Efficiency Evaluation of Freight Cars Perspective Draft Gear Coupler

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Procedia Engineering 206 (2017) 299–304

International Conference on Industrial Engineering, ICIE 2017 International Conference on Industrial Engineering, ICIE 2017

Efficiency Evaluation of Freight Cars Perspective Draft Gear Efficiency Evaluation of Freight Cars Perspective Draft Gear Coupler Coupler A.S. Vasiliev* A.S. Vasiliev* Bryansk State Technical University, 7, Bulvar 50 let Oktyabrya, Bryansk 241035, Russia Bryansk State Technical University, 7, Bulvar 50 let Oktyabrya, Bryansk 241035, Russia

Abstract Abstract The main task of a draft gear coupler (shock absorber) installed on its movable part is to reduce the longitudinal forces in the formation of theoftrain on the and(shock at transient modes of the on train. serviceable ensures forces the safety of The main task a draft gearhumps coupler absorber) installed its Its movable part isand to effective reduce theaction longitudinal in the the train itself as well as that of the goods transported. In the study of the longitudinal loading of a carriage the problem of formation of the train on the humps and at transient modes of the train. Its serviceable and effective action ensures the safety of improving and as introducing newofhigh-performance couples We designedloading the constructions andthemathematical the train itself well as that the goods transported. In becomes the study urgent. of the longitudinal of a carriage problem of models of and advanced shock new absorbers PMC-RBP-120, PMC-RBE-120, AVC-120P, AVC-120E, PA-120 and We improving introducing high-performance couples becomes urgent. We designed the constructions andPA-120M. mathematical managed obtain a statistical distribution of the longitudinal forces affecting the movable part of thePA-120 train through the automatic models oftoadvanced shock absorbers PMC-RBP-120, PMC-RBE-120, AVC-120P, AVC-120E, and PA-120M. We coupler oftothe carriage equipped with promising under various loading Theofresults of the calculations of the managed obtain a statistical distribution of the devices, longitudinal forces affecting theconditions. movable part the train through the automatic statistical used with for the calculation and evaluation of performance effectiveness indicators of draft gear couplers coupler ofdistributions the carriage were equipped promising devices, under various loading conditions. The results of the calculations of the as well as distributions the assessment of the of parametric of the statistical were usedlikelihood for the calculation and failure evaluation of devices. performance effectiveness indicators of draft gear couplers © The Published by ElsevierofB.V. as 2017 well as theAuthors. assessment of the likelihood parametric failure of the devices. © 2017 The Authors. Published by Ltd. committee of the International Conference on Industrial Engineering. Peer-review under responsibility of Elsevier the scientific © 2017 The Authors. Published by Elsevier B.V. Peer-review under of the scientific committee of thecriteria International Conference Industrial Engineering Keywords: draft gear responsibility coupler; absorbing device; mathematical modeling; of economic efficiency.on Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering. Keywords: draft gear coupler; absorbing device; mathematical modeling; criteria of economic efficiency.

1. Introduction 1. Introduction The longitudinal forces arising in the rolling stock during the maneuvers and collisions while moving in a train have very negative impact on the safety rolling stock construction, its equipment and cargo carried. The of The longitudinal forces arising in the of rolling stock during the maneuvers and collisions while moving in task a train reducing forces can beoneffectively by draft couplers of rolling stock. The development new have verythese negative impact the safety solved of rolling stockgear construction, itsthe equipment and cargo carried. The of task of and the modernization constructions are theofmost important in the study of of new the reducing these forces canofbepreviously effectivelyexisting solved by draft gear couplers the rolling stock.goals The development longitudinal loading of freight train cars.existing constructions are the most important goals in the study of the and the modernization of previously longitudinal loading of freight train cars.

* Corresponding author. Tel.: +7-952-961-1567; fax: +7-4832-66-08-10. E-mail address:author. [email protected] * Corresponding Tel.: +7-952-961-1567; fax: +7-4832-66-08-10.

E-mail address: [email protected] 1877-7058 © 2017 The Authors. Published by Elsevier B.V. Peer-review the scientific committee 1877-7058 ©under 2017responsibility The Authors. of Published by Elsevier B.V.of the International Conference on Industrial Engineering . Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering .

1877-7058 © 2017 The Authors. Published by Elsevier Ltd. Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering. 10.1016/j.proeng.2017.10.477

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These objectives are closely related to the conduct of a large number of theoretical and experimental problems. Experiments to assess the strength and durability of the machine elements are money and time-consuming. Mathematical modeling can significantly reduce the amount of experiments. Well-designed calculation model gives an adequate idea of the characteristics of the simulated object, allows us to identify the most promising technical solutions [1]. 2. Methods The most complete assessment of the properties of the draft gear coupler from the point of view of its main purpose can be obtained by using the criterion of economic efficiency, taking into account repair costs of the freight cars damaged by longitudinal loads of freight cars damage from uncoupling and downtime of cars as well as emergency situations arising from its poor performance. The research made by Keglin B.G. and Boldyrev A.P. [2]. For the newly created device the evaluation of the economic efficiency criteria is a difficult task of forecasting the relation between costs and the shock-absorber properties. This problem is related to the definition of the interrelation between the shock absorber properties and the longitudinal loading of carriage in the process of operation and with the establishing of connections between the loading of the carriage and repair and other costs. The solution of the problem as well is also complicated by the difficulty of differentiation of the damage caused by longitudinal or other forces, interrelation of various physical damages; the stochastic nature of the relationship between load and the damage caused by it, as well as different frequency of load composition, technological deviations and volatility properties of the material at the same loads affecting different samples of the cars belonging to one and the same type due to different duration of their service or environmental temperature. Considering the above mentioned factors, it is difficult to establish the relationship of longitudinal loads and damages caused by them. Therefore, the criteria for the effectiveness of the draft gear couplers are limited to mathematical models that reflect the most important aspects of the fracture process [3]. The efficiency of the coupler can be associated with determined and stochastic indicators, which include:  energy capacity and fullness of power characteristics ;  maximum forces (accelerating force);  reliability indexes;  blocks of spectrum of longitudinal loads;  efficiency criteria related to various types of failures. To compare the work and assess the impact of the parameters of modern shock absorbers on the loading of cars such criteria effectiveness criteria as Jr (generalized criterion of efficiency of freight car shock absorber), Jf (criterion of fatigue damage of the carriage components), Jcd (conditional criterion of damage to the carriage from single overload), Jgd (conditional criterion of damage to goods from single overload), as well as the probability of parametric failure. The generalized criterion of the efficiency of freight carriage shock absorber is determined by: J f   сd J сd   gd J gd ;  Jr   m r  J f   i 1 P i ni ;  r  i 1 ( Pi  Pp )2 ni 0 ( Pi  Pp );  J cd   r  i 1 ( ji  j p )2 ni 0 ( ji  j p );  J gd 

(1)

where Jf , Jcd , Jgd – components of the generalized criterion relating to the different types of failures, ni - the number of load from longitudinal forces Pi; m‫ – ׳‬fatigue curve parameter; Pp – the threshold force of the blow, the excess of which leads to a shift of cargo; σ0– Heaviside unit function; jp – threshold acceleration of the carriage, the excess of which leads to a shift of cargo; γcd , γgd – weighting coefficients determined experimentally for different types of cars [3].



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A team of researchers of Bryansk State Technical University have developed and patented [4-7] the construction of new promising draft gear couplers of the rolling stock (Fig. 1), the hallmark of which is the use of modern hightech polymeric materials in joints. The test apparatus PMC-RBP-120, PMC-RBE-120, AVC-120P, AVC-120E, PA-120 and PA-120M in the friction parts have elastic spacer devices of various types instead of V-thrust, which is characteristic of the serial friction devices. These equipment provide a stable operation of the devices that enhance their performance [8,9]. Presented devices have a similar mode of operation. Under the influence of force transmitted from the coupler, their spacers are compressed when moving on sloping walls of the housing. There is a friction force between the spacer plates, which increases as the stroke of the machine rises. This force determines the high frictional force on the friction surfaces. Restoration of the devices to the original state is due to the elastic force exerted by the back-andretaining device.

Fig.1. The perspective draft gear coupler: (a) PMC-RBP-120; (b) PMC-RBE -120; (c) АVC-120P; (d) АVC-120E; (e) PA-120; PA-120M.

Mathematical modeling of devices associated with the definition of their power characteristics, presented in details in numerous studies [10-18]. The calculations were complicated by uncertainty of some physical parameters of modern materials used in draft gear couplers. However, the results of the static and dynamic tests allowed us to identify the necessary parameters of mathematical models, the adequacy of which was tested on the F-Fisher criterion [19]. Further studies suggested knowledge of statistical distributions of the longitudinal forces acting on the rolling stock through an automatic coupler. During mathematical modeling we recorded extremes of forces per regime (compressive and tensile). Since the events (different modes of movement and shunting collisions) are not dependent, the probability of occurrence of this situation is the product of the probabilities of occurrence of force for each design situation p = p1, p2 ... pi. Forces from 0 to 4.0 MN were divided into intervals. For shunting operations as a result of each calculation global extreme compressive and tensile forces occurring on impact in a stationary

