Multiphysics Modeling of
Railway Pneumatic Suspensions
Nicolas Docquier
Université catholique de Louvain, Belgium
Institute of Mechanics, Materials and Civil engineering
Center for Research in Mechatronics
SIMPACK User Meeting
Salzburg, Austria, 18th and 19th May 2011
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Secondary suspension dynamics
• Industrial contextA full pneumatic circuit
Various morphologies
Increase in design complexity
• Scientific motivationsDeep understanding of the dynamic behaviour
Development of accurate models includingthe complete pneumatic circuit
Multibody and pneumatic dynamics coupling
Optimized suspension design tool
Carbody
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Contents
• Description of pneumatic suspension circuits
• Comparison of pneumatic component models
• Experimental validation
• Analysis of a complete metro car
Multibody and pneumatic coupling
Influence of heat transfer
Comparison of various suspension morphologies
• Conclusion
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Pneumatic suspension components
Many possible configurations
Air spring
Auxiliary tank
Connecting pipe
Orifice
Valves
Levelling valveExhaust ValveDifferential valve
Pressure source
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4 levelling valves per carbody
1 levelling valve per bellows
Differential valve is necessary
rail twist, punctured bellowsAnti-roll action in curve
2 levelling valves per carbody
1 levelling for 2 bellows
Anti-roll bar needed
• 4-point suspension
• 2-point suspension
Levelling configurations
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Suspension configuration
• Kind of bogie
• Number of bellows per bogie
• Levelling configuration
• Anti-roll bar
• Auxiliary tank
• Hydraulic damper
Conventional Jakob’s bogie
2-point
Without
2 4
3-point 4-point
With
WithoutWith
WithoutWith
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Contents
• Description of pneumatic suspension circuits
• Comparison of pneumatic component models
• Experimental validation
• Analysis of a complete metro car
Multibody and pneumatic coupling
Influence of heat transfer
Comparison of various suspension morphologies
• Conclusion
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Bellow-tank models
• Spring-mass system
Suitable for multibody software
Difficult to complete with valve models
Difficult to adapt for various topologies
• Oscillating air mass
Volume variation in bellow and tank
Pressure variation
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Component specific model
• Bellows and tanks: pneumatic chambersContinuity equation mass variation
Energy equation temperature variation
Perfect gaz equation pressure
Easy to connect with other components
Bellows reaction force:
Mass variation
Heattransfer
Volume variation
Enteringenthalpy
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• Bellow and tank: pneumatic chambersContinuity equation mass variation
Energy equation temperature variation
Perfect gas equation pressure
• PipeDifferential model
Algebraic model
Component specific models
Mass variation
Heattransfer
Volume variation
Enteringenthalpy
Incompressible flow case:
Bellow reaction force:
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q = C(position) · f(p2, p1)
Valve modeling
Mass flow rate
(pr-pl)
q = f (pr, pl)
admission
C
Lever position
safety
levelling
exhaust p2/p1
f
1
p1a
p1b> p1a
[ISO 6358]
• Levelling valve • Safety valve • Differential valve
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0 5 10 15 20 25 30200
300
400
500
600
700
800
900
1000
1100
Frequency analysis
Two constant levels
low frequencies:bellow and tank excitationhigh frequencies:bellow excitation only
Air mass inertia not taken into account by the algebraic model
Inertia effects negligible for small pipe lengths D
ynam
ic s
tiffnes
s [k
N/m
]
Frequency [Hz]
L = 1 m
• Dynamic stiffness analysisbellow-tank subsystemdisplacement sinusoidal excitation
