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Modelling of a Passive Hydraulic Steering for Locomotives

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Modelling of a Passive Hydraulic Steering for Locomotives Modelling of a Passive Hydraulic Steering for Locomotives by Torsten Peter Löwe Submitted in partial fulfilment of the requirements for the degree Master of Engineering in the Faculty of Engineering, Built Environment and Information Technology (EBIT) University of Pretoria, Pretoria October 2014 (Lard, 2013) 1 Modelling of a Passive Hydraulic Steering for Locomotives. Candidate: Torsten Peter Löwe Supervisor: Prof P.S. Els Co-Supervisor: Dr C. Kat Department: Mechanical and Aeronautical Engineering Degree: Master of Engineering Abstract During the past few decades, substantial improvements were made to rail infrastructure worldwide. This was necessary to accommodate the ever increasing transportation demand and requirements. Nowadays, trains are required to transport heavier loads and to travel at higher speeds. One of the major improvements was achieved by the development of the off-flange curving bogie designs to reduce wheel and rail wear. Off-flange designs include passive steering and actively controlled steering. The development and implementation of self-steering bogies on locomotives was promoted in the early 1980’s by two major locomotive manufacturers. Up to date, thousands of these locomotives, with built-in self-steering bogies, have been manufactured and taken into service (Swenson, 1999). Most self-steering bogies have mechanical linkage systems to steer the wheel sets. As an alternative to the mechanical linkage system, the DCD Group (a South African manufacturer of rail and mining equipment) initiated the development of a Passive Hydraulic Steering (PHS) system. First PHS prototype systems, developed by DCD, have proven that huge wear reduction possibilities exist on both, rails and wheels. In addition the prototype systems also significantly decreased noise and vibration levels when negotiating tight corners (Swenson & Scott, 1996 and DCD Rolling Stock, 2012). However, existing prototype solutions require further improvements and development for optimisation. To be able to identify and implement improvements, the need exists to perform modelling and testing of the systems to obtain a better understanding of the operation and suitability of a complete unit. i The aim of this research project is thus, to mathematically model an existing prototype PHS system and validate the model with data from experiments and tests. This model can then be used in order to improve and optimise performance, cost and reliability of the system, before mass production is considered. A literature survey was conducted, focusing on general wheel and rail wear mechanisms, techniques to improve wheel and rail life and on existing techniques for modelling the hydraulics and multi-body dynamics of locomotive systems. The literature survey was followed by extensive laboratory tests on component basis, a quarter PHS system and on the full PHS system. From these tests all parameters needed for the characterisation of the PHS and the mathematical model were determined. These tests also provided data for the validation of the PHS model. Finally, a mathematical model of the PHS system was successfully generated and validated. This model can now be used in a multi-body dynamic locomotive simulation to evaluate its effectiveness. The results and findings of the literature survey, experiments and modelling are reported on and discussed in this report. ii Acknowledgements I wish to thank my study leader, Prof P.S. Els, co-supervisor Dr C. Kat, my family and friends for their continued guidance, support and contribution to making this project possible. Furthermore, I would like to thank Mr P. Smith and Mr A. Pieterse from DCD, Mr S. Maartens from Transnet, Mr C. Cassel from HYTEC and Mr C. Becker from the University of Pretoria for the valuable information, help and opportunities provided. This project allowed the student to gain valuable knowledge and experience in engineering design, especially in the field of rail infrastructure and systems. Contacts have been made, which may be very useful for the student’s future career as an engineer. Also, a big thank you goes to the DCD Group and the National Research Foundation for providing funds for this project. The financial assistance of the National Research Foundation (NRF) towards this research is hereby acknowledged. Opinions expressed and conclusions arrived at, are those of the author and are not necessarily to be attributed to the NRF. iii Table of Contents Abstract ....................................................................................................................................... i Acknowledgements .................................................................................................................. iii Table of Contents ...................................................................................................................... iv List of Figures .......................................................................................................................... vii List of Tables ............................................................................................................................ ix List of Symbols .......................................................................................................................... x English Letters and Symbols .................................................................................................. x Greek Letters and Symbols ................................................................................................... xi Abbreviations ........................................................................................................................... xii 1. Introduction ........................................................................................................................ 1 2. Literature Survey ................................................................................................................ 3 2.1. Known Major Problems of Rail Systems .................................................................... 3 2.1.1. Wheel and Rail Wear ........................................................................................... 3 2.1.2. Wheel and Rail Fatigue ........................................................................................ 5 2.1.3. Wheel-Rail Friction Conditions ........................................................................... 5 2.2. Measures to Improve Wheel and Rail Life ................................................................. 6 2.3. Off-Flange Curving Designs ....................................................................................... 7 2.3.1. EMD Radial Steering Bogie ................................................................................ 8 2.3.2. General Electric Three-Axle Steerable Truck/bogie .......................................... 11 2.3.3. Adtranz Shifting Axle Drive .............................................................................. 12 2.3.4. DCD Passive Hydraulic Steering (PHS) ............................................................ 13 2.4. The Passive Hydraulic Steering (PHS) System Concept .......................................... 13 2.4.1. The PHS Components ........................................................................................ 14 2.4.2. The PHS Working Principle .............................................................................. 17 2.4.3. PHS for Bo-Bo and Co-Co Bogie Configurations ............................................. 19 2.4.4. Previous Simulations and Experimental Tests of the PHS ................................ 21 2.4.5. Possible Advantages and Disadvantages of the PHS ......................................... 22 2.5. Standards & Safety for Rail systems ......................................................................... 23 2.6. Modelling and Simulating hydraulics and multi-body dynamics of locomotive systems ................................................................................................................................. 23 3. Problem Statement and Scope of Work ............................................................................ 25 4. Initial Model Development and Experimental Test Preparation ...................................... 26 iv 4.1. PHS Component Models ........................................................................................... 26 4.1.1. Hydraulic Cylinder Model ................................................................................. 26 4.1.2. Accumulator and Reservoir Model .................................................................... 27 4.1.3. Piping System Model ......................................................................................... 32 4.1.4. Hydraulic Oil Model .......................................................................................... 33 4.2. Modelling of Thermal Effects on the PHS System ................................................... 34 4.3. Experimental Test Preparation .................................................................................. 36 5. Testing, Modelling and Validating of a PHS Cylinder .................................................... 39 5.1. Laboratory Testing .................................................................................................... 39 5.1.1. Bulk modulus Determination ............................................................................. 40 5.1.2. Force Measurement Investigation .....................................................................
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