HiL testing and identification of mechatronic railway bogie test bench

  • Lüdicke, Daniel (German Aerospace Center (DLR))
  • Posielek, Tobias (German Aerospace Center (DLR))
  • Heckmann, Andreas (German Aerospace Center (DLR))
  • Hippmann, Gerhard (German Aerospace Center (DLR))

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Rail vehicle bogies with independently rotating, driven and controlled wheels are a promising approach to enabling low-floor car body design, improving comfort and reducing wear, energy consumption and noise. [1, 2] A functional prototype of a mechatronic running gear for an ultra-high-speed train concept was built in full scale [3, 4] and put into operation on a roller rig as integration test bench. As part of the mechatronic development process, a co-simulation environment with a multi-body model was developed that simulates the bogie in train/vehicle scenarios and integration test bench scenarios. This is part of a tool chain for developing and testing the control software for the test bench. The ideal physical signals from the multi-body simulation convert sensor models with disturbance and error functions into realistic sensor signals. The identical control software with the same interfaces is executed to the co-simulation environment and the RCP system of the test bench. [5] The structures of the SiL environment and the HiL systems of the real test bench are presented. However, the bogie models need to correspond closely to the real bogie or test bench in order to develop the general software and guidance control in the co-simulation environment. Signals from the bogie model of the multi-body simulation are not (initially) available in the real design. Reference sensors (for distance, acceleration, rotation and force) were installed in the bogie and at the interface to the test bench to identify and verify the measured/assumed bogie/test bench characteristics. The most important state variables of the bogie are measured by sensors in order to observe the 6-dimensional movement of the main bogie parts and the force flow through the bogie. Using a reference scenario for lateral system dynamics and guidance control, the paper compares the behaviour of the co-simulation with the response of the real bogie in the integration test bench. The basic behaviour of the bogie is described and the fidelity of the identified bogie model is evaluated on the basis of characteristic sensor signals and physical variables. This makes it possible to estimate/verify that the mechatronic tool chain for developing the control software is suitable and the co-simulation precisely contains the bogie characteristics.