Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - RUN2Rail (Innovative RUNning gear soluTiOns for new dependable, sustainable, intelligent and comfortable RAIL vehicles)

Teaser

The development of a new generation of running gear is pivotal to the achievement of the ambitious goals set by Shift2Rail for future European trains, encompassing the substantial reduction of life cycle costs, improved reliability and energy efficiency, the reduction of noise...

Summary

The development of a new generation of running gear is pivotal to the achievement of the ambitious goals set by Shift2Rail for future European trains, encompassing the substantial reduction of life cycle costs, improved reliability and energy efficiency, the reduction of noise emissions and of other externalities and the achievement of full interoperability of the rolling stock. Therefore, the challenge for Shift2Rail is to build a Running Gear Technology Demonstrator (TD1.4) that paves the way for the next generation of passenger rail vehicles being light, quiet, reliable, easy-to-manufacture and with a favorable Life-Cycle-Cost.

The aim of the RUN2Rail project is to identify and develop the key methods and tools that are required to allow the design and manufacture of this next generation of running gear. In this regard, RUN2Rail aims at exploring an ensemble of technical developments for the future running gear, by implementing a coordinated set of research activities addressing four work streams:

1) innovative sensors & condition monitoring,
2) Optimised materials & manufacturing technologies,
3) Active suspension & control technology,
4) Noise & vibration.

These activities also include the development of case studies derived from the methods and tools elaborated in the project.

Furthermore, the four thematic Work Streams are not seen as developing separately, but rather as modules that are run in strong interaction, exploiting cross-fertilisation between different fields of technology and fully considering the interrelations that are inherent in the four Work Streams. A cross-cutting Work Stream ‘Impact Management Support and Assessment’ evaluates the impacts for the new technologies explored in the thematic Work Streams and looks into aspects related with the authorisation of vehicles with innovative components.

Work performed

The work performed during the first 12 months of the project in each Work stream, with the main results achieved so far, is described below:

WS1 - Innovative sensors & condition monitoring
• A modular, flexible architecture was designed for the on-board CM system enabling the integration of state-of-the-art technology for sensors, processing units, data storage, communication and power feeding devices.
• A detailed set of requirements for the complete condition monitoring hardware was defined in terms of the number and position of the sensor nodes required for each case study, performances expected from the sensor nodes, conditioning and acquisition of signals, data processing and storage, power supply. Operational requirements for the condition monitoring system were defined as well.
• A review of existing technology was completed to identify suitable hardware for the condition monitoring system, with a focus on smart sensors and smart components with embedded self-diagnosing capability;
• Work has started to define data processing techniques for the three case studies envisaged in the project, in order to define data processing techniques to extract condition monitoring information from the measurements.

WS2 - Optimised materials & manufacturing technologies
• In order to define the performance requirements of the subsystem and evaluate the most appropriate solution, standards have been reviewed and assessment methods proposed with consideration for each of the key subsystems in the vehicle which can influence the running gear performance. Simulation models of the two Run2Rail concept vehicles have been set up and sample load cases produced.
• Initial studies into the possible new materials and manufacturing methods have been carried out and initial concept designs have been proposed.

WS3 – Active suspensions & mechatronics
• In order to perform a comprehensive assessment of off-the-shelf technology for active control, technical information on a large number of actuators has been gathered and documented. A level of maturity matrix and technical validation matrix have been developed as guideline for choosing actuator technology.
• Actuator technology used in especially aviation and in road vehicles has been investigated and judged with regard to usability in rail vehicles to optimise the cost-benefit ratio.
• A concept for innovative single axle solution is under developed.
• Preliminary presentation of a concept based on three levels of safety cases to propose an authorisation strategy for active suspensions

WS4 – Noise & Vibration
• Laboratory measurements to characterise the behaviour of suspension elements (primary suspension spring, lateral damper and traction bar) have been successfully completed. The development of a comprehensive methodology for predicting the transmission of noise and vibration from the running gear to the carbody has been partially achieved through the development of models for both structure-borne and airborne noise.
• Extensive field measurements were carried out at Metro de Madrid in March 2018 into the noise and vibration behaviour of a test vehicle.

Final results

The project contributes to the four main objectives for Innovation Programme 1 – Cost efficient and reliable trains: increase the physical capacity of vehicles, reduce the travel disruptions for passengers by increasing operational reliability and availability of vehicles, reduce life cycle cost of the vehicle, and increase energy efficiency of the vehicle and reduce vehicle mass. Specific results encompass the exploration of new vehicle architectures made possible by the use of innovative materials and mechatronic suspensions, new concepts for advanced condition monitoring systems, tools for analysing noise and vibration transmission from the running gear to the carbody and the assessment of technologies for the reduction of interior noise.

The final outcome of the project will be a comprehensive set of technology concepts, which will altogether provide a scenario and a starting point for the design of future running gear generations with substantially improved performances. Benefits are expected under various respects: the use of novel running gear, materials, manufacturing techniques and sensors will result in low cost and high reliability railway vehicle operation. the use of 3D printing of components and advanced composite manufacturing techniques will allow significantly reduced vehicle mass and more flexibility in the production process. Active suspension, steering and reduced un-sprung mass will result in reduced wheel rail forces and thus reduced maintenance cost both for the vehicle itself and the infrastructure.
Finally, suggestions for R&S documents – essentially for TSIs and EN standards - are expected from all thematic Work Streams; impacting significantly the process of verification of rolling stock required by the targeted TSIs LOC&PAS, WAG and NOI.

Website & more info

More info: http://www.run2rail.eu.