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Article in Proceedings of the Institution of Mechanical Engineers Part F Journal of Rail and Rapid Transit · January 2013
DOI: 10.1177/0954409713508110
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Huailong Shi
Southwest Jiaotong University
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What is This?
Original Article
Abstract
The rotation movement between bogie and carbody is studied using vehicle system dynamics theory and formulas for the
rotation resistance factor are derived for different air spring states. Laboratory tests are conducted and the obtained
results are compared with calculations. The rotation resistance factor for motor and trailer cars experiencing AW0 and
AW4 loading conditions when air springs are in inflated, deflated and over-inflated states are considered so as to validate
the proposed formulas and test and discuss error sources. The rotation resistance factor of the bogie is related to the
rotation angle and speed. The faster the rotation speed, then the greater is the rotation resistance factor. The greater the
rotation angle, then the greater is the rotation resistance factor. The maximum rotation resistance factor is 0.094 for a
trailer car at a rotation speed of 1 deg/s and experiencing AW0 loading conditions and with the air springs in the deflated
state. The maximum rotation resistance factor when the air springs are deflated is much greater than that when the air
springs are in the inflated state for a rotation speed of 1 deg/s. The maximum rotation resistance factor obtained at a
rotation speed of 1 deg/s is much greater than the one obtained at 0.2 deg/s. The over-inflated state of air springs has
little influence on the rotation resistance of the bogie. The calculated results obtained when considering air springs in
inflated and over-inflated states are slightly smaller than test results with a maximum difference of 0.02. For the deflated
state of the air springs, the calculated and test results for a trailer car are equivalent and the calculated results are slightly
larger than the test results for a motor car with a maximum difference of about 0.02. The theoretical formulas should
consider the dynamic nature of stiffness properties and damping effect of air springs. The effects of other suspension
components should also be considered. A laboratory test or field test after assembly is an essential requirement. The
comparison of test and calculated results validates the proposed formulas and allows sources of error to be discussed.
Keyword
Bogie rotation resistance; theoretical calculation; laboratory test; rotation angle; rotation speed; air springs; deflated;
inflated; over-inflated
load-sensitive dampers that display friction effects and tow-axle passenger vehicle were reported by Huang
rubber bushings that display hysteresis effects. The and Wang16 and Simson and Brymer.17 However
combination of these components allows valid and these papers did not present calculation formulas
sophisticated modeling methods and techniques that and tests for air springs in an over-inflated state and
can yield accurate results. A test procedure and evalu- different rotation speeds.
ation indicators of rotation resistance of a bogie that This paper presents theoretical formulas for bogie
are based on the standard EN143632 have been dis- rotation resistance for air springs in deflated, inflated
cussed by Julian and Evert.3 However, only the basic and over-inflated states. A laboratory test is con-
specifications for laboratory or field tests are pre- ducted and its results are compared with the results
sented and no discussion about error sources or con- obtained in theoretical calculations. The bogie rota-
sideration of tests at different air spring states is tion resistance factor for a motor and a trailer car
presented. under AW0 and AW4 loading conditions at different
The force distributions for three-piece bogies of a air spring states are summarized to validate the pro-
freight car at various load conditions have been ana- posed formulas and test and discuss error sources.
lyzed by Simson and Pearce4–6 and Simson and
Brymer.7 The influences of rotation resistance of a
bogie on wheel/rail contact and wear on curves were
Dynamics model of a railway vehicle
discussed. The greater the rotation resistance, then the The model of the dynamics of the railway vehicle is
higher is the wheel/rail wear. Bogie rotation resistance shown in Figure 1. KS and CS are the stiffness and
was modeled in order to account for uneven loading damping of the secondary suspension system, respect-
effects in track curve transitions. The design of tran- ively, KP and CP are the stiffness and damping of the
sition curvature and the lubrication of rail and center primary suspension system, respectively. 2aþ is the
bearings or side bearers can be used to reduce the high bogie’s wheel base and 2a* is the distance between
wheel/rail wear in three-piece bogies caused by high the centers of two bogies. The relation of the rotation
bogie rotation resistance. resistance torque and rotation angle for a bogie can be
Emereole et al.8 pointed out that there is a very described as shown in Figure 2 provided that the non-
strong correlation between wear and the average linear properties of the suspension system are ignored.
absolute angle of attack of the wheelset. The total M represents the rotation torque between the carbody
wear on the wheels increases with center bearer fric- and bogie, represents the rotation angle and K rep-
tion level. An extensive simulation-based parametric resents the rotation stiffness between the bogie and
study was performed to determine the effects of vary- carbody. The bouncing and pitching movements of
ing side bearer type, center bearer friction level, the carbody are considered while other degrees of
wagon load conditions and speed on the wear charac- freedom are constrained.
teristics of the wheelset.
