Vehicle-Track-Interaction-System , Dr. T. Moshammer, MO MLT BG EN SSV

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Vehicle-Track-Interaction-System 23.11.2016, Dr.

1 Vehicle-Track-Interaction-System , Dr. T. Moshammer, MO MLT BG EN SSV siemens.com/mobility

important? What is a Vehicle-Track-Interaction Monitoring System?

2 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 Seite

3 There is a long History in Development of Bogie Monitoring & Diagnostics Systems at SIEMENS! We are ready to use this Expertise! RUBIN Nürnberg (driverless Metro operation) Electronic Derailment Detection Electronic Obstacle Detection (SIL 3) In operation since 2005 Metro Warshaw Metro Klang Valley All bogies GOA4 Metro Munich C1 Metro Munich C2 Metro Riyadh 4 bogies all bogies GOA4 Charger Locomotive PC based System Generation 0.5 Generation 1.0 Generation bogie 4 bogies 4 bogies ICE 2, ICE 3 Roller Dynamometer First Functional Prototype in ICE between bogies equipped with sensors. Data transfer with GSM ÖBB 1116 (Taurus) In operation trains, Velaro RUS 2010-today *Pre-Installation PKP *Pre-Installation1.0 All bogies Velaro D Velaro Eurostar* Icx* RRX Seite

4 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 Seite

The Traditional Approach Vehicles are assessed separately Testing for the

EN14363 Periodical Maintenance Intervals according to the maintenance

5 The Traditional Approach Vehicles are assessed separately 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... Seite

of track geometry with track recording cars Measuring of wear of the track,

6 The Traditional Approach Tracks are assessed separately 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... Seite

consideration of the interaction between vehicle

7 The Traditional Approach Vehicles are assessed separately Tracks are assessed separately Rarely consideration of the interaction between vehicle and track, rarely permanent diagnostics Seite

time schedules Not the interaction itself is considered but quantities which are assumed to affect the interaction between

8 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. Seite

There are several possibilities to diagnose several aspects of the interaction permanently The SIEMENS Bogie Diagnostics System (SBDS) is a

capture the impacts of the With this Vehicle-Track-Interaction-System abnormal behavior is detected.

9 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 (a x, a y, a z, ω x, ω y, ω y, n,...) State Predictions, Maintenance Instructions Digitizing Algorithms Statistics 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! Seite

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

10 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 Seite

11 The way from OnBoard Diagnostics to Maintenance Process Optimization needs a full IT-Integration of the Diagnostic Data in the Maintenance System OnBoard Diagnostic Systems Diagnostics Infrastructure Maintenance Process Optimization Vehicle-Track-Interaction Data Transfer to Landside Fleet Analysis/Diagnostics Reports RDA BMD Cellular Infrastructure Alerts Landside IT Infrastructure WebAccess Trend Analysis/Prognostics models Bogie-Diagnostics Internet Human Machine Interface for Diagnostics Personal Maintenance Orders/Maintenance Measures Seite

Siemens Bogie Diagnostics including the Vehicle Track Interaction System provides a wide range of functions SIEMENS Bogie Diagnostics and Vehicle Track Interaction System Functions BHC Bogie Health

12 Siemens Bogie Diagnostics including the Vehicle Track Interaction System provides a wide range of functions SIEMENS Bogie Diagnostics and Vehicle Track Interaction System Functions BHC Bogie Health Check ID Code Function BFP Bogie Finger Print RCD Ride & Comfort Diagnostics EID Early Instability Detection FOD Field Operation Diagnostics ID Code Function FOD Field Operation Diagnostics APF Advanced Prediction Functions ID Code Function BWP Brake Wear Prognostics WPP Wheel Profile Prognostics RLP Rubber Lifetime Prognostics LoCCo Load Cycle Counter WAD Wheel & Axle Diagnostics ID Code Function ABD Axle Bearing Diagnostics WD Wheel Diagnostics GMD Gear & Motor Diagnostics ID Code Function GBD Gear Box Diagnostics MBD Motor Bearing Diagnostics ACD Advanced Component Diagnostics ID Code Function YDD Yaw Damper Diagnostics ARDD Anti Rolling Device Diagnostics WSGD Wheelset Guidance Diagnostics TSI Supervision ID Code Function HBD Hot Box Detection WMS Wheel Monitoring System URD Unstable Running Detection GOAx Supervision ID Code Function EDD Electronic Derailment Detection EOD Electronic Obstacle Detection GID Gravel Impact Detection ID Code Function GID Gravel Impact Detection TCI Track Condition Indicator ID Code Function TCI Track Condition Indicator Siemens Bogie Diagnostics including the Vehicle Track Interaction System provides a wide range of functions OnBoard and Landside Solutions are needed! Landside Diagnostics systems ID Code TDS Train Diagnostics System CM Configuration Management System BDES Bogie Diagnostics Expert System TCIS Track Conditon Indication System Seite

5 Categories of Functions have to be distinguished Acceleration and rotational speed sensors let the bogie feel 3 levels of acceleration: Unsprung masses: The area of the wheelset including the axle

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.

