车辆动态系统协同仿真及刚柔耦合关键技术的研究与应用
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摘要
对于现代轨道车辆的机械-电子复杂系统而言,基于多体系统(MBS, Multi-body System)的集成设计能力是非常重要的。系统集成设计能力的提高需要以下三要素的支持：具有创新思维的设计理念、多专业软件工具及其接口处理技术,其中,专业软件工具接口处理技术是体现创新思维的关键。
从系统集成设计能力出发,通过多种类型轨道车辆动态仿真研究,以及与试验对比的经验累积,本文提出了协同仿真与设计方法体系(CSDM, Collaborative Simulation and Design Methodologies)。这一方法体系具有如下两个特点：①以控制器模型移植和瞬时工作点线性分析作为MBS与CACE (Computer Aided Control Engineering Software)接口处理技术对策；②以几何约束构建主要约束、弹性内力约束逼近辅助约束作为柔性体对MBS接口处理对策。按照上述接口关系所建立的协同仿真平台更加强调了多专业知识的集成、协同设计的交互和分析工具的互补。
基于上述协同仿真与设计方法体系(CSDM),以四个典型工程案例为研究对象,本文进一步开展了如下基于多体系统的协同仿真及刚柔耦合应用研究与验证：
1.为了提高磁浮车辆电磁悬挂(EMS, Electro-Magnetic Suspension)的轨道适应性及鲁棒稳定性,采用上述MBS与CACE接口处理对策,提出了单轨正交模型及2-DOF主动控制策略。侧滚摄动可以转换为两侧沉浮摄动,因此悬浮单元的2DOF主动控制实质上具有沉浮、点头、横移、摇头和侧滚等5DOF摄动的鲁棒稳定性。由于电磁铁模块运动模态截取误差的适度降低,2DOF主动控制的悬浮与导向稳定性得到提高。主动导向控制以导向电流差动方式实现了悬浮单元的轨道对中控制。在高速磁浮列车模块化组装的协同环境下,对曲线通过性能、线路匹配性能和车桥耦合机制等3个专题进行了深入研究,其中,端部横向力敏感变化及端部减载问题得到了测试数据的证实。
2.为使轨道客车横向稳定仿真分析更好地体现其特殊的自激振动意义,提出了一种基于轮轨匹配的横向稳定性分析新方法。以某出口地铁编组车辆作为研究对象,基于MBS的多车编组非线性协同优化方式,确定了既有线路UIC54/ORE提速120km/h的优化方案。在空簧装车特性的虚拟测试与试验对比基础上,利用模板建模仿真技术,给出了一列8车编组的舒适性评价。在考虑空簧高度阀的位移滞后特性情况下,弹性联结抗侧滚扭杆的改进方案可以形成适当的抗侧滚等效刚度以确保乘坐舒适性。
3.以新型DQ35钳夹车作为大型刚柔耦合系统研究对象,进行了重载横向稳定性、重载曲线通过安全性和空车回送速度等刚柔耦合动态仿真。仿真结果表明：由于采用了上述柔性体接口处理技术对策,大型刚柔耦合动态仿真结果具有试验可比性,如导向销横向力的动荷系数和空载短联挂回送速度等均与线路动力学试验相吻合。对于重物摩擦约束稳定性和重载小半径曲线通过等运行安全性问题,刚柔耦合动态仿真进一步给出了其动力学解释,其所提出的改进建议已在长大货车的研制与试验中被采纳。
4.在刚柔耦合技术应用领域,为了分析结构振动对疲劳寿命的影响程度,进一步提出了一种基于刚柔耦合仿真的振动疲劳分析方法。以集装箱平车车体垂向振动加速度偏大作为是典型分析案例,基于刚柔耦合动态仿真的摩擦减振对比分析揭示了在车体弹性振动激励形成过程中,摇枕悬挂的斜楔摩擦低频卡滞是一个非常关键的影响因素。基于动应力恢复等后处理数据,通过危险点动应力的模态相关性分析和循环应力的幅频统计对比,确定了车体振动对结构疲劳的影响程度。
本文的课题研究工作得到如下项目资助：
1、国家“863”高技术研究发展计划项目：《复杂产品协同设计、仿真、优化一体化平台研究开发及其应用》(项目编号：2006AA04Z160)；
2、国家“863”高技术研究发展计划项目：《高速磁浮车辆研制(一)》(项目编号：2004AA505240)；
3、“十一五”国家科技支撑计划：300KM/H高速动车组现代集成制造系统(项目编号：2006BAFO1A01)。
For the complex mechatronic systems of modern railway vehicles, the integration design capability based on Multi-body System (MBS) is very crucial. To improve the systemic integration capability needs the support of the three following factors:design concept with creative thoughts, multi-discipline software tools and their interface transaction technologies, in which the interface transaction technologies between the different disciplinary software tools are the keys to represent the creative thoughts.
