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DESCRIPTION
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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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