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carriage weighing 90 tons, equipped with PMC-110A were fixed. In this case we use the spectrum of velocities and mass distribution (Table 1-2). For the transition mode of the train movement we regarded regimes of starting and braking mode types with regard to their probability in various masses of trains (Table 3-4). Table 1. The statistical distribution of the mass of freight cars. Weight (t)

Frequency

Weight (t)

Frequency

22.5

0.188

57.0

0.077

25.0

0.040

64.5

0.003

27.5

0.176

76.0

0.019

30.0

0.001

90.0

0.485

51.0

0.004

100.0

0.007

Table 2. The statistical distribution of impact speeds of cars. Velocity (m/s)

1.06

1.46

1.85

2,24

2.64

3.03

3.42

3.72

4.44

Frequency

0.2448

0.2588

0.2077

0.1396

0.0765

0.0523

0.0047

0.0123

0.0033

Table 3. The statistical distribution of the weight of the train. Weight (t)

2700

5000

6400

8000

Frequency

0.78

0.12

0.06

0.04

Table 4. The statistical distribution of velocities by the beginning of braking. Velocity (km/h)

7.5

22.5

37.5

52.5

60

Frequency

0.241

0.253

0.221

0.182

0.103

Taking into consideration the number of carriage loadings per year for each mode [3], the results were combined to build statistical distribution of global extrema for all shunting and train modes. The resulting statistical distribution of global extrema of compressive forces for all operating modes are shown in Fig. 2. Distribution of extrema of tensile strength is of less interest due to their comparable smallness in relation to compressive forces.

Fig.2. The statistical distribution of global extrema of compressive forces.

The obtained results of the computations of statistical distributions were used to calculate performance efficiency indexes of draft gear couplers and the estimation of parametric failure of the devices, which was determined by the



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sum of probabilities of the occurrence of longitudinal compressive forces in excess of the limit load 2.5 MN. The calculation is made on the detailed range of statistical distributions (Fig.2). Table 5 shows estimates of the efficiency of various draft gear couplers for all modes of operation and the results of calculations of the probability of parametric failure. The calculation of the conditional criterion of damage to goods from single overload for the considered devices was not performed, because the weighting coefficient γgd for the studied open cars and tank cars takes a value of zero [3]. Table 5. The results of calculations of the longitudinal loading. Type of draft gear