Wu et al.9 and Wu and Robeda10 pointed out that
a vehicle will exhibit significantly shortened wheel Theoretical calculation of the rotation
maintenance cycle times as a result of a high bogie resistance of a bogie
rotation resistance being retained into the curve and
Definition of rotation resistance factor
high wheelset angles of attack on the leading bogie.
These insights were obtained from vehicle dynamics The rotation resistance factor is used as an index to
simulations performed using the software package measure rotation resistance. It can be expressed as
VAMPIRE. Wear rates can be accelerated due to
the negative impact high angles of attack have on M
X¼ ð1Þ
gauge face lubrication. Bogie warp and wheelset 2Q0 2aþ
angles of attack retained in constant radius curves
are affected by lateral forces such as coupler angle where X is the rotation resistance factor for a bogie,
train forces. M is the rotation resistance torque (unit: kN-m),
The longitudinal stiffness created by the friction
effects of center and side bearers contribute to the
rotation resistance of a bogie on a freight car and
thus reducing the distance between two side bearers
can reduce the extent of the rotation resistance.11,12
The operating movements of a rail vehicle during its
transition around a curve was analyzed by Lacker.13
Katta and Conry14 studied the dynamic stiffness of
the center bearer of a freight car and presented a
damping model and Toyofuku et al.15 studied the
dynamic properties of air springs. A test procedure
and evaluation indicators for rotation resistance of a Figure 1. Model of the dynamics of the railway vehicle.
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Shi et al. 3
KSX Horizontal stiffness of air springs when deflated kN/m 62.5 134.5 59.8 141.5
KSX Horizontal stiffness of air springs when inflated kN/m 149 182 152 188
KSX Horizontal stiffness of air springs when over-inflated kN/m 169 212 172 218
2Q0 The average axle load of the test bogie kN 103 175 90 171
W Vertical load on air springs kN 62.5 134.5 59.75 141.5
Shi et al. 5
turntable using the same rotation speed and angle 4. Calculate the rotation resistance factor X using
as in the bogie’s rotation resistance test, so that the equation (1).
initial resistance and inertia of turntable were 5. Repeat steps 1 to 4 under different rotation speeds
obtained. (0.2 and 1 deg/s).
F0 / kN
F0/ kN
0.0 0.0
-0.1
-0.1
-0.2
A1 A2 A3
-0.3 -0.2
0 10 20 30 40 50 60 0 2 4 6 8 10 12 14
time /s time /s
Figure 6. Time history of turntable rotation resistance force with rotation speed (a) 0.2 deg/s and (b) 1 deg/s.
(a) 6 (b) 15
4 10
M1 /(kN·m)
2 5
F1 / kN
0 0
-2 -5
-4 -10
-6 -15
30 40 50 60 70 80 90 100 -1.0 -0.5 0.0 0.5 1.0
time /s θ /(°)
Figure 7. Rotation resistance of the bogie when air springs are in inflated state (a) time history of the bogie’s rotation resistance
force and (b) resistance torque as a function of rotation angle.
(a) 6 (b) 15
4 10
M1 /(kN·m)
2 5
F1 / kN
0 0
-2 -5
-4 -10
-6 -15
30 40 50 60 70 80 90 100 -1.0 -0.5 0.0 0.5 1.0
time /s θ /(°)
Figure 8. Rotation resistance of the bogie when air springs are in over-inflated state (a) time history of bogie’s rotation resistance
force and (b) resistance torque as a function of rotation angle.
(a) 6 (b) 15
4 10
M1 /(kN·m)
2 5
F1 / kN
0 0
-2 -5
-4 -10
-6 -15
50 60 70 80 90 100 110 120 -1.0 -0.5 0.0 0.5 1.0
time /s θ /(°)
Figure 9. Rotation resistance of the bogie when air springs are in deflated state (a) time history of bogie’s rotation resistance force
and (b) resistance torque as a function of rotation angle.
