On-Track Qualification and Acceptance Testing
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1 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads On-Track Qualification and Acceptance Testing Mark Nordling APTA Rail Conference Philadelphia, PA June, 2013 TTCI/AAR, 1/10/2013. p1
2 Abstract Because it has been found that actual vehicle characteristics as assembled can vary considerably from the published design and measured individual components, the on-track assessment of safety, crashworthiness, ride quality, durability and derailment avoidance of conventional and high speed rail passenger equipment is a fundamental concern to regulators, vehicle designers and manufacturers, and rail operators. This is a review of the mandated and optional dynamic and static on-track testing currently in use for conventional equipment, and envisaged for high speed vehicles soon to be designed and manufactured. Also included is the accompanying role of simulation using validated mathematical models in the process. TTCI/AAR, 1/11/2013. p2
3 Consent Disclaimer Tests and projects discussed here were chosen as representative and illustrative of the types of work done by the Transportation Technology Center, Inc. Each is shown with the consent of the TTCI customer involved. TTCI does not disclose either the existence or results of any test or project without the express consent of the customer. TTCI/AAR, 1/11/2013. p3
4 What do we test? Structural strength and crash tests Braking and acceleration performance Noise and vibration Vehicle - Track Interaction and High Speed Stability Wheel Load Equalization and Static Lean Ride quality Endurance testing Fatigue Component tests TTCI/AAR, 1/11/2013. p4
5 FRA CFR Static Lean Test Load Cells TTCI/AAR, 1/11/2013. p5
6 Where do we test? Longitudinal Squeeze Test Test laboratories Revenue service track Dedicated test facilities Laboratories Test Tracks Manufacturers facilities Bus fatigue test on the Simuloader (SMU) TTCI/AAR, 1/11/2013. p6
7 What is the Role of Mathematical Modeling? Optimize vehicle designs prior to manufacture Develop test plans and extend the range of testing: Wider range of conditions, parametric variations, wear conditions Identify most important test conditions and locations for test instrumentation such as strain gages Extrapolate test results for items not measured such as Wheel/Rail forces Simulate conditions not possible to test such as failure conditions, derailment, ETC Simulations required by some specifications such as: FRA CFR vehicle qualification APTA SS-C&S crash energy management TTCI/AAR, 1/11/2013. p7
8 What types of Modeling? Vehicle-Track Interaction and Vehicle Dynamics NUCARS, VAMPIRE, SIMPACK Theoretical inputs such as FRA Minimally Compliant Analytical Track (MCAT) or AAR CH 11 Measured track geometry from actual routes Low speed derailment in sharp curves and turnouts/crossovers with large crosslevel deviations Structural Linear FEA: Fatigue Non-Linear FEA: Structural failure, Crash Energy Management TTCI/AAR, 1/11/2013. p8
9 How are the tests and modeling validated? Vehicle and Component Characterization Tests Ensure mass and inertial parameters, and stiffness and damping inputs to model are realistic System resonance tests Component tests Comparison between laboratory and on-track test results and simulation results to demonstrate validity APTA SS-M wheel load equalization Measured track geometry from actual test track location Specific track geometry designed to excite dynamic response, such as FRA MCATs and AAR CH 11 Actual revenue service route or qualification test location TTCI/AAR, 1/11/2013. p9
10 Force (kips) Force (kips) Vehicle Characterization Tests Some examples of characterization test results Secondary Stiffness_CabEnd_Right y = x R² = Displacement (inches) force on bogie kips Linear (force on bogie kips) Lateral Cab-End Left Velocity (in/s) Mode w/tractionrods W/o TractionRods Pitch Bounce Yaw Lower Center Roll Upper center roll Direction Secondary with traction Rods Secondary without traction rods Primary Suspension kips/inch Per Corner kips/inch Per Corner kips/inch Per Axlebox Longitudinal 24.1 NA 17.1* Lateral Vertical *Primary Longitudinal Stiffness Measurement Affected by Equalizer Beams TTCI/AAR, 1/11/2013. p10
