degraded adhesion conditions; it has been verified in the simulation environment that the results of the proposed localisation algorithm are always compliant with the ERTMS requirements. The estimation strategy has good performance also under degraded adhesion conditions and could be put on board of high-speed railway vehicles; it represents an accurate and reliable solution. The IMU board is tested via a dedicated Hardware in the Loop (HIL) test rig: it includes an industrial robot able to replicate the motion of the railway vehicle. Through the generated experimental outputs the performances of the innovative localisation algorithm have been evaluated: the HIL test rig permitted to test the proposed algorithm, avoiding expensive (in terms of time and cost) on-track tests, obtaining encouraging results. In fact, the preliminary results show a significant improvement of the position and speed estimation performances compared to those obtained with SCMT algorithms, currently in use on the Italian railway network.     

基于LabVIEW RT的硬件在环仿真

利用实时仿真环境LabVIEW RT,构建了包括整车转向盘转角、油门、制动物理信号的硬件在环仿真系统.采用实时车辆动力学软件CarSim RT建立了车辆模型,并利用所搭建的试验台架进行了HIL仿真.结果表明,利用LabVIEW RT和CarSim RT能快速搭建面向整车开发的HIL系统,所建系统性价比高,而且有很好的实时性和扩展性.     

Development of a real-time bogie test rig model based on railway specialised multibody software

The design of mechatronic systems of rail vehicles requires performing verification and validation in the real-time mode. One useful validation instrument is the application of software-in-the-loop, hardware-in-the-loop or processor-in-the-loop simulation approaches. All of these approaches require development of a real-time model of the physical system. In this paper, the investigation of the usage of the model of the locomotive's bogie test rig created in Gensys multibody software has been performed and the calculation time for each time step has been analysed. The verification of the possibility of the usage of such an approach for real-time simulation has been made by means of a simple data transferring process between Gensys and Simulink through the TCP/IP interface. The limitations and further development issues for the proposed approach have been discussed in this paper.     

Recent Development in Active Steering of Railway Vehicles

Summary This paper presents the recent development on active steering for railway vehicles, and carries out a technical appraisal of different actuation schemes and control approaches. It brings together the latest research activities and findings for the full active steering techniques for rail vehicles with the solid-axle wheelsets, independently-rotating wheelsets and wheel-pairs without axles, but relevant work on passive and semi-active solutions is also briefly described. Potential benefits of the use of a combination of modern control technology and mechatronic approach are evaluated, and in particular solutions for the difficult design trade-off between the stability and the curving performance are presented. Various actuation configurations are discussed, and advantages and drawbacks of those schemes are investigated. The outline design using a number of control methods is analysed, and measurement requirement and state estimation techniques essential for implementation of the active steering schemes are also explored. In addition the issue of safety criticality is highlighted and a possible approach for developing fault-tolerant systems is proposed. Overall the paper provides an authoritative assessment of the major advances in actively-steered wheels and addresses outstanding critical issues.     

Overview of Coupling of Multibody and Control Engineering Tools

The role of Computer Aided Engineering in vehicle development has been significantly increased during the last decade. Specialised simulation tools became very complex, however, growing demands on complexity and particularly interdisciplinarity of vehicles and their simulation models have led to a number of approaches trying either to develop multidisciplinary simulation tools or to connect various specialised simulation tools by interfaces. This paper addresses some aspects of interconnection of the specialised simulation tools as one possibility for simulating complex mechatronic vehicle systems. It classifies the interfaces between specialised software packages in general, mentions some historical development of the interfacing and further discusses the examples of the implemented couplings between the Multibody System codes and Computer Aided Control Engineering tools. Finally, the performance of selected interfaces is compared on an example simulation of a controlled vehicle suspension.     

Strategies to simulate wheel–rail adhesion in degraded conditions using a roller-rig

Railway vehicles adopt mechatronic devices to maximize the traction/braking effort. These systems often use complex algorithms that require long experimental validation tests on track. The possibility to perform the same tests on a roller-rig gives the opportunity to simplify the validation activity, under safe conditions, and to reduce the costs. The main challenge is to be able to reproduce the same adhesion conditions on a roller-rig with respect to the track, especially in degraded conditions. First, the paper shows experiments performed to reproduce degraded adhesion on a conventional roller-rig for a single wheelset. Then, an innovative roller-rig is proposed in order to reproduce the effect of the passage of several wheelsets on the track.     