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Shi et al. 7
characteristic occurs for the deflated state compared Tables 3 and 4 show the rotation characteristics of
with the behavior of the inflated and over-inflated a trailer car in AW0 and AW4 loading conditions,
states. This is mainly a result of the friction damping respectively. Tables 5 and 6 show the rotation char-
effect of the sliding plate. The bogie’s maximum rota- acteristics of the motor car in AW0 and AW4 loading
tion resistance factor is 0.094 for a trailer car in AW0 conditions, respectively.
loading in the deflated state. However, the bogie’s Table 7 shows a summary of the test results on the
rotation resistance factor of the motor car and trailer bogie’s rotation resistance factor. First, the results
car are nearly the same. show that the bogie’s rotation resistance factor at
Trailer bogie tare load Symbol Deflated Inflated Over-inflated Deflated Inflated Over-inflated
Trailer bogie heavy load Symbol Deflated Inflated Over-inflated Deflated Inflated Over-inflated
Motor bogie tare load Symbol Deflated Inflated Over-inflated Deflated Inflated Over-inflated
Motor bogie heavy load Symbol Deflated Inflated Over-inflated Deflated Inflated Over-inflated
the speed of 1 deg/s is much bigger than the result which is much larger than air damping, so the deflated
at the speed of 0.2 deg/s. Thus, it can be concluded state is worse than the inflated and over-inflated
that the bogie’s rotation resistance factor is related states. The maximum rotation resistance factor is
to the rotation speed. The faster the rotation speed, 0.094 for a trailer car under the AW0 loading condi-
then the greater is the rotation resistance factor. This tion and the air springs in the deflated state. However,
is mainly caused by the dynamic stiffness property of the rotation resistance factors of the motor car and
the air springs, i.e. the faster the moving speed the trailer car are nearly the same.
greater is the stiffness, which directly affects the rota- Comparing the test results in Table 7 and theoret-
tion resistance of the bogie. ical calculation results in Table 2, the test results at
In addition, the results show that there is little dif- the rotation speed of 1 deg/s are larger than the test
ference between air springs in the inflated and over- results at 0.2 deg/s and the calculated results. As the
inflated states which indicates that over-inflation has theoretical calculation did not consider the effect of
little influence on the rotation resistance of the bogie. rotation speed, a comparison between the theoretical
However, the results show that there is a major calculation results and laboratory test results at the
difference between air springs in the inflated and rotation speed of 0.2 deg/s is presented in Table 8. The
deflated states at the rotation speed of 1 deg/s; the following conclusions can be drawn.
deflated state of air springs has a significant effect
on the rotation resistance. This is mainly a result of 1. In the inflated and over-inflated states of the air
the friction damping effect created by the sliding plate springs, the calculated results are slightly smaller
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Shi et al. 9
than the test results with a maximum difference of springs, the calculated and test results for the
0.02 for the AW4 loading case. This is due to the trailer car are equivalent and the calculated
point that the theoretical formulas ignore the results are slightly larger than the test results for
dynamic nature of the stiffness of air springs at the motor car with a maximum difference of
different rotation speeds and also the influences about 0.02.
of vertical loading and other suspension compo- 6. The theoretical formulas should consider the
nents are not considered. It can be concluded that dynamic nature of stiffness properties and damp-
a laboratory test or field test after assembly is ing effect of air springs. The effects of other sus-
essential. pension components should also be considered.
2. In the deflated state of the air springs, the calcu- A laboratory test or field test after assembly is
lated and test results are equivalent for the case of an essential requirement.
the trailer and the calculated results are slightly 7. The comparison of test and calculated results val-
bigger than test results for the motor car with idates the proposed formulas and allows sources
maximum difference of about 0.02 which may be of error to be discussed.
due to friction effects that are related to the load-
ing and the speed of the sliding plate.
Funding
This work was supported by the Railway Ministry Science
& Technology Development Project (grant 2012J006-B), the
National Science & Technology Pillar Program (grant
Conclusions 2009BAG12A01), the National Basic Research Program
of China (grant 2011CB711100), and the National Science
The rotation movement between bogie and carbody is & Technology Pillar Program (grant 2011BAG05B04).
studied using vehicle system dynamics theory and for-
mulas for the rotation resistance factor are derived for
different air spring states. Laboratory tests are con- References
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