Low adhesion detection and identification in a railway vehicle system using traction motor behaviour

It is important to monitor the wheel-rail friction coefficient in railway vehicles to improve their traction and braking performance as well as to reduce the number of incidents caused by low friction. Model based fault detection and identification (FDI) methods, especially state observers have been commonly used in previous research to monitor the wheel-rail friction. However, the previous methods cannot provide an accurate value of the friction coefficient and few of them have been validated using experiments. A Kalman filter based estimator is proposed in this research project. The developed estimator uses signals from the traction motor and provides a new and more efficient approach to monitoring the condition of the wheel-rail contact condition. A 1/5 scaled test rig has been built to evaluate the developed method. This rig comprises 2 axle-hung induction motors driving both the wheelsets of the bogie through 2 pairs of spur gears. 2 DC generators are used to provide traction load to the rollers through timing pulleys. The motors are independently controlled by 2 inverters. Motor parameters such as voltage, current and speed are measured by the inverters. The speed of the wheel and roller and the output of the DC generator are measured by incremental encoders and Hall-effect current clamps. A LabVIEW code has been designed to process all the collected data and send control commands to the inverters. The communication between the PC and the inverters are realized using the Profibus (Process Field Bus) and the OPC (Object Linking and Embedding (OLE) for Process Control) protocol. 3 different estimators were first developed using computer simulations. Kalman filter and its two nonlinear developments: extended Kalman filter (EKF) and unscented Kalman filter (UKF) have been used in these 3 methods. The results show that the UKF based estimator can provide the best performance in this case. The requirement for measuring the roller speed and the traction load are also studied using the UKF. The results show that it is essential to measure the roller speed but the absence of the traction load measurement does not have significant impact on the estimation accuracy. A re-adhesion control algorithm, which reduces excessive creepage between the wheel and rail, is developed based on the UKF estimator. Accurate monitoring of the friction coefficient helps the traction motor work at its optimum point. As the largest creep force is generated, the braking and accelerating time and distance can be reduced to their minimum values. This controller can also avoid excessive creepage and hence potentially reduce the wear of the wheel and rail. The UKF based estimator development has been evaluated by experiments conducted on the roller rig. Three different friction conditions were tested: base condition without contamination, water contamination and oil contamination. The traction load was varied to cover a large range of creepage. The importance of measuring the roller speed and the traction load was also studied. The UKF based estimator was shown to provide reliable estimation in most of the tested conditions. The experiments also confirm that it is not necessary to measure the traction load and give good agreement with the simulation results. With both the simulation and experiment work, the UKF based estimator has shown its capability of monitoring the wheel-rail friction coefficient

Identification of Two-Mass Mechanical Systems Using Torque Excitation: Design and Experimental Evaluation

This paper deals with methods for parameter estimation of two-mass mechanical systems in electric drives. Estimates of mechanical parameters are needed in the start-up of a drive for automatic tuning of model-based speed and position controllers. A discrete-time output error (OE) model is applied to parameter estimation. The resulting pulse-transfer function is transformed into a continuous-time transfer function, and parameters of the two-mass system model are analytically solved from the coefficients of this transfer function. An open-loop identification setup and two closed-speed-loop identification setups (direct and indirect) are designed and experimentally compared. The experiments are carried out at nonzero speed to reduce the effect of nonlinear friction phenomena on the parameter estimates. According to results, all three identification setups are applicable for the parameter estimation of two-mass mechanical systems.Peer reviewe