11 Example Resonance Drop Test Test = Red, Model = Blue TTCI/AAR, 1/11/2013. p11
12 Wheel/Rail L/V Ratio Displacement (in) NUCARS verification of perturbed track test: Articulated Low Floor LRV Air Suspension Vertical Deflection Dark line = test data Light line = model Distance (ft) Test Model L/V Ratios at Track Perturbation (negative values indicate flanging force) Strain Gaged Rails Distance (ft) Test Model Strain Gauges TTCI/AAR, 1/11/2013. p12
13 Who says we have to? FRA rules (CFRs) FTA recommendations APTA recommendations Transit agency procurement specifications ISO UIC Consultant-defined Other regulatory authorities TTCI/AAR, 1/11/2013. p13
14 For whom do we do the tests? Car and Locomotive Builders Adtranz Alstom Bombardier Brookville Locomotive CAF GE EMD Hyundai Rotem Kawasaki Kinkisharyo Motive Power Nippon Sharyo Siemens Talgo Railroads and Operators Amtrak BART Denver Transit Partners Long Island Railroad MBTA METRA Metro North Railroad NYCTA PATH Texas Central HSR Via Rail Washington Group WMATA TTCI/AAR, 1/11/2013. p14
15 For whom do we do the tests? (continued) Government ERDC FBI FRA FTA ORR (UK) RSSB (UK) TCRP UIC (Europe) Victoria DOI (Australia) Volpe Center Contractors and Consultants Arup BAH DenSpie ENSCO Foster Miller HDR Interfleet Technologies LTK NRC Parsons Brinckerhoff Systra TMG TTCI/AAR, 1/11/2013. p15
16 TTCI Test Facilities Railroad Test Track 13.5 miles (21.9 km) 165 mph (267 kph) Overhead electrification Transit Test Track 9.1 miles (14.7 km) 80 mph (130 kph) 3 rd rail electrification Small radius loops Track Geometry Perturbations AAR CH 11 and FRA MCAT Crash wall Structural squeeze test TTCI/AAR, 1/11/2013. p16
17 Acela Testing and Qualification Customer - Bombardier/Alstom Fitted with TTCI s high speed instrumented wheelsets Testing at TTC followed by testing on the NEC Annual requalification tests TTCI/AAR, 1/11/2013. p17
18 New Jersey Transit / Agence Metropolitaine de Transport Locomotive Bombardier s NJT and Montreal AMT new Dual Power Locomotive ALP 45DP TTCI/AAR, 1/11/2013. p18
19 NYCT R142 Crash Testing Kawasaki subway car tested for compliance with NYCT requirements for: Safety Crashworthiness Energy management Impact with the crash wall at TTC TTCI/AAR, 1/11/2013. p19
20 FRA Passenger Car Crash Testing Measurements of strain, acceleration, displacement and coupler force to validate computer models Anthropomorphic Test Devices used to measure passenger response Impact wall tests Single and double Pioneer type (SEPTA) Train to other tests Pioneer car (SEPTA), two M1 cars (LIRR) and T-car (FRA) into freight locomotive Standard and modified Pioneer car into steel coil TTCI/AAR, 1/11/2013. p20
21 Massachusetts Bay Transportation Authority Problem articulated car derailments NUCARS modeling including independently rotating wheels New wheel and rail profiles designed Revised track geometry standards and speed limits TTCI/AAR, 1/11/2013. p21
22 Oregon DOT / Amtrak Cascade Service Testing Customer - Talgo Static testing Dynamic testing Ride quality High speed stability Curve compatibility Brake testing TTCI/AAR, 1/11/2013. p22
23 Sampling of Upcoming TTCI Projects California Illinois PRIIA 305 bi-level cars Next generation Amtrak NEC high speed trains New Amtrak electric locomotives Long Island Railroad new generation cars (M9) New MBTA locomotives Toronto Metrolinx and California SMART DMUs TTCI/AAR, 1/11/2013. p23
24 What do we learn? Identify vehicles performance characteristics Comply with statutory requirements Comply with safety parameters Meet specifications Appropriate wheel rail interface Crashworthiness Identify needed modifications Identify and remedy dynamic problems after revenue service has begun TTCI/AAR, 1/11/2013. p24
25 Conclusions Wide range of passenger rail vehicle testing and simulation requirements Requirements vary considerably by type of vehicle and expected operating environment Light rail and streetcars Heavy rail (subway/metro) Commuter rail Below 90 mph Above 90 mph TTCI/AAR, 1/11/2013. p25
26 Questions? TTCI/AAR, 1/11/2013. p26
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