Modular Railway Testing Plant for Curve Simulation
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Solution Overview
Problem
Current methods for testing the driving properties and operation safety of railway vehicles, particularly on warped rails and curved tracks, are inadequate in terms of safety, accuracy, and universality, failing to meet European standards and being unsuitable for various types of rail tracks.
Innovation Solution
A modular testing plant comprising A-, B-, and C-type mobile modules with adjustable wheel sets, force sensors, movement sensors, and hydraulic mechanisms, allowing for precise measurement of vertical forces and simulation of rail tilting, enabling testing on different wheel gauges and curved tracks without requiring transportation to a laboratory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If simple universal test devices and jigs are used, then the device complexity is low, but the measurement precision and reliability are insufficient
Solution Approach 1:
The testing plant is divided into multiple mobile modules (type A, B, C modules) that can be independently configured and assembled. Each module contains specific measurement and adjustment components, allowing the system to be scaled and customized based on testing requirements while maintaining modularity and ease of deployment.
Solution Approach 2:
The testing plant is designed as a universal system capable of testing various types of railway vehicles (rail, tram, underground vehicles) with different wheel gauges. The mobile modules can be reconfigured for different testing scenarios including curve simulation, warped rail testing, and resistance measurement, eliminating the need for multiple specialized devices.
2Adaptability or versatility
If complex specialized test devices are used for individual test areas, then the measurement precision improves, but the device complexity increases and universality decreases
Solution Approach 1:
The testing plant uses standardized mobile modules that can be universally applied to different railway vehicle types. The modules incorporate adjustable components (wheel brackets with gauge adjustment, removable adapters) that allow the same hardware to test rail vehicles, trams, and underground vehicles without requiring specialized dedicated equipment for each vehicle type.
Solution Approach 2:
The testing plant incorporates dynamically adjustable components including hydraulic cylinders for vertical movement, rotating binders for curve simulation, and adjustable wheel brackets. These dynamic elements allow the system to adapt its configuration for different testing scenarios and vehicle types, providing versatility without requiring multiple fixed specialized devices.
3Reliability
If traditional test methods are used, then the ease of operation is maintained, but the reliability and safety of the test are not satisfactory
Solution Approach 1:
The testing plant incorporates force sensors and movement sensors that provide real-time feedback on the testing process. The control computer receives data from these sensors and can monitor and adjust the testing parameters to ensure safety and reliability. This feedback mechanism allows the complex system to be controlled safely through continuous monitoring and automated adjustment.
Solution Approach 2:
The testing plant uses mobile modules as intermediaries between the railway vehicle and the measurement system. These modules include protective elements and controlled interaction mechanisms that safely interface with the vehicle during testing. The modular design allows for controlled engagement and disengagement, enhancing safety while managing the complexity of the testing system.
4Measurement precision
If curve simulation is performed using travelling platforms or turning tables, then the measurement precision for curve testing improves, but the device complexity and loss of time increase
Solution Approach 1:
The testing plant uses a rotating binder mechanism that can dynamically adjust the simulated curve radius and angle. The hydraulic cylinders enable rapid positioning and adjustment of the binder rotation, allowing the system to quickly transition between different curve simulation scenarios without requiring time-consuming movement of heavy turning tables or platforms.
Solution Approach 2:
The curve simulation capability is integrated into the mobile modules rather than requiring a separate large-scale turning table or travelling platform. Each module can independently perform curve simulation, allowing for parallel testing and reducing the time required to position and configure the testing system for curve measurements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular testing plant provides accurate and safe measurements, meeting European standards, and allows for universal testing on various rail types, optimizing safety and operation of railway vehicles without the need for laboratory transport, facilitating compliance with SN EN 14363 standards.
Implementation Method 1
two movable wheel brackets connected via two hydraulic cylinders and setting mechanism
Data Source
AI summary
The testing plant for stationary tests of railway vehicles consists of a mobile module of turning plate (101) consisting of the turning plate (102) fixed on the travel (103) and fitted with at least two adjustable wheel brackets (104) and at least one rotating hydraulic mechanism (105) and of mobile modules of twisting plant (106) and (107), where each of them consists of the main frame (108) fitted with four independent travelling wheels (109) and two vertically adjustable wheel brackets (110) connected via two lifting members (111) and setting mechanism (112) and it is furthermore fitted at least two load sensors (113) and at least two movement sensors (114), furthermore, it is fitted with at least two adapters (115) either lateral and/or longitudinal fitted to the wheel brackets (110). The mobile module of the turning table (101) consists of the travel frame (1) with radial bearing (2) installed axially on it, also with the turning table runner (3) to which at least two binders (4) are attached to which at least two wheel brackets (5) are installed, wherein the fork (8) fixed to the travel frame (1) has hydraulic cylinder (7) installed on one end and the other end has hydraulic cylinder (7) in the fork (9) attached on the turning table runner (3). The procedure of the tests is controlled using software application installed on the control computer, where the movement is controlled using curves - pre-defined sequences that give direction of the movement and change to path or angle of rotation of the binder depending on time during which the track change and movement speed should occur, whereas the control system allows controlling of multiple modules at the same time, which is synchronized module control, and the position, path of individual wheel brackets or angle of rotation of the binder is displayed on the monitor of the control computer during their movement, whereas the curve operation starts by clicking on relevant button of the control panel shown on the control computer monitor and during the curve operation, the movement can be continuously controlled using the controls on the control panel and during the curve operation, the monitor displays also force values measured on the load gauges of the controlled module, whereas measurement data is saved in the measurement computer memory for further processing.