Solving Your Rail Related Problems

Solving Your Rail Related Problems

Rail vehicle simulations
Dynamics, stability, derailment
Detailed Rail-Wheel interaction, wear
Control systems, brake systems, traction
Wagon interaction, buffer impact

Permanent way simulations

Rail stresses, deformation
Substructure stresses, deformation

Component simulations
Stress, Fatigue

The Solution Triangle

The Technology

Virtual Prototyping Defined

Functional simulation of real-world systems

Reduces time-intensive, costly, hardware buildtest-refine cycles
Improves quality (cut warranty and
repair/maintenance costs)

Virtual Prototyping Defined

Functional simulation of real-world systems

Reduces time-intensive, costly, hardware buildtest-refine cycles
Improves quality (cut warranty and
repair/maintenance costs)

Virtual Prototyping Defined

Thermal Comfort and Air
Quality in Carriages

Functional simulation of real-world systems

Reduces time-intensive, costly, hardware buildtest-refine cycles
Improves quality (cut warranty and
repair/maintenance costs)

VI-Rail
Applications

The Functional Digital Train

Full Railway System

Bogie

Body

Accessories

Permanent Way

Suspensions

Interference

Buffers

Track beams

Wheels / Contact

Packaging

Brakes

Ballasts

Dampers

Passenger Safety

Engine groups

Bridges

Active devices
Pantographs

The Functional Digital Train

Full Railway System

Bogie

Body

Accessories

Permanent Way

Suspensions

Interference

Buffers

Track beams

Wheels / Contact

Packaging

Brakes

Ballasts

Dampers

Passenger Safety

Engine groups

Bridges

Active devices
Pantographs

Integration Platform
CAD
Integration Platform

Durability

FEA

Controls
Vibration

In-House
Solutions

VI-Rail
Vehicle Stability
Automatic Stability Analysis
Specification of critical damping to determine stability (0%, 5%,...)
Specification of conicity range for automatic generation of stability map

VI-Rail
Traction/Braking
Friction coefficient variability

Friction Coefficient

With track distance

With creepage
With lateral coordinate on rail / wheel

VI-Rail
Traction/Braking
Application: detailed drive simulation during traction maneuver
Oscillations in drive system can be carefully tracked down and eliminated

Packaging/Interference
DMU/Replay integrates ADAMS/PPT into CATIA v5
to perform virtual collision check and envelopes
calculation
Conceptual collision detection also available in the
ADAMS environment

Integrated Flexibility/Durability
Flex body representation
Stress recovery calculation
and color map visualized
into ADAMS/PPT

Integrated Vibration Analysis

Frequency response optimization of ride
indexes according to
Equivalent conicity
Suspension stiffnesses
Damper characteristics

Immediate information about qualitative

influence of design changes on running
comfort

Integrated DOE/Optimization
Through the use of ADAMS/Insight:
The scaling factors for all VI/Rail components
are automatically defined
Several design changes can be automatically
investigated
Results are formatted in 3D response
surfaces, animations, and HTML pages which
can be directly published for the whole
engineering team
Lat Acc RMS
0,65
0,6
0,6-0,65
0,55-0,6
0,5-0,55
0,45-0,5
0,4-0,45

0,55
0,5
0,45

1,4

0,4
0,6

0,8

1
PD Damping Factor 1,2 1,4

1
PS ZStiff
0,6 Factor

VI-Rail
Detailed Wheel/Rail Contact
Real Lift-Off Representation

VI-Rail
Detailed Wheel/Rail Contact
Flanging with Multi-Point-Contact

VI-Rail
Detailed Wheel/Rail Contact
Allows to switch between different profiles along the track
Implemented for WRGEN contact element

VI-Rail
Detailed Wheel/Rail Contact
Possibility to change wheel radius along circumference
Available when using WRGEN contact element
Different radii specified in wheel configuration matrix

From Concept to Prototype

Functional Virtual Prototyping as a complete solution for railway

engineering

Confirmed by several customers and several applications

Enabling communication between the engineering tools
Rely on railway expertise and powerful, specialistic tools through strategic
relationships

REFERENCES

Deutsche Bahn AG
Business:

European railway operator

Challenge: Evaluate stresses developing in

rail bridges from high speed trains
Solution:

Using ADAMS/Rail in combination

with FE to virtually estimate the
bridge mid-span stress time
histories

Value:

Enables prediction of stress

histories without expensive
physical testing

A high flexibility in modeling different types of vehicles has

been reached by taking advantage of the template-builder
structure to build up different ICE assemblies by referencing
simply to an ICE bogie and an ICE car body template.
--Manfred Zacher,
Deutsche Bahn AG

RDSO
Business:

Research arm of the Indian

Ministry of Railways

Challenge: Develop a flat rail car for safe

operation at 100 km/h
Solution:

Using ADAMS/Rail and

NASTRAN with field wheel/rail
measurements to virtually
evaluate acceptance criteria

Value:

Virtual tests demonstrated that

design shall pass the field
criteria of Indian Railways

ADAMS/Rail is for RDSO a necessary virtual prototyping tool to

ensure good financial health of the organization and reduction in
cost of development and testing of a new design.
-- Nitin Chowdary
Director, Vehicle Dynamics Group

