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CHINA High Speed Train
The key technologies and maintenance system
Gan Dunwen Associate Researcher
China Academy of Railway Sciences
中国高速铁路网规划China high speed railway development planning
Speed upgrade on existing railways: 200 ~ 250km/h,8000 km41 Passenger Dedicated
Lines by 2012, more
than 13000 km;
16000km by 2020
The world first-class bogie, car body, assembly, debugging production lines
The whole manufacturing process technology design, craft standard system
Continuous improvement technology innovation system
Bogies Lines Car-body Lines Debugging LinesAssembly Lines
• new-built 300 EMUs /year• overhaul 200 EMUs/year
A high level of technology platform and R&D team of innovation
HSTs’ systems integrators – CSR & CNR
Key technologies -- System Integration
Key technologies -- Bogies
Keys• Anti-roll movement
• Derailment safety
• Structural strength and reliability
Structure function• Running Machinery
•The core of HSTs
• Loading, directing, suspension, traction and braking etc.
• Improving box positioning stiffness according to line conditions
• Selecting yaw damper parameters, and ensuring redundancy
• Determining the maintenance cycle to ensure a good equivalent conicity
Nonlinear critical speed >550 km/h
Key technologies -- BogiesYaw damper
Postioning Stiffness
equivalent conicity
Wheel/rail surface Matching
气动
作用
Structure characteristics• Thin-walled cylindrical aluminum alloy welding
structure• Drum wide body (3.3m), Large sections(11.2m2)• Thin (1.5mm) and long (25m) profiles• Overall carrying, hanging equipment to the base
plate
Keys Structure strengthModal designingVibration and noise reducingdrag reducing
Key technologies -- Bodies
Aluminum alloy car-body Parameters• more than 20 years service life
• ±6000Pa airtight strength requirements
• Weight: less 8.5t, under 15% of totalsurface pressure bypassing
Airtight fatigue strength analysis
Key technologies -- Bodies
Wheel/rail noise
Equipment noise
Aerodynamic noise
Pantograph-Catenary noise
Structure noise
The conventional measures of sound isolation/absorption, have little effect on structure-borne noise. As shown in the Fig., the study needs to emphasize optimizing the structural design and controlling the vibration mode of structure. However, the body of the train is a 25m-long enclosed sheet. For such a structure of large enclosed strip, body mode and interior acoustic mode easily resonate due to external excitations like wheel-rail. The resonance might cause acoustic-structure coupling.
Key technologies -- Bodies
Vibration and Noise Control
• Mastering the noise source distribution and spread rule
• Analyzing the interior noise spectrum
Key technologies -- Bodies
An optimization process to reduce drag, noise, pressure waves and lift
Pressure distribution
Tunnel crossing Lateral force
Train bypassing
Aerodynamic Noise
Key technologies – Aerodynamic nose design
Molding Angle Control outlineSection Rate
Opt2
Before
Opt1
Requirements• Excellent aerodynamics
• Less drag and noise
• Good following
• Better matching between the skate and line
Keys• Stable current-collection with simple
catenary structure at 350km/h
• Stable current-collection with two pantographs
• Drag and noise reduction
Key technologies -- Pantograph
• the fully compensated simple catenary system• the novel copper base alloy contact wire with high tensile strength and well conductivity• optimizing the space between the two pantographs• optimizing the pantographs’ dynamic performance• improving debugging technologies
Rear pantograph
Space
Front pantograph
Catenary
Key technologies -- Pantograph
Keys• Lightweight shell-type transformer• High-power, small size converter• Lightweight traction motor and
gearbox
Power-distributed, AC-DC-AC traction drive system
• Traction Drive Control Technology
• High-power IGBT module
Key technologies – Traction system
Unit 1
T1 M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 T2
Unit 2 Unit 7
Target: Modular, lightweight, small size, high power, high efficiency
Key technologies – Traction system
Improving:• Synchronous control technology• Changing the ratio of motor and trailer cars• Increasing the power of traction motors
Emergency brake:only for safetyService brake:ED brake preferred,environment friendly.Parking brake:Parking reliableBackup brake:Perfectly safeWSP:Special for High Speed Fault diagnosis:Real-time Monitoring High capacity brake discs:heavy load
Key technologies – Braking system
Key technologies – Braking system
Fault-safety principle:
Abiding “Safety First”
Avoiding “out of brake”
“unexpected brake”
“Breakdown”
Key technologies – Braking system
Keys:
• ED-EP blending control• High speed WSP• High capacity brake discs• Deceleration acc.to adhesion• Short brake distance at
350km/h
Emergency brake
Step 6 brake curve
Full service brake
ED curve
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
Dec
(m/S
2 )
0 50 100 150 200 250 300 350 400V (km/h)
Key technologies – Network Control System
Hardware system
Central control MMI Sub-control unitI/O unit
Software System
Train control Train diagnosis Simple control Control monitor
combined adjusting and test on System
Subsystemfaultsimulation
通信协议测试
maintenance for system operation fault
Communication protocols’ configuration
Control logictest
Diagnosislogic test
Subsystemfunction test
Communicationprotocol test
Hardware test
platform
Software test
platform
Semi-Physical
Simulation and testing platform
Network Structure and Composition
TCU and CCU Simulation
Key technologies – Network Control System
Semi-Physical Simulation platform For 16-car-electrical-multiple units
Wireless transmitting device: transmit real time EMU fault information and operation statusprovide maintenance guidance and advices; inquire and statistically analyze faults through established website
Key technologies – Network Control System
Display screen and GSM radiomodel commuticate throughRS232 , MVB connect withMVB service port
Transmit real-time data toground through GSM net
RS232, DC24V,GSM/GPS; MVBnet
e-mail program------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
e-mail program------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Data base
Servers of TCR or Maintenance center
Servers ofCARS
Transmit data throughEthernet .