To develop an efficient variable speed compressor motor system

This research presents a proposed new method of improving the energy efficiency of a Variable Speed Drive (VSD) for induction motors. The principles of VSD are reviewed with emphasis on the efficiency and power losses associated with the operation of the variable speed compressor motor drive, particularly at low speed operation.The efficiency of induction motor when operated at rated speed and load torque is high. However at low load operation, application of the induction motor at rated flux will cause the iron losses to increase excessively, hence its efficiency will reduce dramatically. To improve this efficiency, it is essential to obtain the flux level that minimizes the total motor losses. This technique is known as an efficiency or energy optimization control method. In practice, typical of the compressor load does not require high dynamic response, therefore improvement of the efficiency optimization control that is proposed in this research is based on scalar control model.In this research, development of a new neural network controller for efficiency optimization control is proposed. The controller is designed to generate both voltage and frequency reference signals imultaneously. To achieve a robust controller from variation of motor parameters, a real-time or on-line learning algorithm based on a second order optimization Levenberg-Marquardt is employed. The simulation of the proposed controller for variable speed compressor is presented. The results obtained clearly show that the efficiency at low speed is significant increased. Besides that the speed of the motor can be maintained. Furthermore, the controller is also robust to the motor parameters variation. The simulation results are also verified by experiment

EXTENDED KALMAN FILTER DESIGN FOR RAILWAY TRACTION MOTOR

Monitoring the adhesion force between a railway wheel and a rail surface is very essential in maintaining the high acceleration and braking performance of railway vehicles. Due to the difficulties encountered in direct measurement of friction coefficient, creepage and adhesion force, state observers are used as indirect estimation methods. This paper proposes an effective estimation method, which exploits railway traction motor behaviour to give an assistance for realizing wheel slip and adhesion control in order to be used in railway applications. This method plays an active role in optimizing the use of the existing adhesion and reducing wheel wear by decreasing high creep values. With this method, adhesion force can be indirectly estimated by measuring stator currents, and angular speed of the AC traction motor and using dynamic relationships based on the extended Kalman filter (EKF) simulation model. The re-adhesion controller can be designed to regulate the motor torque command according to the maximum available adhesion depending on the estimated results. To test the proposed method, simulations were performed under different friction coefficients.   

Modeling and experimental characterization of belt drive systems in micro-hybrid vehicles

Belt Drive Systems (BDS) constitute the traditional automotive mechanism used to power the main internal accessories (such as the alternator, water pump and air conditioning pump) taking power from the engine's crankshaft rotational motion. BDS usually work in the severe ambient conditions of the engine compartment and are subject to highly dynamic excitations coming from the crankshaft harmonics. The substitution of the traditional alternator with an electric machine, namely Belt Starter Generator (BSG), is the most promising micro-hybrid technology towards a quick and effective satisfaction of the current regulations of fuel consumption and pollutant emissions reduction. The use of a BSG leads to increased stresses in the already complex front end accessory drive. As a matter of fact, a BSG is an electrical machine able to work both as motor and as generator and defines two distinct functioning modes of the drive, namely motor and alternator modes. The relative alternation of tight and slack spans profoundly changes the functionality of the overall drive and affects its transmissions capability and efficiency, furthermore resulting in NVH (noise vibration harshness) effects that need to be carefully addressed. Traditional automatic tensioners acting on the slack span of the alternator mode application are not capable of facing the irregular stresses of a BSG-based BDS which requires the use of a tensioning device capable of keeping the belt tension inside a safe range and of preventing slippage during all the operating conditions of the drive. With this goal many solutions are currently being investigated, such as the cooperation of two tensioners one for each span, active tensioners, double arm tensioners or hydraulic tensioners. The critical issues due to the involvement of BSG in BDS require a deep study focused on the tension conditions of the belt and its influence on the overall efficiency of the system. The aim of the research described in this thesis is to obtain a defined modelling approach of belt drive systems for micro-hybrid vehicles and to validate it through extensive experimental analysis. To obtain a reliable testing environment, a dedicated full-electric test rig was designed and realized. The test rig presented in this work is capable of assuring the repeatability and accuracy of the measurements leaving aside the uncertainties deriving from the irregularities of the ICE behaviour that usually affect the experimental activities conducted on front engine accessory drives. After providing both the modelling and testing environment as assets for the analysis, several experimental activities are carried out with the goal of assessing the dynamic behaviour of belt drive systems and their efficiency, comparing the performances of different tensioning solutions, understanding the behaviour in static and dynamic conditions of a traditional automatic tensioner and one example of an omega twin arm tensioner, which is the tensioning solution most explored by the manufacturers at present. The ultimate goal of gaining a complete understanding of belt drive systems in the special case of micro-hybrid vehicles is eventually fulfilled by an experimental validation of the static and dynamic models proposed