Incompressible differential
Incompressible algebraic
L = 0.1 m
L = 0.01 m
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Contents
• Description of pneumatic suspension circuits
• Comparison of pneumatic component models
• Experimental validation
• Analysis of a complete metro car
Multibody and pneumatic coupling
Influence of heat transfer
Comparison of various suspension morphologies
• Conclusion
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Experimental setup
Several pipe configurations
Laboratoire d’Essais Mécaniques, Structure et Génie Civil (LEMSC, UCL/iMMC)
Collaboration with:
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Dynamic tests: Excitation amplitude
Incompressible differential model is suitable
Pipe volume added to the bellows and to the tank volume
Loss coefficient estimated for zmax = 1.3 mm
Good match with experimental results for the 2 other amplitudes
Phase error
Stiffnes
s [k
N/m
]
Frequency [Hz]
Angle
[°]
Frequency [Hz]
Dynamic stiffness Displacement-force phase
0 2 4 6 8 10200
300
400
500
600
700
800
900
1000
1100
0 2 4 6 8 100
10
20
30
40
50
60
zmax = 1.3 mmzmax = 2.75 mm
zmax = 0.5 mm
ExperimentSimulation
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0 5 10 15 20200
300
400
500
600
700
800
900
1000
1100
Pipe length Resonance frequency
Incompressible model is still suitable
For higher frequency: 2nd resonance effect Discretized model
Dynamic tests: Pipe length
0 5 10 15 200
10
20
30
40
50
60
zmax = 0.5mm - 10m pipe
zmax = 0.5 mm - 1.35m pipe
Stiffnes
s [k
N/m
]
Frequency [Hz]
Angle
[°]
Frequency [Hz]
Dynamic stiffness Displacement-force phase
ExperimentSimulation
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Contents
• Description of pneumatic suspension circuits
• Comparison of pneumatic component models
• Experimental validation
• Analysis of a complete metro car
Multibody and pneumatic coupling
Influence of heat transfer
Comparison of various suspension morphologies
• Conclusion
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Application to a metro car
• Vehicle main propertiesCarbody mass 17 tons
Bogie mass 3.5 tons
Bogie centre distance 10 m
• Modeling assumptionsPerfectly rigid carbody
Rigid bogie frame
• 2nd Suspension characteristics full pneumatic4-point configuration
No anti-roll bar
No hydraulic damper
Bellows directly connected to tanks
no pipe
10 m2 m
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Hybrid simulation via co-simulation
• Multibody (Newton-Euler)
• Pneumatics
Hybrid modelSIMPACK
SIMULINK
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( )
Hybrid Simulation by co-simulation
• Co-Simulation
2 process integrated in parallel
Interaction at fixed time step
Simpack( )
Matlab-Simulink
MultibodyModel
PneumaticModel
F
SIMULINK diagram
z, z, L.
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Various situations to be analysed
• Curve passing
• Rail twist
• Station loading/unloading
• Passanger comfort
• Failure mode (leakage, …)
10 m/s
100 m
50 mm
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0 10 20 30 40 50 60 70 80 90 100
-2
-1.5
-1
-0.5
0
Influence of the heat transfer
• Without valvesk=0 W/K (adiabatic)
larger stiffness
smaller roll angle
k=104 W/K (≈isotherm)
smaller stiffness
larger roll angle
k=1 W/K ... 10 W/K
close to the adiabatic case at firsttends toward the isotherm case after a longer time
Time [s]
Carbody roll angle [°]
k = 0 W/K
k = 1 W/K
k = 10 W/K
k = 104 W/K
10 m/s
100 m
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Influence of the heat transfer
• Valves connectedLevelling valves reduced roll angle
Levelling action
less influence of heat transfer
Intermediate k values
temperature and stiffness progressively decrease
levelling valve periodically engaged
0.1° oscillations
k air consumption
Time [s]
Carbody roll angle [°]
Air consumption [kg]
Heat transfer coefficient [W/K] 0 10 20 30 40 50 60 70 80 90 100
-1
-0.5
0
0.5
1
k = 0 W/K
k = 1 W/K
k = 10 W/K
k = 104 W/K0 1 10 10 000