Trenitalia
Business: European railway operator
Challenge: Implement braking device in
experimental railway vehicle
Solution:

Behavior of the WSPD (Wheel

Slide Protection Device)
active system is investigated
using ADAMS-Matlab CoSimulation

Value:

Able to optimize slide

protection device with the help
of virtual prototyping

The proposed model has a behaviour qualitatively and

quantitatively analogous to the on line tests.
-- P. Presciani
Manager, UTMR Trenitalia

Bombardier
Business:

Railway rolling stock

manufacturer

Challenge: Rapidly develop an optimized

traction control system
Solution:

Using MSC.Patran/Nastran,
ADAMS/Rail with
ADAMS/Controls + MATLAB as
integrated virtual prototyping
solution for mechatronics

Value:

Increased confidence in product

Commissioning of traction control could be finished in a short

time with very good results to the satisfaction of our customer,
even though the conditions were very difficult.
-- Peter Haese
Traction Systems Engineering

Alstom
Business:

European railway vehicles

manufacturer

Challenge: Investigate poor performance

caused by car body torsion
interaction with bogie hunting
Solution:

Integrated VI/Rail bogie model

with FE carbody

Value:

Overall comfort performance

optimize, resulting in wide
commercial success

A complete DOE analysis enabled the engineers to test the

dynamic behaviour of the complete system and to find out the
optimal parameter settings which restricts the vibration of the
construction and therefore optimises the comfort behaviour.
-- Pascal Geoffroy
Manager, Rolling Stock

Alstom
Business:

Railway vehicles manufacturer

Challenge: Optimize new streetcar

for rollover stability and
derailment avoidance
Solution:

Evaluated the vehicle behavior

virtually to optimize the design

Value:

Improved safety; greater

confidence

The simulation produced results in agreement with all

service conditions and the overall dynamic behavior.
Derailment and rollover stability measurements have
been matched with a maximum error of 3%.

-- Massimo Lenti
Manager R&D, Alstom IPS

Case Study:
GE Transportation
Business:
North American locomotive manufacturer
Challenge:
Investigate the effect of wheel back-to-back
distance on locomotive stability and safety
Solution:
Parametric model built in ADAMS/Rail and
run through standard suite of maneuvers
Value:
Met customer critical-to-quality
requirements on locomotive design
We have done a lot of wonderful work using ADAMS.

-- Jingjun Zhang
Control and Auxiliary Systems

Patentes Talgo
Business:

Railway rolling stock

manufacturer

Challenge: Meet UIC518 acceptance

requirements when operating
on tracks with different gauges
Solution:

Virtual comfort and safety

studies for different system
configurations

Value:

Fulfilled UIC518 requirements

The results achieved have been coherent

regarding tilting in curves, accelerations on car
bodies, contact forces, and guidance system.
-- Emilio Garcia,
Manager, Talgo

Patentes Talgo
Business: Railway rolling stock manufacturer
Challenge: Investigate dynamic behavior of highspeed train
Solution:

VPD and MSC.ADAMS/Rail

Value:

Simulation enables to virtually

perform design certification with less
cost and to investigate system
behavior through tests which cannot
be performed physically

Simulation reduces the cost of design. It is a

fundamental tool to present technical information
to our customers and ensure the viability of our
products. It facilitates the investigation of design
issues like comfort and derailment safety.
-- Emilio Garcia,
Manager, Talgo

Skoda Loc
Business: Railway vehicle manufacturer
Challenge: Establish locomotive bogie
design between different variants
Solution:

ADAMS/Rail detailed models of

locomotives with different
traction devices

Value:

Recommend for implementation

better arrangement for running
gear thanks to simulation results

Thanks to simulation it has been possible to

choose the most cost-effective design for the
locomotive bogies, by evaluating the behavior of
all different variants.
--Vaclav Kraus
Skoda Locomotive

VUKV
Business: Railway vehicle manufacturer
Challenge: Position itself successfully in a
global market
Solution:

Following an extensive
benchmarking, implemented the
state-of-the-art simulation
technology from MSC.Software

Value:

Show competence presenting

highly sophisticated solutions to
their customers

By using MSC.Software products we have been

able to acquire new customers and, most
significantly, open new markets. Our initial
estimate of a three-year payback period proves
to be significantly shorter.
-- Zdenek Malkovsky
VUKV

Case Study:
Association of American Railroads
Challenge:
Perform crash tests on railcar prototype
Solution:
VPD from MSC.Software (based on LS Dyna)
Value:
After correlation with physical testing, VPD can be used to
perform virtual crash tests with enormous cash saving

Voith Turbo
Business:

Supplier for locomotive drive

systems

Challenge: Optimize the complete

locomotive + drive assembly
Solution:

Nastran and ADAMS Functional

Digital Train with FE
components enabled them to
improve traction/braking and
impact performance

Value:

Improved collaboration with

customer. Better information
earlier in the process

Fiat CRF
Business:

European service provider

Challenge: Develop a semi-active lateral

suspension for a new tilting train
Solution:

