高速动车组构架载荷特征研究

THE LOAD CHARACTERISTICS OF THE BOGIEFRAME OF HIGH-SPEED EMUS

  • 摘要: 高速动车组转向架构架不仅承受和传递来自一系和二系悬挂系统的载荷,而且承受来自电机、齿轮箱以及牵引制动等部件产生的载荷,因此,这些载荷引起的构架结构疲劳可靠性受到广泛关注,但这些与构架结构可靠性密切相关的载荷却少有研究。该文提出解耦和降维法识别某型高速动车组构架轴箱弹簧垂向载荷、定位节点横向载荷、电机垂向和横向载荷、齿轮箱垂向载荷以及抗侧滚装置载荷,制作测力构架并首次实际线路全面测试该型动车组运行过程中载荷引起的应变信号,列车最高试验速度368 km/h。对测试数据进行处理和分析,获得了高速动车组运行工况下这些载荷的时间历程,分析了载荷的时域和频域特征,给出了轴箱弹簧载荷峰值与运行速度之间关系。采用雨流计数法统计了载荷峰谷值和频次,获得了不同速度等级下载荷谱,给出了构架200万次试验条件下的等效载荷。结果表明:轴箱弹簧载荷、定位节点横向载荷、电机载荷以及齿轮箱载荷受列车运行速度和轨道激扰影响明显,抗侧滚装置受列车速度和曲线条件影响明显,轨道随机激扰对抗侧滚装置载荷影响不明显。钢轨现场焊接接头不平顺使得轴箱弹簧承受明显的冲击载荷并作用于构架,且该冲击载荷频率一般为49 Hz~51 Hz。列车正线行驶时,轴箱弹簧载荷最大动荷系数0.23,构架侧滚和浮沉载荷系数最大值分别为0.14和0.1。电机和齿轮箱载荷峰值接近标准JIS E4208给出的动载荷值。幅值频率积可直观地表示中高频范围内载荷幅值变化特性。该文研究结果对高速动车组动力学研究和构架结构设计及疲劳试验等具有重要意义。

     

    Abstract: The bogieframe of the bogie of a high-speed electric multi-unit (EMU) carries not only forces from the primary and secondary suspensions, but also loads caused by the vibrations of the components of the vehicle. The components include the motors, gear boxes, traction devices, brake equipment and so on. Consequently, the structural strength of the bogieframe is important to the operation safety and reliability of the high-speed EMU. However, there are few studies related to the load characteristics of the bogieframe of EMUs. The decoupling and dimension reduction method for load identification is presented. The identification loads of the bogieframe include the axlebox spring force, lateral force of the trailing arm knot, motor vertical and lateral forces, gearbox force and anti-roll bar force. The bogieframe of a Chinese standard high-speed EMU was manufactured and calibrated for the force measurement. All forces were measured in a field experiment on a high-speed railway in China. The measured peak speed of the high-speed EMU was 368 km/h. After dealing with the sampled data, the time history of the forces was obtained. The dynamic characteristics of the forces were analyzed in the time and the frequency domains. The rain flow count method was implemented to count the loads. The maximum loads and load spectra were presented with different operation speeds of the train. The equivalent loads of the measured forces of the bogieframe for two-million-time fatigue tests were presented according to the load spectrum and the service life of the high-speed train. The results show that the operation speed of the train and track excitations had a great effect on the axlebox spring forces, trailing arm knot forces, motor forces and gearbox forces. The operation speed of the train and curve radius of the track had great influences on the forces of the anti-roll bar devices. Large impact loads of the bogieframe occurred because of the field welding joints of the rails. The frequency of the impact loads of the axlebox springs ranged from 49 Hz to 51 Hz. The maximum dynamic load factor of the axlebox force was 0.23. When the train operated on the main section of the railway, the maximum vertical and roll load coefficients of the bogieframe were 0.14 and 0.1, respectively. The peak loads of the motor and gearbox were close to the dynamic values presented by JIS E4028. The amplitude ratio is helpful to reveal the changing characteristics of the amplitude in the frequency domain. The investigation is useful to disclose the dynamic characteristics of the loads and to study the structural damages and fatigue test of the bogieframes of high-speed EMUs.

     

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