Worked Examples Vehicle Acceptance and Testing (Mechanical Systems)

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Emergency Brake Rate

Sample Test Result
Train Speed (km/h)

Average Brake Rate a_e Instantaneous Brake Rate a_i

Brake Cylinder Pressure (bar)

t _0

t _1

Time (s)
2

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Emergency Brake Rate

Acceptance Criteria 1. Emergency brake rate >= 1.4 m/s2
Question : Train speed = 35 km/h at t = 3 sec, and the train stopped at t = 9.5 sec. Find the emergency brake rate. Answer : Measured emergency brake rate = (35/3.6) / (9.5 3) = 1.496 m/s2 Therefore the required emergency brake rate >= 1.4m/s2 can be satisfied.

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Emergency Brake Rate

Acceptance Criteria 2. Maximum braking distance <= calculated braking distance (based on 1.4 m/s2 - 14%)
Question : As read from graph, t_0 = 0.4 sec and t_1 = 1.4 sec. If the initial train speed = 40 km/h. Check the maximum allowable braking distance for minimum instantaneous emergency brake rate 1.4 m/s2 -14%. Answer : The maximum allowable emergency braking distance can be calculated by: S_i = Uo*(to+0.5*t1) + Uo^2/(2*a_i) or S_e = Uo^2/(2*a_e)
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Emergency Brake Rate

Parameter Initial speed Velocity Dead time Brake force build up time (90%) Emergency brake rate (instantaneous) Average brake rate Abbr. Speed Uo t_0 t_1 a_i a_e S_e or S_i Value Unit Formula Read from graph = Speed in km/h / 3.6 Read from graph Read from graph Design requirement specification =a_i / (1 + ( 2*t_0 + t_1 )*a_i / Uo) =Uo^2/(2*a_e) or = Uo*(to+0.5*t1) + Uo^2/(2*a_i)
5

40 km/h 40/3.6= m/s 11.11 0.4 sec 1.4 sec 1.4*0.86= m/s2 1.204 0.972 m/s2

Maximum Allowable Braking Distance

63.5 m

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Vehicle Weighing
Axle No Axle1 Axle 2 Axle 3 Axle 4

Wheel No

W1A

W1B

W2A

W2B

W3A

W3B

W4A

W4B

First

5,080

5,025

5,130

4,985

5,095

5,215

4,970

5,335

Wheel Load Measure ment

Second

5,035

5,070

5,160

4,950

5,020

5,290

4,985

5,315

Third

5,080

5,025

5,105

5,010

5,100

5,205

4,945

5,360

Fourth Wheel Load, WL Axle Load, AL

5,050 5,061

5,060 5,045

5,135 5,133

4,975 4,980

4,945 5,040

5,360 5,268

5,060 4,990

5,240 5,313

Average 5,104 10,207

10,106

10,113

10,308

10,303

Question: Check for axle load balance and wheel load balance on axle 1 from vehicle weighing results.
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Vehicle Weighing
1. Axle load balance (for power car) 2. Wheel load balance : a. Difference in load from the average load per wheel for a given axle For Axle 1, *Calculate AL/2 = 10106/2 = 5053 =Max(5061-5053,50455053)/(5053) *Calculate the total WL for each side For Side A, 5061+5133+5040+4990 = 20224 For Side B, 5045+4980+5268+5313 = 20606 Average load on both sides of vehicle = (20224+20606)/2 = 20415 =Max(20224-20415,2060620415)/(20415) 0.2% <=4% = Abs (AL - average of AL) / ( average of AL) *Calculate the average of AL = 10207 For Axle 1, =Abs (10106-10207)/(10207) 1.0% <=2%

= Maximum of Abs (WL AL/2) / (AL/2)

b. Difference in load from one side of the vehicle to the average load on both sides of the vehicle

= Maximum of Abs ( total WL on one side - average of both sides WL) / (average of both sides WL)

0.9% <=4% 7

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Wheel Off-loading Calculation

Question: Given twisted track condition as above, calculate track twists at bogie centre distance 15.6m and bogie wheelbase distance 2.5m.
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Wheel Off-loading Calculation

Answer: For bogie centre distance 15.6m, 1:260 cant gradient will give track twist of 15.6*1000*1/260 = 60mm. For bogie wheelbase distance 2.5m, 1:230 cant gradient will give track twist of 2.5*1000*1/230 = 10.9mm. Note: Cant gradient is a measure of rate of change in cant.

