This study discusses the design of a force control strategy for reducing force disturbances in the Virginia Tech – Federal Railroad Administration (VT-FRA) Roller Rig. The VT-FRA Roller Rig is a state-of-the-art roller Rig for studying contact mechanics. It consists of a 0.2m diameter wheel and a 1m diameter roller in vertical configuration, which replicates the wheel-rail contact in a 1/4th scale. The Rig has two 19.4 kW servo motors for powering the rotational bodies and six heavy-duty servo linear actuators that control other boundary conditions.
The Rig was operationalized successfully with all degrees of freedom working in the default position feedback control. During the Rig's commissioning, this approach was found to result in vertical force fluctuations that are larger than desired. Since the vertical force affects the longitudinal and lateral traction between the wheel and roller, keeping the fluctuations to a minimum provides a better test condition. Testing and data analysis revealed the issue to be in the control method. The relative position of the wheel and roller was being controlled instead of controlling the forces between them. The latter is a far more challenging control setup because it requires a faster dynamic response and full knowledge of forces at the interface. Additionally, force control could result in dynamic instability more readily than position control.
Multiple methods for force control are explored and documented. The most satisfactory solution is found in a cascaded loop force/position controller. The closed loop system is tested for stability and performance at various load, speed, and creepage conditions. The results indicate that the controller is able to reduce the standard deviation of vertical force fluctuations at the wheel-rail contact by a factor of four. In terms of power of the vertical force fluctuations, this corresponds to a 12 dB reduction with the force control when compared with the previous control method.
This study also explores the possibility of automating the tests in order to enable running a larger number of tests in a shorter period of time. A multi-thread software is developed in C++ for executing a user-defined position, velocity, or force vs. time trajectory, and for recording the data automatically. The software also provides continuous monitoring, and performs a safe shutdown if a fault is detected. An intuitive GUI is provided for constant data polling and ease of user operation. The code is modular in order to accommodate future modifications and additions for various testing needs.
The engineering upgrades included in this study, together with the baseline testing, complete the commissioning of the VT-FRA Roller Rig. With unparalleled parameter control and testing repeatability, the VT-FRA Roller Rig holds the promise of being used successfully for various contact mechanics needs that may arise in the railroad industry. / MS / Roller Rigs have seen widespread use around the world for research and development of railway vehicles. These test rigs are specialized machinery that provide the means to test a particular aspect of railroading in a controlled environment, allowing for thorough parametric analyses which aid in the design and development of railroad vehicles. One such test rig is the Virginia Tech – Federal Railroad Administration (VT-FRA) Roller Rig, located at the Railway Technologies Laboratory in Blacksburg, Virginia. It is a state-of-the-art test rig which is developed with the objective of providing a controlled test environment for studying railway contact mechanics. A good understanding of the wheel/rail contact is critical to railroad engineering, and this problem has been the subject of research for about a century now. Several compelling mathematical models have been proposed, but the experimental verification of those theories has proven to be difficult. Traditionally, field testing data has been utilized for comparison with prediction from the models. However, field tests are plagued by a low level of noise control and the inability to carry out sophisticated parametric analyses. VT-FRA Roller Rig holds the promise to fill this gap with its sophisticated electro-mechanical design and high precision instrumentation.
The VT-FRA Roller Rig replicates the wheel-rail contact in a 1 /4 th scale by utilizing the INRETS scaling strategy. The locomotive wheel is replicated by a 0.2m diameter wheel and the tangent track is replicated by a 1m diameter roller. The relative size difference ensures that the contact distortion effects from the use of roller are kept to a minimum. The wheel and the roller are arranged in a vertical configuration, and are independently powered by two 19.4 kW servo motors. This enables the VT-FRA Roller Rig to achieve a precise creepage control of up to 0.1%. VT-FRA Roller Rig also has six heavy-duty servo linear actuators which are responsible for controlling four boundary conditions: cant angle, angle of attack, lateral displacement and vertical load. A sophisticated six-axis contact force-moment measurement system allows for precise measurements with a high dynamic bandwidth.
The Rig was operationalized successfully with all degrees of freedom working in the default position feedback control. During the Rig’s commissioning, this approach was found to result in force fluctuations that were larger than desired. Since the vertical force affects the longitudinal and lateral traction between the wheel and roller, keeping the fluctuations to a minimum provides a better test condition. Testing and data analysis revealed the issue to be in the control method. The relative position of the wheel and roller was being controlled instead of controlling the forces between them.
This study documents the development process of a reliable force control methodology for the VTFRA Roller Rig. Force control is a far more challenging control problem when compared to position control because it requires a faster dynamic response and full knowledge of forces at the interface. Additionally, force control could result in dynamic instability more readily than position control. Multiple methods for force control were implemented on the VT-FRA Roller Rig.
Satisfactory solution is achieved with the complicated cascaded loop force/position controller, and the stability and performance of the control system is ensured by a slew of tests at various operating conditions.
This study also explores the possibility of automating the tests in order to enable running a larger number of tests in a shorter period of time. A multi-thread software is developed in C++ for executing a user-defined position, velocity, or force vs. time trajectory, and for recording the data automatically. The software also provides continuous monitoring, and performs a safe shutdown if a fault is detected. An intuitive GUI is provided for constant data polling and ease of user operation. The code is modular in order to accommodate future modifications and additions for various testing needs.
The engineering upgrades included in this study, together with the baseline testing, complete the commissioning of the VT-FRA Roller Rig. With unparalleled parameter control and testing repeatability, the VT-FRA Roller Rig holds the promise of being used successfully for various contact mechanics needs that may arise in the railroad industry.
| Identifer | oai:union.ndltd.org:VTETD/oai:vtechworks.lib.vt.edu:10919/96710 |
| Date | 13 August 2018 |
| Creators | Dixit, Jay Kailash |
| Contributors | Mechanical Engineering, Ahmadian, Mehdi, Mirzaeifar, Reza, Southward, Steve C. |
| Publisher | Virginia Tech |
| Source Sets | Virginia Tech Theses and Dissertation |
| Detected Language | English |
| Type | Thesis |
| Format | ETD, application/pdf |
| Rights | In Copyright, http://rightsstatements.org/vocab/InC/1.0/ |
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