Probability of parametrical

coupler

failure

PMC-110A PMCP-110

Criteria Jr

Jf

Jcd

Standard units

%

Standard units

%

Standard units

%

0.00232

44177

100

26800

100

24.965

100

0.00172

27560

63.39

14473.62

54.01

11.875

47.57

PA-120

0.00089

5235

11.85

2772.56

10.34

2.923

11.71

PA-120М

0.00082

5114

11.57

2537.25

9.47

2.636

10.56

PMC-RBP-120

0.00064

3785

8.56

1999.23

7.45

2.008

8.04

PMC-RBE-120

0.00055

3672

8.31

1912.13

7.13

2.002

8.02

AVC-120P

0.00088

3925

8.84

2112.75

7.88

2.114

8.47

AVC-120E

0.00077

3881

8.78

2089.23

7.79

2.078

8.32

The results of the calculations showed that the probability of parametrical failure in perspective absorbers is significantly lower than that of serial PMC-110A and PMCP-110. For PMC-RBE-120 the probability of parametrical failure is reduced in 3 times in case if the load limit is increased by 2.5 MN, in comparison with PMCP -110; for AVC-120P and PA-120 in 2 times. Using perspective friction absorbers reduces the probability of parametric failure and in most cases leads to a decrease in longitudinal loads. Obviously, the best indicators of efficiency criterion are provided by perspective absorbing devices. In comparison with serial friction devices according to the generalized criterion the difference reaches 12 times. 3. Conclusions The findings of the research suggest the obvious advantages of promising absorbing devices. Further research is needed to optimize the designs with the subsequent manufacturing of prototypes and conducting the experiments. The use of high-energy efficient devices can reduce the longitudinal forces arising in the trains and to reduce damage to cars and cargo, avoid derailment of cars and train wrecks. It is also important that in the carriage design process the assessment of bearing capacity will be made at lower longitudinal forces, leading to the simplification of the structure and the carriage mass reduction. Therefore, it is necessary to provide the rolling stock with such devices not only by their installation on the rolling stock during its construction, but also on the cars undergoing scheduled maintenance [20]. References [1] A.S. Vasiliev, A.P. Boldyrev, Calculation of the characteristics of modern shock absorbers of railway rolling stock using the appropriate mathematical models, Herald of Bryansk State Technical University. 4 (2015) 19–24. [2] A.P. Boldyrev, B.G. Keglin, Calculation and design of the rolling stock shock absorbers, Engineering -1, Moscow, 2004. [3] A.P. Boldyrev, Scientific fundamentals of perfection of draft gear couplers: Dis .... Dr. Of tehn. science, Bryansk, 2006. [4] V.A. Aldyuhov, A.P. Boldyrev, A.S. Vasiliev, A.M. Gurov, B.G. Keglin, A.P. Shlyushenkov, Friction-absorbing polymeric coupler, Pat. 2486090 RF MPK8 F16F11/ 00, F16F9/14, B61G11/14, Bull. No18. [5] V.A. Aldyuhov, A.P. Boldyrev, A.S. Vasiliev, A.M. Gurov, B.G. Keglin, A.P. Shlyushenkov, Friction-elastomeric draft gear coupler, Pat. 120935 RF, MPK B 61 G 11/12, B 61 G 11/14, F 16 F 11/00, F 16 F 9/14., Bul. No28. [6] E.A. Fatkov, A.P. Boldyrev, A.M. Gurov, Friction-elastomeric draft gear coupler, Pat. 112133 RF MPK 61 G 11/14, Bull. No9.

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[7] E.A. Fatkov, A.P. Boldyrev, A.P. Shlyushenkov, B.G. Keglin, Friction-polymer absorbing device, Pat. 239786 RF MPK B 61 G 11/00, Bull No9. [8] A.S.Vasiliev, Use of spacer devices in friction shock absorbers, XXIII International innovation-oriented conference of young scientists and students (MICMUSS-2011), Proceedings of the conference, Publishing house IMASH RAS, Moscow, December 14-17, 2011. [9] A.S. Vasiliev, R.R. Pryadeha, Methods of increase of efficiency of work of pairs of friction of the friction shock absorbers of the railway rolling stock, Vector of the development of modern science. X International scientific-practical conference, "Olympus" Publishing House, Moscow, 2016. [10] A.S. Vasiliev, Improving the efficiency of the friction of the draft gear coupler by applying elastomeric spacer assemblies: Dis .... cand. tehn. science, Bryansk, 2013. [11] A.S. Vasiliev, E.A. Fatkov, Research work on absorbing devices with volume spacer blocks, Herald of Bryansk State Technical University. 1 (2013) 57–62. [12] A.S. Vasiliev, B.G. Keglin, A.P. Boldyrev, A.P. Shlyushenkov, Development and research of the friction shock absorber with an elastic spacer assembly, Herald of Bryansk State Technical University. 1 (2012) 25–31. [13] A.P. Boldyrev, B.G. Keglin, Prospective design of absorbing couplers, Railway transport. 6 (2005) 41–45. [14] A.P. Boldyrev, B.G. Keglin, Computational and experimental evaluation of the longitudinal loading of rail cars for different operation modes, Mechanics and tribology of transport systems, Proceedings of the International Congress, Rost. State. Univ. of Railways, Rostov - on - Don, 2003, pp. 76–82. [15] A.P. Boldyrev, B.G. Keglin, Development and implementation of advanced draft gear coupler for freight cars, Heavy Engineering. 12 (2005) 20–24. [16] A.S. Vasiliev, Investigation of characteristics of friction-elastomeric shock absorber and calculation of stress-strain state of its units, Herald of Bryansk State Technical University. 2 (2013) 33–41. [17] A.S. Vasiliev, A.P. Boldyrev, B.G. Keglin, A.M. Gurov, Study of the longitudinal loading of freight cars fitted with a new version of friction draft gear absorbers, when the train is in transient driving mode, Herald of Bryansk State Technical University. 1 (2014) 12–17. [18] A.S. Vasiliev, The new generation of combined draft gear coupler of the rolling stock, Achievements of young scientists in the development of innovative processes in the economy, science, education: Proceedings of the III International scientific-practical conference, Bryansk, 2011, pp. 19–20. [19] A.S. Vasiliev, A.P. Boldyrev, Experimental studies of modern friction shock absorbers of the railway rolling stock, Bulletin of Samara Scientific Center of the Russian Academy of Sciences. 15(4) (2013) 507–510. [20] A.P. Boldyrev A.M. Gurov, Effectiveness of high-power consumption absorbing devices for freight cars, Transport of the Russian Federation. 3(52) (2014) 43–45.