Application characteristics of HSTs in China
• High speed• Long running mileage• Complicated operating environment• Large passenger flow
HSTs Maintenance System in China
• Conditions Monitoring and Faults Diagnosis Technology
• Information-based Technology of Life-span Prediction
• Technology of Reliability
Technical elements of CRH maintenance
(1) Damage consistenceAccording to the damage consistence criteria of load
spectrum, the load spectrum of complicated structures of EMUwere edited to provide the definition of maintenance period or lifewith the quantitative basis.
(2) Nondestructive testingThe initiation and spread law of fatigue crack were studied
continuously. The test interval of EMU hollow axle, wheel andbogie were adjusted and optimized.
Key technologies
HSTs Maintenance System in China
.
.
Key technologies
HSTs Maintenance System in China
(3) Wheel-rail relationThe matching relationship of wheel-rail materials and the wheel-
rail contact fatigue were systematically studied, and the wheel rotarycutting cycles were optimized to ensure the dynamics performance ofEMU and the traveling comfort of passengers.
(4) LubricationIn connection with rotating components just like the bearings, the
continuous studies of friction, wear and lubrication were implemented.Based on the statistical data analysis, the oil filling and replacementperiods of bearing were reasonably adjusted so as to suit theoperational conditions of high speed and long running distance.
Key technologies
HSTs Maintenance System in China
(5) Information systemThe application and maintenance management information
system of EMU was established to realize the real-time control ofdispatching, on-site operation, parts management and so on.
(6) Life cycle costThrough implementing the modeling, calculation, analysis,
and evaluation of life cycle cost for high speed trains, thefoundation of economy were provided for the selection of design,material, craft as well as maintenance strategies.
EMU Maintenance
Preventive maintenance
Corrective maintenance
Scheduled Maintenance
On-Condition maintenance
Level-1 and 2 maintenance
Level-3 maintenance
Level-4 maintenance
Level-5 maintenance
Condition monitoring
Fault repair in the run
Recovery processing inside the depot
SafetyPreventabilityComfort
ReliabilityEconomy
HSTs Maintenance System in China
Primary contents of all levels of maintenance procedures
(1) Level-1 maintenance-- Routine inspection
including the routine inspection of bogie, braking and pantograph as well as the toilet sewage discharge and cleaning, etc.
HSTs Maintenance System in China
(2) Level-2 maintenance-- Special maintenance
mainly including the crack detection of hollow axle and wheel, tread surface modification, gearbox oil replacement, bearing lubrication and functional tests of important systems and components, etc.
Primary contents of all levels of maintenance procedures
HSTs Maintenance System in China
(3) Level-3 maintenance—decomposition inspection of some important components, esp. bogies
mainly including the decomposition inspection of those key spare parts, such as bogies, traction motors, braking system, air-conditioning and ventilators etc, as well as the implementation of functional test of each important system.
Primary contents of all levels of maintenance procedures
HSTs Maintenance System in China
mainly including decomposition inspection of important system and its subsystem of EMU, such as bogies, pantographs and braking systems, performance tests of motors and electric devices, painting and repair of vehicle bodies, as well as the maintenance and decoration of facilities in vehicles.
(4) Level-4 maintenance—overall decomposition inspection of some important systems
Primary contents of all levels of maintenance procedures
HSTs Maintenance System in China
(5) Level-5 maintenance—overall decomposition inspection of the whole vehicle
Including the decomposition inspection of the whole vehicle and renewing the spare parts in a large scope, as well as the modernization upgrading and improvement, such as the train decomposition, inspection, repair, overall cleaning, pressure seal inspection and vehicle body repainting.
Primary contents of all levels of maintenance procedures
HSTs Maintenance System in China
Evaluation on reception
Inspect electrical equipment sUnmarshallLifting EMU and lowering
steering wheel
Inspect the bogie
Basic Process Flows of Overhaul
HSTs Maintenance System in China
Lowering EMU and marshalling
Static debugging
Weighing
Dynamic debugging
Delivery
HSTs Maintenance System in China
Over 5000km from south to north and east to westclimatic conditions: cold, high temperature and high humidity, sand, strong corrosionTransport requirements: High density, high speed, short-long combined with large-capacity
Stretch cold
Humidity, high temperature& corrosion
Sandy
Temperate
Challenges -EMU seriations
Custom
ization
Design and manufacture of integration platform and customization techniques
Req
uire
men
t an
alys
is
Basic models PrototypeR
equi
rem
ents
D
atab
ase
Generic technology
EMU Physical models
承载组份模块群
高寒高温
高湿
风沙
高原
新能源
强腐蚀
design
Test
Evaluation
Manu.
configuring
Evaluation
走行组份模块群
动力组份模块群
其它组份模块群
Challenges -EMU seriation
k
RequirementsDatabase
Mapping/description
客室布置车内环境旅客设施娱乐餐饮特殊文化
定员速度动力学制动距离强度轴重
Key Req. Passenger Req.
城际大容量、中短途、快速乘降
沿海适应盐雾、
高湿、高温及强风运行环境
Subject Req. + +
Challenges -EMU seriation
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