Solving Your Rail Related Problems

Solving Your Rail Related Problems

Rail vehicle simulations Dynamics, stability, derailment…

Detailed Rail-Wheel interaction, wear…

Control systems, brake systems, traction…

Wagon interaction, buffer impact…

Permanent way simulations Rail stresses, deformation…

Substructure stresses, deformation…

Component simulations Stress, Fatigue…

The Solution Triangle

The Technology

Virtual Prototyping Defined

Functional simulation of real-world systems Reduces time-intensive, costly, hardware build-test-refine cycles

Improves quality (cut warranty and repair/maintenance costs)

Virtual Prototyping Defined

Functional simulation of real-world systems Reduces time-intensive, costly, hardware build-test-refine cycles

Improves quality (cut warranty and repair/maintenance costs)

Virtual Prototyping Defined

Functional simulation of real-world systems Reduces time-intensive, costly, hardware build-test-refine cycles

Improves quality (cut warranty and repair/maintenance costs)

Thermal Comfort and Air

Quality in Carriages

VI-Rail

Applications

Full Railway System

Bogie Body Accessories Permanent Way

Suspensions

Wheels / Contact

Dampers

Interference

Packaging

Passenger Safety

Buffers

Brakes

Engine groups

Track beams

Ballasts

Bridges

Active devices

Pantographs

The Functional Digital Train

Full Railway System

Bogie Body Accessories Permanent Way

Suspensions

Wheels / Contact

Dampers

Interference

Packaging

Passenger Safety

Buffers

Brakes

Engine groups

Track beams

Ballasts

Bridges

Active devices

Pantographs

The Functional Digital Train

Controls

FEA

Durability

Integration Platform

CAD

Vibration In-House

Solutions

Integration Platform

• Automatic Stability Analysis

• Specification of critical damping to determine stability (0%, 5%,...)

• Specification of conicity range for automatic generation of stability map

VI-Rail

Vehicle Stability

• Friction coefficient variability

• With track distance

• With creepage

• With lateral coordinate on rail / wheel

Friction C

oeffic

ient

VI-Rail

Traction/Braking

• Application: detailed drive simulation during traction maneuver

• Oscillations in drive system can be carefully tracked down and eliminated

VI-Rail

Traction/Braking

Packaging/Interference

• DMU/Replay integrates ADAMS/PPT into CATIA v5

to perform virtual collision check and envelopes

calculation

• Conceptual collision detection also available in the

ADAMS environment

Integrated Flexibility/Durability

Flex body representation

Stress recovery calculation and color map visualized into ADAMS/PPT

Integrated Vibration Analysis

Frequency response optimization of ride

indexes according to

Equivalent conicity

Suspension stiffnesses

Damper characteristics

Immediate information about qualitative

influence of design changes on running

comfort

Integrated DOE/Optimization

Through the use of ADAMS/Insight:

The scaling factors for all VI/Rail components

are automatically defined

Several design changes can be automatically

investigated

Results are formatted in 3D response

surfaces, animations, and HTML pages which

can be directly published for the whole

engineering team

0,60,8

11,2

1,40,6

1

1,4

0,4

0,45

0,5

0,55

0,6

0,65

Lat Acc RMS

PD Damping Factor

PS ZStiff

Factor

0,6-0,65

0,55-0,6

0,5-0,55

0,45-0,5

0,4-0,45

VI-Rail

Detailed Wheel/Rail Contact

Real Lift-Off Representation

VI-Rail

Detailed Wheel/Rail Contact

Flanging with Multi-Point-Contact

VI-Rail

Detailed Wheel/Rail Contact

Allows to switch between different profiles along the track

Implemented for WRGEN contact element

VI-Rail

Detailed Wheel/Rail Contact

Possibility to change wheel radius along circumference

Available when using WRGEN contact element

Different radii specified in wheel configuration matrix

• Functional Virtual Prototyping as a complete solution for railway

engineering

• Confirmed by several customers and several applications

• Enabling communication between the engineering tools

• Rely on railway expertise and powerful, specialistic tools through strategic

relationships

From Concept to Prototype

REFERENCES

Deutsche Bahn AG

Business: European railway operator

Challenge: Evaluate stresses developing in rail bridges from high speed trains

Solution: Using ADAMS/Rail in combination with FE to virtually estimate the bridge mid-span stress time histories

Value: Enables prediction of stress histories without expensive physical testing

“A high flexibility in modeling different types of vehicles has been reached by taking advantage of the template-builder structure… to build up different ICE assemblies by referencing simply to an ICE bogie and an ICE car body template.”

--Manfred Zacher, Deutsche Bahn AG

RDSO

Business: Research arm of the Indian Ministry of Railways

Challenge: Develop a flat rail car for safe operation at 100 km/h

Solution: Using ADAMS/Rail and NASTRAN with field wheel/rail measurements to virtually evaluate acceptance criteria

Value: Virtual tests demonstrated that design shall pass the field criteria of Indian Railways

“ADAMS/Rail is for RDSO a necessary virtual prototyping tool to ensure good financial health of the organization and reduction in cost of development and testing of a new design.”

