March 2004 Ruben Siegmund Inova GmbH Page 1
Servohydraulic Testing Systems
Inova componentsfor Bogie Test Rig
Dipl.- Ing. Ruben Siegmund, Inova GmbH
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Examples of Bogie test rigsThyssen Transrapid at Kassel
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Thyssen Transrapid at Kassel
Examples of Bogie test rigs
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DWA / IFS / Bombardier / RST at Berlin
Examples of Bogie test rigs
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Examples of Bogie test rigsDWA / IFS / Bombardier / RST at Berlin
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Principle of Bogie test rigs
Main parts which could be done by Customer
– Civil engineer work– Power supply – Seismic mass– T-slot table– Portal frame with crossbeam– Mounting brackets– Attachment between bogie and rig
Main parts must be done by Inova– Linear actuators with accessory – Hydraulic power pack system– Hydraulic Distribution System– Hydraulic Control Stations– Digital measuring an control system– Project design and management– Installation and training
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600
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Principle of Bogie test rigs
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1900
5000
Principle of Bogie test rigs
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Concrete design of a Bogie test Lab
Test area
Special Labs
Power pack room
preparation area
Central line control station
stockroom
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Recommended components• First of all - skilled engineers• hydraulic actuators with high accuracy load cells• backlash free joins• adequate oil supply• adequate tube system• adequate t-slot table• adequate Portal frame with crossbeam• flexible Control Electronic with Test and evaluation
software• powerful data acquisition system• Attachment between bogie and rig
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Linear actuator• Hydrostatic bearing linear
actuators series AH
• Nom. Load from 3kNup to 2500 kN
• Nom. stroke:20 mm up to 400 mm
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hydrostatic bearing
• wear and tear free
• friction free operation
• optimal control property
• high side load capacity
• suitable with permanent high speed
• maintenance free
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Load cell series KA• high accuracy class 0,1
• low influence of the side load to the measured signal (< 0.02% at Fq=0.1*Fnom)
• high stiffness
• high own frequency
• easy mounting
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Cardan Joints Series JC
• free from backlash
• working angle +/- 8°
• low friction
• less maintenance work (only smear)
• long live time
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Hydraulic Power Packs Series HU• hydraulic Power Packs Series HU
• adjustable pressure (nominal pressure 280 bar)
• usage of controlled pumps
• expandable flow by connection of several power packs
• several types of power pack remote control
• long life time
• flow rate from 6.3 up to 345 l/min
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Hydraulic Power Packs Series HU• hydraulic Power Packs Series HU
• adjustable pressure (nominal pressure 280 bar)
• usage of controlled pumps
• expandable flow by connection of several power packs
• several types of power pack remote control
• long life time
• flow rate from 6.3 up to 345 l/min
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Safety Start-Stop Valves Series PB• safety Start-Stop Valves Series PB
• high pressure mode up to 315 bar
• low pressure mode 10 up to 100 bar
• restricted flow between 2l/min and 25 l/min in low pressure mode
• modular concept with flow rates of:63, 130, 250 and 630 l/min
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Digital Controller Series EU2000D
• Digital control and measure system• Flexible configuration from one up to eight channels• Multi channel, multi station concept• Configuration as 19“ rack or as central unit with peripheral
controller boxes
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Digital Controller Series EU2000D
Carrying out as:
-Field box
-PC-control cabinet
-Full size control cabinet
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Software LabExpert
• User interface to the digital controller EU2000D
• Comprehensive base functionalities:• - Block programming,• - Peak value controller• - event triggered test run schedule
• Modular extensible:• - Iterative outer loop control• - Damper testing• - elastomer testing• - LCF Test• - command value generation out of
classification tables• - Import- Export of the main Data Formats
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Software LabExpert• easy definition of loading blocks
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Software LabExpert• Building of test sequenz
10*(5*(10*M1+M2)+M3)
• Schleife1=10*M1• Schleife2=5*(S1+M2)• Schleife3=10*(S2+M3)
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Iteration software ITFC / ITRM• Time or frequency based
iteration software
• system identification by sweep signals (frequency bases) dynamic stiffness of specimen (time based)
• Screening of convergence and iteration quality
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Iteration software ITFC / ITRM• Principle function of iteration
software
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Iteration software ITFC / ITRM
LabExpert ITRM
TCP/IP
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Iteration software ITFC / ITRM• First test run
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Iteration software ITFC / ITRM• Result after 4 iteration steps
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100 102 104-5
0
5
10
100 102 104-4
-2
0
2
4
100 102 104-4
-2
0
2
4
100 102 104-20
-10
0
10
20
100 102 104-4
-2
0
2
4
100 102 104-5
0
5
100 102 104-20
-10
0
10
20
100 102 104-4
-2
0
2
4
100 102 104-5
0
5
10
Fx Fy Fz
M1
M2
M3
Level Crossing Plot overview
target signalmeasured signalwithout iteration
Example of results
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• Signal M1• Achse Fx
Example of results
450 450.2 450.4 450.6 450.8 451 451.2
-2
-1
0
1
2
3
4
5
6
time[s]
load
[kN
]
Time Plot m1-kraft-x
m1-kraft-x - target.gdtm1-kraft-x - response-1.gdtm1-kraft-x - response.gdt
100
101
102
103
104
-4
-2
0
2
4
6
8
10Level Crossing Plot m1-kraft-x/
Number of level crossings
Load
[kN
]
m1-kraft-x - target.gdtm1-kraft-x - response-1.gdtm1-kraft-x - response.gdt
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• Signal M2• Achse Fx
Example of results
189.8 190 190.2 190.4 190.6 190.8 191
-10
-8
-6
-4
-2
0
2
4
6
8
10
time[s]
load
[kN
]
Time Plot m2-kraft-x
m2-kraft-x - target.gdtm2-kraft-x - response-1.gdtm2-kraft-x - response.gdt
100 101 102 103 104-15
-10
-5
0
5
10
15Level Crossing Plot m2-kraft-x/
Number of level crossings
Load
[kN
]
m2-kraft-x - target.gdtm2-kraft-x - response-1.gdtm2-kraft-x - response.gdt
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• Signal M2• Achse Fz
Example of results
73.6 73.8 74 74.2 74.4 74.6-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
time[s]
load
[kN
]
Time Plot m2-kraft-z
m2-kraft-z - target.gdtm2-kraft-z - response-1.gdtm2-kraft-z - response.gdt
100 101 102 103 104-5
-4
-3
-2
-1
0
1
2
3
4
5Level Crossing Plot m2-kraft-z/
Number of level crossings
Load
[kN
]
m2-kraft-z - target.gdtm2-kraft-z - response-1.gdtm2-kraft-z - response.gdt
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What must be check for a quote
• analyse the quantity and time schedule of tests which must be doneresult will be: the right lab design
• analyse your experience with servohydraulicresult will be: the right quote design
the right number of actuators in the first step
• analyse your experience in bogie testresult will be: the consulting service needs
the education and training needs
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Servohydraulic Testing Systems
Inova GmbHFürstbischof-Rudolf-Straße 10D - 65385 Rüdesheimphone +49 6722 / 97 22 65fax +49 6722 / 97 22 67 [email protected]