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A Toolkit for Simulating Mechatronics in Railway Vehicles
Heinz-Peter KotzSiemens TS HR BG EN
Copyright (C) Siemens AG 2003. All Rights Reserved.
Siemens TS Development Centers
Software & Electrical components
UerdingenTS LRTS TR
ErlangenTS GT E
MünchenTS LM
GrazTS HR BG
GT EMarkus GaudenzAchim DegenhardtWolfgang Fetter
Simulation & Mechanical components
HR BG Andreas HaigermoserChristian BrandstätterHeinz-Peter Kotz
LMWerner BreuerYu MinyiTim Weigel
LRHelmut NetterMichael Seibert
TRRoger GansekowKaspar Schröder
Copyright (C) Siemens AG 2003. All Rights Reserved.
Motivation
Old approach: Designing electrics & mechanics independently
•Drive train vibrations•Vehicle vibrations•Instable behaviour of controllers
non-optimal system design
New approach I: Simulating complete railway vehicles
•Full mechanical SIMPACK-model (200 DOFs)•Low-level implementation of controller-software•Emulation of controller-hardware
too complex, problems withusability & maintainability
New approach II: User friendly toolkit
•Providing building blocks of different complexity•Building electrical components in MATLAB/SIMULINK•Providing various simulation-methods•Comfortable simulation-environment•Automatic creation of simulation-models •Automatic simulation & post-processing
Copyright (C) Siemens AG 2003. All Rights Reserved.
Aims
1. Validated know-how on simulation methods for• Drive train vibrations < 100 Hz
• Vehicle vibrations caused by interaction of mechanics & electrics
• Longitudinal dynamics caused by interaction of mechanics & electrics
• Partitioning of Power & Torque within groups of engines
2. Development of tools• Extended friction laws
• Models for gear units
• Models for metal-rubber-elements
• Models for tachometer generators
3. User-interface
• High usability & maintainability
• Automatisation of standard simulation scenarios
Copyright (C) Siemens AG 2003. All Rights Reserved.
Structure of the Toolkit
SubsystemMechanics
Incr
easi
ng C
ompl
exity
Subsystem Electrics
Incr
easi
ng C
ompl
exity
Co-Simulation
Optimization
Assessment & Evaluation
Post-Processing
Copyright (C) Siemens AG 2003. All Rights Reserved.
Building blocks: Mechanics
Platform:
Wheelset
•Frame with 1DOF•Drive train as rotator chain•Primary suspension & guidance
Bogie
•Frame with 6 DOF•Drive trains as rotator chains•Primary suspension & guidance
Vehicle
•All configurations up to 4 motors
Copyright (C) Siemens AG 2003. All Rights Reserved.
Building blocks: Electrics
Platform:
Level I – Traction control unit• Set values (traction force, wheel slip, intermediate circuit voltage)• Slip and acceleration control (PI-controller)• Direct feed-through of torque set value
Level II - Level I + motor dynamics• Differential equations for induction machine (4th order ODEs)• Up to four induction machines in parallel at one converter• Magnetic flux and torque control (field orientation)
Level III - Level II + tachometer generator dynamics• Simulation of incremental encoder with toothed wheel• Sample rate of measurement increasing with rotational speed
Copyright (C) Siemens AG 2003. All Rights Reserved.
Coupling Electrics & Mechanics
SIMPACK stand-alone
SIMULINK stand-alone
•User routines
•Control loop
•Import of system-matrices
•Import of SIMULINK „symbolic code“
•Simple mechanics
•Import of system-matrices
•Import of SIMPACK „symbolic code“
LinearSystemAnalysis
Co-Simulation•SIMAT
•MATSIM
Nonlineartime domaincalculations
Copyright (C) Siemens AG 2003. All Rights Reserved.
Coupling: Co-Simulation
efficient modelling both in SIMPACK & SIMULINK
calculations in time domain
loss of performance
no linear system analysis
Copyright (C) Siemens AG 2003. All Rights Reserved.
Coupling: Linear System Analysis
efficient modelling both in SIMPACK & SIMULINK
powerful tools for linear system analysis
DuCxyBuAxx
+=+=&
changing the model requires re-export of matrices
automation not (yet) possible
Copyright (C) Siemens AG 2003. All Rights Reserved.
Extended Friction-LawsExtended Friction-Laws
-1 0 1 2 3 4 5 6 7 8-0.05
0
0.05
0.1
0.15
0.2
0.25
0.3
Friction-law from measurements:
µ decreases with increasing slip
Extensions needed In Kalker‘s theory (SIMPACK): No decrease of µ
Physical model
based on Haese und Menth [eb 5/96]
-25000.00
-20000.00
-15000.00
-10000.00
-5000.00
0.00
5000.00
10000.00
15000.00
20000.00
25000.00
-2.00 -1.50 -1.00 -0.50 0.00 0.50 1.00 1.50 2.00
s
Tx [N
]
37
1115
1923
12
34
5
0
0.1
0.2
0.3
0.4
vZug [m/s]
vg [m/s]
f(vg,
v Zug)
•Consideration of layer between wheel and rail
•Model is determined by the layer‘s physical properties
•State variables: Temperature, viscosity,...
•Extension: Dynamics (hysteresis)
reasing part
pirical parameters
r‘s theory
ν
f(ν)
•Correct description of the inc
•Decrease of µ covered by 2 em
Empirical extension of Kalke
Copyright (C) Siemens AG 2003. All Rights Reserved.
Simulation Environment
Requirements & Features
•Automatic model-generation from symbolic description
•Choice of different complexity levels for electrics & mechanics
•Definition of interfaces between Mechanics-Electrics
•Reproduceable simulations
•Automatic post-processing
Input (model description) Output (SIMULINK model)
Copyright (C) Siemens AG 2003. All Rights Reserved.
Simulation Methods
Linear system analysis
•Eigenvalues & eigenfrequencies
•Root locii & stability analysis
•Response plots
Non-linear time integration
•Acceleration scenarios
•Tracks: different topologies & irregularities
•Crossings & twists
•Different friction models
Variation of parameters
•Wheel-Rail-Contact
•Mechanical properties
•Controller settings
Copyright (C) Siemens AG 2003. All Rights Reserved.
Summary
Within a R&D-project Siemens TS developed a toolkit for simulating the effects based on
interactions between electrics & mechanics of railway vehicles with the following features:
Mechanics in SIMPACK
Hierarchy of objects: drive train – bogie – vehicle - train
Electrics in SIMULINK
Traction control unit + motor dynamics + tachometer generator dynamics
Coupling the systems
Co-Simulation SIMPACK – MATLAB (nonlinear time domain)
Export of ABCD-Matrices from SIMPACK (LTI analysis)
Additional Models
Extended friction laws, models for coupling elements (gear unit, metal-rubber-elements)
Simulation Environment
User-friendly interface, generates models for the needed level of complexity, automatic simulation & postprocessing