Studies And Applications On Key Technologies Of Collaborative Simulation And Rigid-flex Coupling For Vehicle Dynamical Systems

For the complex mechatronic systems of modern railway vehicles, the integration design capability based on Multi-body System (MBS) is very crucial. To improve the systemic integration capability needs the support of the three following factors:design concept with creative thoughts, multi-discipline software tools and their interface transaction technologies, in which the interface transaction technologies between the different disciplinary software tools are the keys to represent the creative thoughts.From the viewpoint of the integration design capability, and with the groundwork of the accumulated experiences in the dynamical simulations and test contrasts of the various-type railway vehicles, Collaborative Simulation and Design Methodologies (CSDM) are proposed in this paper, which are characterized as the two following features:(1) specifying the migration of the controller model and the linearization on the working point as the interface transaction between MBS and CACE (Computer Aided Control Engineering Software); (2) representing the main constraints constructed by the geometric pairs and the slave ones approached with the elastic inner-force restrictions as flex-body interfacing to MBS. And the platform formed by these above interface transactions has emphasized more the integration of multi-discipline knowledge, the reciprocity of collaborative design, and the complementarity of analysis tool.With the CSDM, the four typical cases about the industrial applications of collaborative simulations based on MBS were further studied and validated in this paper.1. in order to improve the adjustability and robust-stability of Electro-Magnetic Suspension in MagLev vehicle to railway, Mono-rail Ortho-Model and 2-DOF active control strategy were presented by the above interface transaction technology between MBS and CACE. Since the rolling disturbance can be converted the bouncing disturbances on both sides,2-DOF active control of levitating unit has actually the rubost control stability to 5-DOF disturbances, i.e. bouncing, pitch, lateral, yaw and roll. Because of the reasonable reduction in the error of electro-magnet module's kinematic modal truncation, the 2-DOF active control stability of levitation and guidance can be gotten improved. Meanwhile the rail centering of levitating unit is achieved by the guiding active control in the differential guiding current mode. Under the collaborative environment with the modeling modularization of high-speed MagLev trainset, the three following special topic studies were furthermore investigated:the curve negociation performance, track match performance and vehicle-bridge coupling mechanism, in which the sensitive variation of lateral forces and unloading problems in both ends are received by the measuring data validation.2. in order that the simulation analysis of railway passenger vehicle's lateral stability may better represent the uncommon significance of self-excited vibration, a novel analysis methodology of lateral stability was proposed based on wheel/rail match. For an export tram marshalling plan, with the non-linear collaborative optimization mode of multi-vehicle trainset based on MBS, the optimization scheme was determined for increasing velocity 120km/h on existing line condition (UIC54/ORE). After the virtual measuring of assembled air-spring's characteristics and contrasting with testrig data, the comfort indices of the 8-vehicle trainset, which are assembled by template-based modeling technique, were evaluated. Under the condition of considering the displacement lag feature of air-spring's leveling valve, the suitable anti-roll equivalent stiffness can be formed by the improved solution of elastic-joined anti-roll torsion bar to ensure the ride comfort quality.3. As a large-scale rigid-flex coupling system, the new-built 350T Schnabel Wagon were investigated on laden lateral stability, laden curve negociation safty and tare returning velocity. These contrast simulation analyses show that:due to the application of the above flex-body interface transaction technology strategy, the large-scale flex-rigid coupling simulation has comparability with testing data, e.g., the dynamic load coefficient of lateral force of guide pin and the returning velocity of tare short-trailer, etc., are consistent with line dynamic test. For the laden run-time safty problems, e.g., the stability of the weight's friction constraints and the laden small-radius curve negociation, etc., the dynamic explainations were given by flex-rigid coupling simulations, and the improving advices proposed have be adopted in the development and tests of Long and Big Cargo Freight Cars.4. for the applications of rigid-flex coupling techniques, a methodology of vibration fatigue analysis was presented based on flex-rigid coupling simulation in order to analysis the influencing extent of structural vibration effects on fatigue life. Taking the case that the container flatcar's vertical vibration acceleration is on the high side as a topical analysis paradigm, the friction damping contrast analysis based on flex-rigid coupling simulations reveals that the dynamical interaction of the wedge's stick-slip friction in the bolster suspension is playing a very important role in generating the excitation of carbody's elastic vibration. With the post-processing data such as dynamic stress recovery, the influencing extent of carbody vibration to structural fatigue was determined by means of the correlation between dynamical stress and modal vibration, and the stress range histograms by which the amplitude and number of cycle stress on critcal points are contrasted stastically among the multi-condition.The research works in this paper are suppoted as follows:1.863 National High-Tech. R&D Program for Integrative-platform Development and Application of Complex Products' Collabrative Design, Simulation and Optimazition, No. 2006AA04Z160;2.863 National High-Tech. R&D Program for Reseach and development of Hign-speed MagLev Vehicle, PART I, No.2004AA505240; 3. National Key Technology R&D Program in the 11th Five Year Plan of China for Concurrent Integrating Manufactory System of 300km/h High-speed Trainset, No. 2006BAF01A01...