0.000
0.020
0.040
0.060
0.080
10 m/s
100 m
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2-point suspension+ classical anti-roll bar
Configurations comparison
• Classical configurations
4-point suspension
• Novel configurations
2-point suspension + Kinetic H2 anti-roll system
Hydraulic version Pneumatic version
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0 10 20 30 40 50 60 70
-1
-0.8
-0.6
-0.4
-0.2
0
0.2
0.4
0.6
0.8
Curve entry
Anti-roll bar and H2 systems: set so as to obtain a comparable rollangle as for the 4-point case
Time [s]
Carbody roll angle [°]
2-pts + ARB
4-pts
2-pts + Pneumatic H2
2-pts + Hydraulic H2
10 m/s
100 m
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ΔQ/Q test
• Rail twist excitationMeasurement of the wheel/rail force vertical component variations
Stationary vehicle
Wheelset motion imposedno wheel/rail contact calculation
Wheel displacement: 50 mm
• Secondary suspension reactionCrushed diagonal
Extended diagonal
Front bogie
Rear bogie
50 mm
Time [s]
Wheel displacement [mm]
0 5 10 50
0
25
50
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0 20 40 60
15
20
25
30
35
40
0 20 40 60
15
20
25
30
35
40
0 20 40 60
15
20
25
30
35
40
0 20 40 60
15
20
25
30
35
40
ΔQ/Q: wheel load variations
For the 4-point suspension
Increased wheel unloadingdue to the leveling system
For H2 systems:
Small unloadingPossibility of increasedroll stiffness
Wheel load [kN]Right wheelsLeft wheels
1st wheelset
4th wheelset
Time [s] Time [s]
2-pts + ARB
4-pts
2-pts + Pneumatic H2
2-pts + Hydraulic H2
Front bogie
Rear bogie
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Contents
• Description of pneumatic suspension circuits
• Comparison of pneumatic component models
• Experimental validation
• Analysis of a complete metro car
Multibody and pneumatic coupling
Influence of heat transfer
Comparison of various suspension morphologies
• Conclusion
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Conclusion
• Industrial demand Scientific approach
Pneumatic suspension analysis Advanced modeling techniques
• Model comparison
Suspension design and morphology Choice of the model
• Experimental analysis
Heat transfer assessment
Model validation
• Generic tool for suspensions
Analyses of multibody-pneumatic interactions in complex situations
Comparison of various configurations
Investigation for new pneumatic circuit morphologies
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Prospects
• Multiphysics modeling
For systems with higher dynamics
Investigation of pressure wave effects
Refinement of valves modeling
Influence of multibody coupling techniques strong coupling?
• Railway pneumatic suspension
How to avoid many experimental tests for determining model
parameters?
Use the developed models in a mechatronics approach within an
industrial framework
Detect earlier unexpected behaviour
Optimization of existing suspension configurations
Investigation of novel configurations
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Conclusion
• ReferencesDocquier N., Fisette P., Jeanmart H., Multiphysic modelling of railway vehicles equipped with pneumatic suspensions, Vehicle system Dynamics, 2007, 45, 6, pp. 505-524.
Docquier N., Poncelet A., Delannoy M., Fisette P., Multiphysics modellingof multibody systems : application to car semi-active suspensions, Vehicle System Dynamics, 2010, 48, 12, pp. 1439-1460.
Docquier N., Fisette P., Jeanmart H., Model-based evaluation of railwaypneumatic suspensions, Vehicle System Dynamics, 2008, 46 (SUPPL.1), pp. 481-493
Docquier N., Fisette P., Jeanmart H., Influence of Heat Transfer on Railway Pneumatic Suspensions Dynamics, In: 21th IAVSD International Symposium on Dynamics of Vehicles on Roads and Tracks, 2009, Stockholm, Sweden.
Docquier N., Fisette P., Jeanmart H., Multidisciplinary approach to railway pneumatic suspensions: pneumatic pipe modelling, In: MultibodyDynamics 2007, ECCOMAS Thematic Conference, 2007, Milano, Italy, 25-28 June 2007.