Design, development and characterisation of a FPGA platform for multi-motor electric vehicle control

Two three-phase squirrel-cage induction motors are used as a propulsion system of an electric vehicle (EV). A simple XC3S1000 FPGA is used to simultaneously control both electric motors, with field oriented control and space vector modulation techniques. To electronically distribute the torque between the two electric motors, a simple, yet effective, strategy based on a uniform torque distribution has been implemented. Experimental results obtained with a multi-motor EV prototype demonstrate the proper operation of the proposed system

Traction axial flux motor-generator for hybrid electric bus application

Tato dizertační práce se zabývá návrhem původního motor-generátoru s axiálním tokem a buzením permanetními magnety, zkonstruovaným specificky pro hybridní elektrický autobus. Návrhové zadání pro tento stroj přineslo požadavky, které vedly k této unikátní topologii tak, aby byl dosažen výkon, účinnost a rozměry stroje. Tato partikulární topologie motor-generátoru s axiálním tokem je výsledkem literární rešerše, kterou následoval výběr koncepce stroje s představeným návrhem jako výsledkem těchto procesů. Přístup k návrhu stroje s axiálním tokem sledoval „multi-fyzikální“ koncepci, která pracuje s návrhem elektromagnetickým, tepelným, mechanickým, včetně návrhu řízení, v jedné iteraci. Tím je v konečném návrhu zajištěna rovnováha mezi těmito inženýrskými disciplínami. Pro samotný návrh stroje byla vyvinuta sada výpočtových a analytických nástrojů, které byly podloženy metodou konečných prvků tak, aby samotný návrh stroje byl přesnější a spolehlivější. Modelování somtného elektrického stroje a celého pohonu poskytlo představu o výkonnosti a účinnosti celého subsytému v rozmanitých operačních podmínkách. Rovněž poukázal na optimizační potenciál pro návrh řízení subsystému ve smyslu maximalizace účinnosti celého pohonu. Bylo postaveno několik prototypů tohoto stroje, které prošly intensivním testováním jak na úrovni sybsytému, tak systému. Samotné výsledky testů jsou diskutovány a porovnány s analytickými výpočty parametrů stroje. Poznatky získané z prvního prototypu stroje pak sloužily k představení možností, jak zjednodušit výrobu a montáž stroje v příští generaci. Tato práce zaznamenává jednotlivé kroky během všech fází vývoje elektrického stroje s axiálním tokem, počínaje výběrem konceptu stroje, konče sumarizací zkušeností získaných z první generace prototypu tohoto stroje.This thesis deals with a design of a novel Axial-Flux Permanent Magnet Motor-Generator for a hybrid electric bus application. Thus, the design specification represents a set of requirements, which leads toward a concept of a unique topology meeting performance, efficiency and dimensional targets. The particular topology of the Axial-Flux Permanent Magnet Motor-Generator discussed in this work is an outcome of deep literature survey, followed by the concept selection stage with the layout of the machine as an outcome of this processes. The design approach behind this so-called Spoke Axial-Flux Machine follows an idea of multiphysics iterations, including electromagnetic, thermal, mechanical and controls design. Such a process behind the eventually proposed design ensured a right balance in between all of these engineering disciplines. A set of bespoke design and analysis tools was developed for that reason, and was backed up by extensive use of Finite-Element Analysis and Computational Fluid Dynamics. Therefore, the actual machine design gained higher level of confidence and fidelity. Modelling of the machine and its drive provided understanding of performance and efficiency of the whole subsystem at various operational conditions. Moreover, it has illustrated an optimization potential for the controls design, so that efficiency of the machine and power electronics might be maximized. Several prototypes of this machine have been built and passed through extensive testing both on the subsystem and system level. Actual test results are discussed, and compared to analytical predictions in terms of the machine's parameters. As a lesson learned from the first prototype of this machine, a set of redesign proposals aiming for simplification of manufacturing and assembly processes, are introduced. This work records steps behind all phases of development of the Axial Flux Machine from a basic idea as an outcome of concept selection stage, up to testing and wrap-up of experience gained from the first generation of the machine.