12/04/2018

1

ADVANCES IN TESTING ROLLING STOCKBy Don Skerman

Formerly with Queensland Railways/Aurizon

Thursday 12th April 2018

TESTING IN 1980’S. MONITORING AND RECORDING EQUIPMENT IN TEST CAR (FM TAPE RECORDERS, CHART RECORDERS, ANALOGUE RIDE INDEX METERS, VIDEO)

12/04/2018

2

SECTION OF “ROUGH TRACK” SELECTED FOR INSTRUMENTED TESTS BASED ON TRACK RECORDING CAR DATA

ISSUES

Suitable track not always available when needed

Track may have high Track Condition Index (statistical measure of roughness) but no isolated irregularities near reporting limits

No jointed track suitable for axle load of new coal wagons loaded to their service mass

Cyclic irregularities can develop quickly in tracks with similar heavy wagons running at consistent speeds

Any cyclic irregularities may not be negotiated at critical speed

Rail head profile on favourite hunting test track sections ground more frequently than more remote sections of track on high speed routes (particularly outside Queensland)

Ride Index averages out response to isolated irregularities in track

Acceptance limits not defined

12/04/2018

3

DEVELOPMENT OF STANDARDS

ROA Roadworthiness Acceptance Tests in 1989

(which later became Section 3 of the ROA Manual of Engineering Standards and Practices published in 1991)

Based on parts of AAR Specification M-1001 Chapter XI, Service-Worthiness Tests and Analyses for New Freight Cars and NSW twist test

Static twist test, P2 force calculation, on-track tests for Hunting, Pitch & Bounce, Curve Stability (also some structural tests)

Not all tests representative of Australian conditions, particularly 1067 mm gauge track

FEBRUARY 1998 - DERAILMENT OF LOADED COAL TRAIN DESCENDING CONNORS RANGE AT 32 KM/H

12/04/2018

4

TESTING OF LOADED COAL WAGON OVER DERAILMENT SITE MEASURING SPRING DISPLACEMENTS

CONTROLLED TEST USING TAMPING MACHINE OR PACKING OF RAIL TO FORM HUMPS AT BOGIE CENTRE SPACING “V”

12/04/2018

5

VIDEO OF TESTS ON LATER (HIGHER CG) WAGONS AT 20, 25, 30, 40, 60 KM/H

KLEX WAGON (11 M BOGIE CTRS) – DERAILMENTS WHILE EMPTY ON 12.2 M RAILS WITH EQUAL

STAGGER JOINTS. NOT KOJX (9 M CTRS)

12/04/2018

6

QR SAFETY MANAGEMENT SYSTEM STANDARD STD/0026/TEC“ROLLINGSTOCK DYNAMIC PERFORMANCE” – ISSUED 2001

Track irregularities for testing based on the “d1” track recording reporting level requiring assessment within 24 hours of detection

Isolated irregularity tests with top and versine irregularities at 120% d1, combination irregularities added later

Cyclic irregularity test with humps at bogie centres, height 67% d1 originally, later revised to 40% d1

Additional cyclic irregularity test for curve entry with misaligned cant ramp and transition

Hunting test similar to ROA

Static twist test modified for QR track and Rotational Resistance included for “Transition Curve Negotiation”

P2 force calculation modified for QR track, limits specified for Lateral and Vertical Wheel/Rail forces and Track Shifting force

Rollover test and static test for interference with structures

INTERFERENCE WITH STRUCTURES DUE TO LOW ROLL AND/OR LATERAL SUSPENSION STIFFNESS

12/04/2018

7

IMPROVEMENTS TO TWIST TEST METHOD AND EQUIPMENT (LEAD WHEELSET ON PORTABLE TRAIN

WEIGHER, HYSTERESIS GRAPH)

0

1000

2000

3000

4000

5000

6000

-100 -80 -60 -40 -20 0 20 40 60 80 100

Jacking Left Side : Jacking Right Side

Whee

l Lo

ad (kg

)

LeftWheel -Jackingleft

RightWheel -Jackingright

LeftWheel -Jackingright

RightWheel -Jackingleft

Left wheel starting load.

Right wheel starting load

The measured load on the left wheel when the rolling stock has been raised on the right hand side to the maximum height.

Wheel load remaining on the right wheel when the rolling stock has been raised on the right hand side to the maximum height.

The measured load on the right wheel when the rolling stock has been raised on the left hand side to the maximum height.

Wheel load remaining on the left wheel when the rolling stock has been raised on the left hand side to the maximum height.

AS7509 ROLLING STOCK DYNAMIC BEHAVIOUR – PUBLISHED 2009, REVISED 2017

Most tests for 1067 mm gauge based on QR STD/0026

Additional tests and criteria added for 1435 mm and 1600 mm track

Shapes of irregularities better defined

Base Ride Acceleration, clearance checks for horizontal and vertical curve negotiation, wind loads included

AS7508 published for Track Forces and Stresses

Enhanced criteria included for verification of computer modelling and exemption from testing

Recognition of importance of effective conicity of wheel and rail profiles for hunting tests

Related to RISSB Hazard Register

12/04/2018

8

MORE REALISTIC TWIST TEST CRITERIA FOR STANDARD GAUGE ROLLING STOCK

IMPLEMENTED JANUARY 2014 FOLLOWING ANALYSIS OF TRACK RECORDING CAR DATA

EFFECT OF RAIL PROFILE ON EFFECTIVE CONICITY AND HUNTING

Critical speed for hunting of FQAY wagon

0

20

40

60

80

100

120

140

0 0.05 0.1 0.15 0.2 0.25

Equivalent Conicity y=3

Sp

eed

km

/h

WPR 2000 onground rail

worn ANZR-1 on worn rail

WPR 2000 on worn railworn ANZR-1

on ground rail

new ANZR-1 on ground rail

Partly worn ANZR-1 wheel

12/04/2018

9

COMPUTER MODELLING (NUCARS, VAMPIRE ETC)

Purpose built software for rail vehicles and track

Suitable connection elements between component masses to describe non-linear stiffness and damping characteristics

Must cater for wheel to rail interaction non-linearities

Commonly used as part of the design process

Highly desirable to reduce the number of physical tests

Simulate response to defined track geometry irregularities without the difficulty in obtaining track with suitable defects

Allow wheel to rail forces and derailment potential to be predicted without expensive instrumented wheelsets

Physical testing necessary to validate key elements of the vehicle simulation model and confirm the parameters used

VALIDATION OF COMPUTER MODELS

12/04/2018

10

VALIDATION OF COMPUTER MODELS – HARMONIC ROLL TEST

OMITTED FROM 2017 REVISION OF AS7509 - MUST NOW BE OBTAINED FROM THE RAIL INFRASTRUCTURE MANAGER(S) FOR THE RAILWAY NETWORK(S) WHERE THE ROLLING STOCK IS TO OPERATE

12/04/2018

11

UNATTENDED DATA ACQUISITION, AUTO DOWNLOADING

CHECKING WAGON PERFORMANCE OVER ENTIRE ROUTE, TRACK CONDITION MONITORING

12/04/2018

12

QUESTIONS ?