Overview of Coupling of Multibody and Control Engineering Tools

The role of Computer Aided Engineering in vehicle development has been significantly increased during the last decade. Specialised simulation tools became very complex, however, growing demands on complexity and particularly interdisciplinarity of vehicles and their simulation models have led to a number of approaches trying either to develop multidisciplinary simulation tools or to connect various specialised simulation tools by interfaces. This paper addresses some aspects of interconnection of the specialised simulation tools as one possibility for simulating complex mechatronic vehicle systems. It classifies the interfaces between specialised software packages in general, mentions some historical development of the interfacing and further discusses the examples of the implemented couplings between the Multibody System codes and Computer Aided Control Engineering tools. Finally, the performance of selected interfaces is compared on an example simulation of a controlled vehicle suspension.     

A design methodology for mechatronic vehicles: application of multidisciplinary optimization,multibody dynamics and genetic algorithms

A design methodology for mechatronic vehicles is presented. With multidisciplinary optimization (MDO) methods, strongly coupled mechanical, control and other subsystems are integrated as a synergistic vehicle system. With genetic algorithms (GAs) at the system level, the mechanical, control and other relevant parameters can be optimized simultaneously. To demonstrate the feasibility and efficacy of the proposed design methodology for mechatronic vehicles, it is used to resolve the conflicting requirements for ride comfort, suspension working spaces and unsprung mass dynamic loads in the optimization of half-vehicle models with active suspensions. Both deterministic and random road excitations, both rigid and flexible vehicle bodies and both perfect measurement of full state variables and estimated limited state variables are considered. Numerical results show that the optimized vehicle systems based on the methodology have better overall performance than those using the linear quadratic Gaussian (LQG) controller. It is shown that the methodology is suitable for complex design optimization problems where: (1) there is interaction between different disciplines or subsystems; (2) there are multiple design criteria; (3) there are multiple local optima; (4) there is no need for sensitivity analysis for the optimizer at the system level; and (5) there are multiple design variables.     

An overview: modern techniques for railway vehicle on-board health monitoring systems

Health monitoring systems with low-cost sensor networks and smart algorithms are always needed in both passenger trains and heavy haul trains due to the increasing need for reliability and safety in the railway industry. This paper focuses on an overview of existing approaches applied for railway vehicle on-board health monitoring systems. The approaches applied in the data measurement systems and the data analysis systems in railway on-board health monitoring systems are presented in this paper, including methodologies, theories and applications. The pros and cons of the various approaches are analysed to determine appropriate benchmarks for an effective and efficient railway vehicle on-board health monitoring system. According to this review, inertial sensors are the most popular due to their advantages of low cost, robustness and low power consumption. Linearisation methods are required for the model-based methods which would inevitably introduce error to the estimation results, and it is time-consuming to include all possible conditions in the pre-built database required for signal-based methods. Based on this review, future development trends in the design of new low-cost health monitoring systems for railway vehicles are discussed.     

A design methodology for mechatronic vehicles: application of multidisciplinary optimization, multibody dynamics and genetic algorithms

A design methodology for mechatronic vehicles is presented. With multidisciplinary optimization (MDO) methods, strongly coupled mechanical, control and other subsystems are integrated as a synergistic vehicle system. With genetic algorithms (GAs) at the system level, the mechanical, control and other relevant parameters can be optimized simultaneously. To demonstrate the feasibility and efficacy of the proposed design methodology for mechatronic vehicles, it is used to resolve the conflicting requirements for ride comfort, suspension working spaces and unsprung mass dynamic loads in the optimization of half-vehicle models with active suspensions. Both deterministic and random road excitations, both rigid and flexible vehicle bodies and both perfect measurement of full state variables and estimated limited state variables are considered. Numerical results show that the optimized vehicle systems based on the methodology have better overall performance than those using the linear quadratic Gaussian (LQG) controller. It is shown that the methodology is suitable for complex design optimization problems where: (1) there is interaction between different disciplines or subsystems; (2) there are multiple design criteria; (3) there are multiple local optima; (4) there is no need for sensitivity analysis for the optimizer at the system level; and (5) there are multiple design variables.