Bogie test rig allgemein Druckversion - THCE

March 2004 Ruben Siegmund Inova GmbH Page 1

Servohydraulic Testing Systems

Inova componentsfor Bogie Test Rig

Dipl.- Ing. Ruben Siegmund, Inova GmbH


Examples of Bogie test rigsThyssen Transrapid at Kassel


Thyssen Transrapid at Kassel

Examples of Bogie test rigs


DWA / IFS / Bombardier / RST at Berlin

Examples of Bogie test rigs


Examples of Bogie test rigsDWA / IFS / Bombardier / RST at Berlin


Principle of Bogie test rigs

Main parts which could be done by Customer

– Civil engineer work– Power supply – Seismic mass– T-slot table– Portal frame with crossbeam– Mounting brackets– Attachment between bogie and rig

Main parts must be done by Inova– Linear actuators with accessory – Hydraulic power pack system– Hydraulic Distribution System– Hydraulic Control Stations– Digital measuring an control system– Project design and management– Installation and training


600

800

10000

5000



1900

5000



Concrete design of a Bogie test Lab

Test area

Special Labs

Power pack room

preparation area

Central line control station

stockroom


Recommended components• First of all - skilled engineers• hydraulic actuators with high accuracy load cells• backlash free joins• adequate oil supply• adequate tube system• adequate t-slot table• adequate Portal frame with crossbeam• flexible Control Electronic with Test and evaluation

software• powerful data acquisition system• Attachment between bogie and rig


Linear actuator• Hydrostatic bearing linear

actuators series AH

• Nom. Load from 3kNup to 2500 kN

• Nom. stroke:20 mm up to 400 mm


hydrostatic bearing

• wear and tear free

• friction free operation

• optimal control property

• high side load capacity

• suitable with permanent high speed

• maintenance free


Load cell series KA• high accuracy class 0,1

• low influence of the side load to the measured signal (< 0.02% at Fq=0.1*Fnom)

• high stiffness

• high own frequency

• easy mounting


Cardan Joints Series JC

• free from backlash

• working angle +/- 8°

• low friction

• less maintenance work (only smear)

• long live time


Hydraulic Power Packs Series HU• hydraulic Power Packs Series HU

• adjustable pressure (nominal pressure 280 bar)

• usage of controlled pumps

• expandable flow by connection of several power packs

• several types of power pack remote control

• long life time

• flow rate from 6.3 up to 345 l/min

March 2004 Ruben Siegmund Inova GmbH Page 15 a

Hydraulic Power Packs Series HU• hydraulic Power Packs Series HU

• adjustable pressure (nominal pressure 280 bar)

• usage of controlled pumps

• expandable flow by connection of several power packs

• several types of power pack remote control

• long life time

• flow rate from 6.3 up to 345 l/min


Safety Start-Stop Valves Series PB• safety Start-Stop Valves Series PB

• high pressure mode up to 315 bar

• low pressure mode 10 up to 100 bar

• restricted flow between 2l/min and 25 l/min in low pressure mode

• modular concept with flow rates of:63, 130, 250 and 630 l/min


Digital Controller Series EU2000D

• Digital control and measure system• Flexible configuration from one up to eight channels• Multi channel, multi station concept• Configuration as 19“ rack or as central unit with peripheral

controller boxes


Digital Controller Series EU2000D

Carrying out as:

-Field box

-PC-control cabinet

-Full size control cabinet


Software LabExpert

• User interface to the digital controller EU2000D

• Comprehensive base functionalities:• - Block programming,• - Peak value controller• - event triggered test run schedule

• Modular extensible:• - Iterative outer loop control• - Damper testing• - elastomer testing• - LCF Test• - command value generation out of

classification tables• - Import- Export of the main Data Formats


Software LabExpert• easy definition of loading blocks


Software LabExpert• Building of test sequenz

10*(5*(10*M1+M2)+M3)

• Schleife1=10*M1• Schleife2=5*(S1+M2)• Schleife3=10*(S2+M3)


Iteration software ITFC / ITRM• Time or frequency based

iteration software

• system identification by sweep signals (frequency bases) dynamic stiffness of specimen (time based)

• Screening of convergence and iteration quality


Iteration software ITFC / ITRM• Principle function of iteration

software


Iteration software ITFC / ITRM

LabExpert ITRM

TCP/IP


Iteration software ITFC / ITRM• First test run


Iteration software ITFC / ITRM• Result after 4 iteration steps


100 102 104-5

0

5

10

100 102 104-4

-2

0

2

4

100 102 104-4

-2

0

2

4

100 102 104-20

-10

0

10

20

100 102 104-4

-2

0

2

4

100 102 104-5

0

5

100 102 104-20

-10

0

10

20

100 102 104-4

-2

0

2

4

100 102 104-5

0

5

10

Fx Fy Fz

M1

M2

M3

Level Crossing Plot overview

target signalmeasured signalwithout iteration

Example of results


• Signal M1• Achse Fx

Example of results

450 450.2 450.4 450.6 450.8 451 451.2

-2

-1

0

1

2

3

4

5

6

time[s]

load

[kN

]

Time Plot m1-kraft-x

m1-kraft-x - target.gdtm1-kraft-x - response-1.gdtm1-kraft-x - response.gdt

100

101

102

103

104

-4

-2

0

2

4

6

8

10Level Crossing Plot m1-kraft-x/

Number of level crossings

Load

[kN

]



• Signal M2• Achse Fx

Example of results

189.8 190 190.2 190.4 190.6 190.8 191

-10

-8

-6

-4

-2

0

2

4

6

8

10

time[s]

load

[kN

]

Time Plot m2-kraft-x


100 101 102 103 104-15

-10

-5

0

5

10

15Level Crossing Plot m2-kraft-x/


Load

[kN

]



• Signal M2• Achse Fz

Example of results

73.6 73.8 74 74.2 74.4 74.6-6

-5

-4

-3

-2

-1

0

1

2

3

4

5

time[s]

load

[kN

]

Time Plot m2-kraft-z

m2-kraft-z - target.gdtm2-kraft-z - response-1.gdtm2-kraft-z - response.gdt

100 101 102 103 104-5

-4

-3

-2

-1

0

1

2

3

4

5Level Crossing Plot m2-kraft-z/


Load

[kN

]

m2-kraft-z - target.gdtm2-kraft-z - response-1.gdtm2-kraft-z - response.gdt


What must be check for a quote

• analyse the quantity and time schedule of tests which must be doneresult will be: the right lab design

• analyse your experience with servohydraulicresult will be: the right quote design

the right number of actuators in the first step

• analyse your experience in bogie testresult will be: the consulting service needs

the education and training needs


Servohydraulic Testing Systems

Inova GmbHFürstbischof-Rudolf-Straße 10D - 65385 Rüdesheimphone +49 6722 / 97 22 65fax +49 6722 / 97 22 67 [email protected]

Documents

Bogie test rig allgemein Druckversion - THCE