Integrating train model in

ADAMS/Rail with MATLAB model
of sky-hook suspension design

Value:

Increased low-frequency ride

comfort

Tilting system modifications investigated with the

integrated virtual prototype enabled us to reach
reduction of nearly 50% of the lateral ride figures.
-- Mauro Montiglio
Manager, Vehicle Engineering Projects

Fiat CRF
Business:

European service provider

Challenge: Develop innovative railway

wheelsets with outstanding
reliability performances
Solution:

ADAMS/Rail model of railcar

including MSC.Nastran flexible
wheelsets

Value:

Predict load spectra with

simulation: increase confidence
in design
Average service (400 km)

straight
curve
total

Vertical force

Significant developments in the design of railway

wheelsets in terms of improved durability, reduced noise
and vibration impact, and lower life cycle costs are
expected to be the final result of the project.
-- K. Bel Knani
Manager, HIPERWHEEL Project, Fiat CRF

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10

10

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Case Study:
Warsaw University
Challenge:
Buffer impact simulation
Solution:
VPD from MSC.Software (based on ADAMS/Rail
detailed buffer model mounted on complete
vehicles)

Value:
Guarantee safe performance of buffer

Nedtrain Consulting
Business: Railway Services Consultant
Challenge: Improve railcar efficiency by
reducing delays due to technical
failure
Solution:

Full virtual prototype of door

system (including electric and
pneumatic)

Value:

Virtually improve operational

safety of door opening system

The simulation results will be used to introduce

improvements in the door system operation.
-- E.J.J. De Jong
Nedtrain Consulting

Nedtrain Consulting
Business: Railway Services Consultant
Challenge: Develop a compact system to
measure train weight and wheel
defects (GOTCHA)
Solution:

Measuring site ADAMS model to

gain insight in the dynamic behaviour
of the measuring system

Value:

GOTCHA already used to monitor

wheel tread quality on almost all
electrical NS rolling stock

Using the model the processing of the

measuring signal was optimised resulting in a
high accuracy and reproducibility of the system.
-- E.J.J. De Jong
Nedtrain Consulting

RTU
Business: Railway industry consultant
Challenge: Simulate UK freight wagon ride
acceptance tests
Solution:

ADAMS/Rail model of freight

wagon with custom
simulation/postprocessing event

Value:

Allow prediction of the results of

the UK vehicle acceptance test
within simulation environment

With ADAMS/Rail the effects of modifications to the

vehicle can be evaluated before the actual test
procedure is carried out.
--Yann Bezin
Rail Technology Unit, MMU

Corus - RTU
Business: Railway industry consultant
Challenge: Develop a methodology to
virtually investigate rolling
contact fatigue
Solution:

ADAMS/Rail vehicle models in

combination with non linear FE
rail-ballast models

Value:

Virtually predict the typical stress

response of rail when subjected
to vehicle loads

The forces predicted from the vehicle dynamic

modelling using Adams/Rail are in broad agreement with
measured data from on site instrumentation. The
predicted forces can then be used with confidence in
both the global track and contact stress models.
--Stephen Blair
Corus Rail Technologies

Transnet Freight Rail

Business: largest Railway company in
South Africa
Challenge: predict by simulation the loads in
the overhead system, and the
pantograph during operation, in
order to optimise the tension in
the overhead system to minimise
the forces.
Solution:

MSC.Marc for a unique capability

of line/line contact approach

Value:

The cost of the physical damage

is around 250k, but the cost of
the lost revenue on the unsused
lines runs into millions.

How Can We Help You?

With The Right Tools

With The Right Tools

Product Lifecyle Management (PLM)
Computer Aided Drawing (CAD)
Finite Element Analysis (FEA)
Systems & Controls (S&C)
Multi Body Dynamics (MBD)
Computation Fluid Dynamics (CFD)
Test & Measurement (T&M)

Linking to the Rail Community

Which Tools does the Rail Community use?
MSC Masterkey
Access to Multiple specialised CAE tools
Flexible licensing system
All products integrate easily

VI-Rail
Rail focused MBD tool
Runs on top of MSC Adams
Integrates fully with MSC Masterkey products

Supporting the Rail Community

Consulting Services
VI-Rail Simulations
Thermal Simulations
Thermal Structural Analysis
(UIC510-5)

With The Right People

With The Right People

Product Training
Discipline Training
THRIP Program @ UP Chair in Railway
Engineering
University Program
Recruitment

With The Right Ways

With The Right Ways

Product Support
Service Level Agreement (SLA)
On-Site training
On-Site Mentoring
Knowledge Transfer

Internship program

ESTEQ is your solution!

Who is ESTEQ?

Engineering Solutions focused

company
Since 1994
Head office in Gauteng, offices in
Western Cape & KwaZulu Natal
45 Employees

Brings World Class Technology to SA:

22 Mechanical Engineers
3 Industrial Engineers
1 Electrical Engineer
1 Civil Engineer

SIEMENS, MSC Software, HBM, Mentor Graphics,

Endevco

Who do we help?

Over 1500 local companies

16 local Universities
Over 5 000 users