-- Nitin Chowdary Director, Vehicle Dynamics Group

Trenitalia

Business: European railway operator

Challenge: Implement braking device in experimental railway vehicle

Solution: Behavior of the WSPD (Wheel Slide Protection Device) active system is investigated using ADAMS-Matlab Co-Simulation

Value: Able to optimize slide protection device with the help of virtual prototyping

“The proposed model has a behaviour qualitatively and quantitatively analogous to the on line tests.”

-- P. Presciani Manager, UTMR Trenitalia

Bombardier

Business: Railway rolling stock manufacturer

Challenge: Rapidly develop an optimized traction control system

Solution: Using MSC.Patran/Nastran, ADAMS/Rail with ADAMS/Controls + MATLAB as integrated virtual prototyping solution for mechatronics

Value: Increased confidence in product

“Commissioning of traction control could be finished in a short time with very good results to the satisfaction of our customer, even though the conditions were very difficult.”

-- Peter Haese

Traction Systems Engineering

Alstom

Business: European railway vehicles manufacturer

Challenge: Investigate poor performance caused by car body torsion interaction with bogie hunting

Solution: Integrated VI/Rail bogie model with FE carbody

Value: Overall comfort performance optimize, resulting in wide commercial success

“A complete DOE analysis enabled the engineers to test the dynamic behaviour of the complete system and to find out the optimal parameter settings which restricts the vibration of the construction and therefore optimises the comfort behaviour.”

-- Pascal Geoffroy Manager, Rolling Stock

“The simulation produced results in agreement with all service conditions and the overall dynamic behavior. Derailment and rollover stability measurements have been matched with a maximum error of 3%.”

-- Massimo Lenti Manager R&D, Alstom IPS

Business: Railway vehicles manufacturer

Challenge: Optimize new streetcar for rollover stability and derailment avoidance

Solution: Evaluated the vehicle behavior virtually to optimize the design

Value: Improved safety; greater confidence

Alstom

Case Study:

GE Transportation

Business: North American locomotive manufacturer

Challenge: Investigate the effect of wheel back-to-back distance on locomotive stability and safety

Solution: Parametric model built in ADAMS/Rail and run through standard suite of maneuvers

Value: Met customer critical-to-quality requirements on locomotive design

“We have done a lot of wonderful work using ADAMS.”

-- Jingjun Zhang

Control and Auxiliary Systems

Patentes Talgo

Business: Railway rolling stock manufacturer

Challenge: Meet UIC518 acceptance requirements when operating on tracks with different gauges

Solution: Virtual comfort and safety studies for different system configurations

Value: Fulfilled UIC518 requirements

“The results achieved have been coherent

regarding tilting in curves, accelerations on car

bodies, contact forces, and guidance system.”

-- Emilio Garcia,

Manager, Talgo

Business: Railway rolling stock manufacturer

Challenge: Investigate dynamic behavior of high-speed train

Solution: VPD and MSC.ADAMS/Rail

Value: Simulation enables to virtually perform design certification with less cost and to investigate system behavior through tests which cannot be performed physically

“Simulation reduces the cost of design. It is a fundamental tool to present technical information to our customers and ensure the viability of our products. It facilitates the investigation of design issues like comfort and derailment safety.”

-- Emilio Garcia,

Manager, Talgo

Patentes Talgo

Skoda Loc

Business: Railway vehicle manufacturer

Challenge: Establish locomotive bogie design between different variants

Solution: ADAMS/Rail detailed models of locomotives with different traction devices

Value: Recommend for implementation better arrangement for running gear thanks to simulation results

“Thanks to simulation it has been possible to choose the most cost-effective design for the locomotive bogies, by evaluating the behavior of all different variants.”

--Vaclav Kraus Skoda Locomotive

VUKV

Business: Railway vehicle manufacturer

Challenge: Position itself successfully in a global market

Solution: Following an extensive benchmarking, implemented the state-of-the-art simulation technology from MSC.Software

Value: Show competence presenting highly sophisticated solutions to their customers

“By using MSC.Software products we have been able to acquire new customers and, most significantly, open new markets. Our initial estimate of a three-year payback period proves to be significantly shorter.”

-- Zdenek Malkovsky VUKV

Challenge: Perform crash tests on railcar prototype

Solution: VPD from MSC.Software (based on LS Dyna)

Value: After correlation with physical testing, VPD can be used to

perform virtual crash tests with enormous cash saving

Case Study:

Association of American Railroads

Voith Turbo Business: Supplier for locomotive drive

systems

Challenge: Optimize the complete locomotive + drive assembly

Solution: Nastran and ADAMS Functional Digital Train with FE components enabled them to improve traction/braking and impact performance

Value: Improved collaboration with customer. Better information earlier in the process

Fiat CRF

Business: European service provider

Challenge: Develop a semi-active lateral suspension for a new tilting train

Solution: Integrating train model in ADAMS/Rail with MATLAB model of sky-hook suspension design

Value: Increased low-frequency ride comfort

“Tilting system modifications investigated with the integrated virtual prototype enabled us to reach reduction of nearly 50% of the lateral ride figures.”