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Question: Calculate dQ/Q based on the following parameters together with track twist 60mm over bogie centre distance and 10.9mm over bogie wheelbase distance.
Wheel spacing Primary suspension spacing Secondary suspension spacing Primary vertical stiffness per wheelset Secondary vert stiffness per bogie Anti roll bar stiffness per bogie Body torsional stiffness Bogie torsional stiffness 2b 2bp 2bs 2kp 2ks m m m KN/m KN/m KN/m 1.505 1.94 1.88 1800 7000 5000 8000 6000 for 2 bogie vehicle (8 wheels) 10

k * +

KN m/rad KN m/rad

Total car weight W

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kN

250

Answer : Using the following formulae:

1. Two angles t* and t+ are calculated from the measured track twists Twist* Twist+ t* = -----------t+ = ----------2b 2b 2. The stiffness C* and C+ can be worked out from the vehicle parameters 1 C* = -----------------------------------------------------[ 1/ * + 2/ (2ksbs2 + k ) + 2/ (4kpbp2) ] 1 C+ = -----------------------------[ 1/ + + 2/ (2kpbp2 ) ] 3. Two values of wheel off-loading dQ* and dQ+ are calculated by C* t* C+t+ dQ* = ---------dQ+ = --------2 x 2b 2b 4. Then add these two values to give the total wheel off-loading dQ = dQ* + dQ+ 5. The value of dQ/Q can be calculated.
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Twist height Twist angle

Twist* Twist+ t* t+

mm mm rad rad KN m/rad KN m/rad kN kN kN kN %

60 10.9 0.0399 0.0072 1118.2 742.1 14.81 3.56 18.37 31.25 58.9%

=15600/260 =2500/ 230 =(60/1000)/1.505 =(10.9/1000)/1.505 =1/(1/8000+2/(7000*0.94^2+500 0)+2/(2*1800*0.97^2)) =1/(1/6000+2/(1800*0.97^2)) =(1118.2*0.0399)/(2*1.505) =(742.1*0.0072)/1.505 =14.81+3.56 =250/8 =18.37/31.25

Total stiffness

C* C+ dQ* dQ+ dQ = dQ* + dQ+

Wheel off-loading

Nominal wheel load Delta Q / Q

Q dQ/Q

Notes :

*" for bogie centre distance (15.6m) +" for bogie wheelbase distance (2.5m)

The wheel off-loading factor is calculated to be 0.589 and is acceptable.

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Wheel Off-loading Test

Wheel: Step 1 Height: Weight: Step 2 Height: Weight: 1A 2A 3A 4A 1B 2B 3B 4B

Level Track 0.1 -0.1 0.1 -0.1 0 0.2 -0.2 0.1 mm 45.4 kN

41.69 45.39

47.3 44.96 48.11 44.09 43.17

Jack to maximum height at wheel 1A 70.9 63.18 60.2 9.9 0.6 0.5 0 -0.1 -0.7 mm

52.9 35.91 20.02 26.74

35.7 54.35 70.07 kN

Question: Check for maximum dQ/Q from wheel off-loading test results.

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Wheel Off-loading Test

Answer: Wheel Off-loading Factor :

dQ = Q

Q0 Qt Q0

where, Q0 = nominal wheel static load at level track condition Qt = wheel load at maximum track twist condition Q0 = 44.96 kN, Min. Qt = 20.02 kN Max dQ/Q = (Q0 - Qt ) / Q0 = (44.96 20.02) / 44.96 = 55.5% Acceptance limit : The wheel off-loading of any wheel shall not exceed 60% of the nominal static load value, i.e. dQ/Q <= 0.6.

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Bogie Rotational Resistance

Measured T are : +18.52 kN

2T

-18.59

Question : Given that : Vehicle weight = 42085 kg for a 4-axled vehicle Bogie semi-wheel base = 1.25m Calculate the X-factor from bogie rotational resistance test result.
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Bogie Rotational Resistance

Answer : The expression for Bogie Rotational Resistance (X-factor) is : X = T / (W * 2a) where, T = Torque to rotate the bogie W= average axle load on the bogie being rotated a = bogie semi-wheel base Axle load W = 42085 * 9.81 / (4 *1000 ) = 103.2 kN Total torque, 2T = 18.52+18.59 = 37.11 KN X = (37.11 /2) / (103.2 * 2 * 1.25) = 0.072 < 0.1

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Vehicle Overturning
Question : Assess the vehicle design against overturning for the worst combination of wind loading and track cant.
Carbody mass Height of body CG above rail Height of lateral load above rail Lateral offset of CG Maximum installed cant Wheel contact patch spacing Body lateral force Acceleration due to gravity M h_body h_x d c b F g 32000 1.483 1.649 0.005 150 1.505 53538 9.81 kg m m m mm m N m/s2

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Vehicle Overturning

c , b
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Vehicle Overturning
Answer : = arcsin (150 / 1505) Q1 + Q2 = M/2 * g Take moment about A : Mg/2 * sin x h_body + Mg/2 * d + F/2 * h_x = (Q_2 - Q_1) x 1.505 / 2 Thus, Q1 = Mg/4 - Mg * d/3 - F * h_x/3 Mg * sin * h_body/3 To prevent overturning, check if min. Q1 > 0. Q1 = 32000*9.81/4 32000*9.81*0.005/3 53538*1.649/3 32000*9.81*(150/1505)*1.483/3 = 33062 N > 0.

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