13 5 Categories of Functions have to be distinguished Acceleration and rotational speed sensors let the bogie feel 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. 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 Seite

Vehicle-Track-Interaction-System BMD RDA

14 US Locomotive: Simple Vehicle Track Interaction System OnBoard: Vehicle-Track-Interaction-System RDA Cellular Infrastructure BMD Alerts WebAccess Internet Track Condition Landside: Vehicle-Track-Interaction-System BMD RDA Sensors Bogie Monitoring & Diagnostics Electronics Global Positioning & Data Provider System Seite

15 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) Seite

Station 1 Station 2 Station 3 Station 4 Station 5 Station 6 Station 7 Station 8 Station 9 Station 10 Station 11 Station 12 Station 13 Station 14 Station 15 Station 16 Station 17 Station 18 Station 19

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 Statistical Vehicle Values give Additional Information Analyzing

16 Station 1 Station 2 Station 3 Station 4 Station 5 Station 6 Station 7 Station 8 Station 9 Station 10 Station 11 Station 12 Station 13 Station 14 Station 15 Station 16 Station 17 Station 18 Station 19 Station 20 Station 21 Station 22 Station 23 Station 24 Station 25 Station 26 Station 27 Vertical Error (10 m Window) 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 Statistical Vehicle Values give Additional Information Analyzing the Track 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) Distance Maximal Speed Mean Speed Track Quality NMV NMV y NMV z Seite

17 Metro Operation: Corrugation Characteristics can be determined and Grinding Results are rated Corrugations: shorter wavelengths Grinding Result Corrugation Development Before Grinding After Grinding Seite

Russian High Speed Train: Track Geometry Analysis according to Russian Track Maintenance

axle bearing housing are double integrated and the vertical track error is calculated with

These vertical errors are analyzed according to the Russian chord measurement method and are

18 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. Seite

19 km/h mm, mm Russian High Speed Train: Track Geometry Analysis according to Russian Track Maintenance Rules (Vertical Error) Track Geometry Analysis: Vertical Error on a Sleeper Track mm mm mm 35 mm mm mm mm mm mm 10 5 mm 5 0 mm km/h Grenzwertueberschreitungen der Gleislage / Bm1_20T18L_VelRus_SF520 / G029_S_B2_Moskau - St. Petersburg_Einweg1 High Speed Track in Russia zl Sehne 6m-Fenster zl zr chord Sehne (6m 6m-Fenster window) Grenzwert zr chord (6m window) Ueberschreitungen: 72 treshholds links, 73 rechts Geschwindigkeit km/h km/h 150 km/h km/h km/h RUS_Fehler_M906_Ch767_Ch770.mat d [m] x km 100 km 200 km 300 km 400 km 500 km 600 km 700 km Seite

20 km/h mm, mm German High Speed Train: Track Geometry Analysis according to Russian Track Maintenance Rules (Vertical Error) Track Geometry Analysis: Vertical Error on a Slab Track mm mm mm mm mm mm 5 5 mm Grenzwertueberschreitungen der Gleislage / Bm1_15T14L_VelD_SF500 / G029_L_Frankfurt-Koeln_for_Tag3 High Speed Track in Germany zl Sehne 6m-Fenster zr Sehne 6m-Fenster zl chord Grenzwert (6m window) zr chord (6m window) treshholds Ueberschreitungen: 10 links, 10 rechts km/h km/h km/h km/h km/h 50km/h Geschwindigkeit km 100 km d [m] 200 km x 10 4 RUS_Fehler_M1754_Ch312_Ch313.mat Seite

21 km/h mm, mm kn, kn, kn, kn High Speed Train: Track Geometry Analysis according to Forces on Components Vertical Track error according to the chord measurement Forces on components Mf: 76:78 81: F.z_20T.FmF1 82: F.z_20T.FmF2 83: F.z_20T.FmF3 84: F.z_20T.FmF Vertical Track Error d.z_20t.rs1 d.z_20t.rs4 zl sehne zr sehne zl sehne 6m-Fenster zr sehne 6m-Fenster Velocity High vertical track errors 239: v_fzg_red 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 d [km] Bm1_20T18L_VelRus_SF520 Seite

Component > 15 kn Not all high vertical track errors produce

22 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 Seite

High Speed Train: The Vehicle Reaction on the Track changes Vehicle Reaction: Lateral Acceleration (1 year observation period) red means high lateral movement blue means stable running

23 High Speed Train: The Vehicle Reaction on the Track changes Vehicle Reaction: Lateral Acceleration (1 year observation period) red means high lateral movement blue means stable running behavior It is obvious that certain track sections induce high lateral movements on the bogie Seite Dr. T. Moshammer / MO MLT BG EN SSV Mobility Division / Mainline Transport

What are the restrictions of the Vehicle-Track-Interaction Monitoring System?

irregularities Different vehicles might show different reactions on certain track defects (when should track maintenance efforts be started?

24 What are the restrictions of the Vehicle-Track-Interaction Monitoring System? Yaw Damper, Wheel Profile, Wheel Guidance System Track Irregularities Conicities 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 Seite

25 Summary: Dr. Thomas Moshammer: Vehicle-Track-Interaction-System 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. Seite

26 Contact! Dr. Thomas Moshammer Head of Department Structure, Simulation, Validation Bogie Engineering Siemens AG Österreich Eggenberger Strasse Graz Tel.: +43 (51 707) Mobile: +43 (664) siemens.com Seite

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