-- Mauro Montiglio Manager, Vehicle Engineering Projects

Fiat CRF

Business: European service provider

Challenge: Develop innovative railway wheelsets with outstanding reliability performances

Solution: ADAMS/Rail model of railcar including MSC.Nastran flexible wheelsets

Value: Predict load spectra with simulation: increase confidence in design

“Significant developments in the design of railway wheelsets in terms of improved durability, reduced noise and vibration impact, and lower life cycle costs are expected to be the final result of the project.”

-- K. Bel Knani Manager, HIPERWHEEL Project, Fiat CRF

100

101

102

103

104

105

Average service (400 km)

Cycle count

Vert

ical fo

rce straight

curve total

Challenge: Buffer impact simulation

Solution: VPD from MSC.Software (based on ADAMS/Rail detailed buffer model mounted on complete vehicles)

Value: Guarantee safe performance of buffer

Case Study:

Warsaw University

Nedtrain Consulting

Business: Railway Services Consultant

Challenge: Improve railcar efficiency by reducing delays due to technical failure

Solution: Full virtual prototype of door system (including electric and pneumatic)

Value: Virtually improve operational safety of door opening system

“The simulation results will be used to introduce improvements in the door system operation.”

-- E.J.J. De Jong Nedtrain Consulting

Nedtrain Consulting

Business: Railway Services Consultant

Challenge: Develop a compact system to measure train weight and wheel defects (GOTCHA)

Solution: Measuring site ADAMS model to gain insight in the dynamic behaviour of the measuring system

Value: GOTCHA already used to monitor wheel tread quality on almost all electrical NS rolling stock

“Using the model the processing of the measuring signal was optimised resulting in a high accuracy and reproducibility of the system.”

-- E.J.J. De Jong Nedtrain Consulting

RTU

Business: Railway industry consultant

Challenge: Simulate UK freight wagon ride acceptance tests

Solution: ADAMS/Rail model of freight wagon with custom simulation/postprocessing event

Value: Allow prediction of the results of the UK vehicle acceptance test within simulation environment

“With ADAMS/Rail the effects of modifications to the vehicle can be evaluated before the actual test procedure is carried out.”

--Yann Bezin Rail Technology Unit, MMU

Corus - RTU

Business: Railway industry consultant

Challenge: Develop a methodology to virtually investigate rolling contact fatigue

Solution: ADAMS/Rail vehicle models in combination with non linear FE rail-ballast models

Value: Virtually predict the typical stress response of rail when subjected to vehicle loads

“The forces predicted from the vehicle dynamic modelling using Adams/Rail are in broad agreement with measured data from on site instrumentation. The predicted forces can then be used with confidence in both the global track and contact stress models.”

--Stephen Blair Corus Rail Technologies

Transnet Freight Rail

Business: largest Railway company in South Africa

Challenge: predict by simulation the loads in the overhead system, and the pantograph during operation, in order to optimise the tension in the overhead system to minimise the forces.

Solution: MSC.Marc for a unique capability of line/line contact approach

Value: The cost of the physical damage is around € 250k, but the cost of the lost revenue on the unsused lines runs into millions.

How Can We Help You?

With The Right Tools…

With The Right Tools…

Product Lifecyle Management (PLM)

Computer Aided Drawing (CAD)

Finite Element Analysis (FEA)

Systems & Controls (S&C)

Multi Body Dynamics (MBD)

Computation Fluid Dynamics (CFD)

Test & Measurement (T&M)

Linking to the Rail Community

Which Tools does the Rail Community use?

MSC Masterkey

Access to Multiple specialised CAE tools

Flexible licensing system

All products integrate easily

VI-Rail

Rail focused MBD tool

Runs on top of MSC Adams

Integrates fully with MSC Masterkey products

Supporting the Rail Community

Consulting Services

VI-Rail Simulations

Thermal Simulations

Thermal Structural Analysis

(UIC510-5)

With The Right People…

With The Right People…

Product Training

Discipline Training

THRIP Program @ UP Chair in Railway

Engineering

University Program

Recruitment

With The Right Ways…

With The Right Ways…

Product Support

Service Level Agreement (SLA)

On-Site training

On-Site Mentoring

Knowledge Transfer

Internship program

ESTEQ is your solution!

Who is ESTEQ?

• Engineering Solutions focused

company

• Since 1994

• Head office in Gauteng, offices in

Western Cape & KwaZulu Natal

• 45 Employees • 22 Mechanical Engineers

• 3 Industrial Engineers

• 1 Electrical Engineer

• 1 Civil Engineer

• Brings World Class Technology to SA: • SIEMENS, MSC Software, HBM, Mentor Graphics,

Endevco…

• Who do we help? • Over 1500 local companies

• 16 local Universities

• Over 5 000 users

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