From the viewpoint of the integration design capability, and with the groundwork of the accumulated experiences in the dynamical simulations and test contrasts of the various-type railway vehicles, Collaborative Simulation and Design Methodologies (CSDM) are proposed in this paper, which are characterized as the two following features:(1) specifying the migration of the controller model and the linearization on the working point as the interface transaction between MBS and CACE (Computer Aided Control Engineering Software); (2) representing the main constraints constructed by the geometric pairs and the slave ones approached with the elastic inner-force restrictions as flex-body interfacing to MBS. And the platform formed by these above interface transactions has emphasized more the integration of multi-discipline knowledge, the reciprocity of collaborative design, and the complementarity of analysis tool.
With the CSDM, the four typical cases about the industrial applications of collaborative simulations based on MBS were further studied and validated in this paper.
1. in order to improve the adjustability and robust-stability of Electro-Magnetic Suspension in MagLev vehicle to railway, Mono-rail Ortho-Model and 2-DOF active control strategy were presented by the above interface transaction technology between MBS and CACE. Since the rolling disturbance can be converted the bouncing disturbances on both sides,2-DOF active control of levitating unit has actually the rubost control stability to 5-DOF disturbances, i.e. bouncing, pitch, lateral, yaw and roll. Because of the reasonable reduction in the error of electro-magnet module's kinematic modal truncation, the 2-DOF active control stability of levitation and guidance can be gotten improved. Meanwhile the rail centering of levitating unit is achieved by the guiding active control in the differential guiding current mode. Under the collaborative environment with the modeling modularization of high-speed MagLev trainset, the three following special topic studies were furthermore investigated:the curve negociation performance, track match performance and vehicle-bridge coupling mechanism, in which the sensitive variation of lateral forces and unloading problems in both ends are received by the measuring data validation.
2. in order that the simulation analysis of railway passenger vehicle's lateral stability may better represent the uncommon significance of self-excited vibration, a novel analysis methodology of lateral stability was proposed based on wheel/rail match. For an export tram marshalling plan, with the non-linear collaborative optimization mode of multi-vehicle trainset based on MBS, the optimization scheme was determined for increasing velocity 120km/h on existing line condition (UIC54/ORE). After the virtual measuring of assembled air-spring's characteristics and contrasting with testrig data, the comfort indices of the 8-vehicle trainset, which are assembled by template-based modeling technique, were evaluated. Under the condition of considering the displacement lag feature of air-spring's leveling valve, the suitable anti-roll equivalent stiffness can be formed by the improved solution of elastic-joined anti-roll torsion bar to ensure the ride comfort quality.
3. As a large-scale rigid-flex coupling system, the new-built 350T Schnabel Wagon were investigated on laden lateral stability, laden curve negociation safty and tare returning velocity. These contrast simulation analyses show that:due to the application of the above flex-body interface transaction technology strategy, the large-scale flex-rigid coupling simulation has comparability with testing data, e.g., the dynamic load coefficient of lateral force of guide pin and the returning velocity of tare short-trailer, etc., are consistent with line dynamic test. For the laden run-time safty problems, e.g., the stability of the weight's friction constraints and the laden small-radius curve negociation, etc., the dynamic explainations were given by flex-rigid coupling simulations, and the improving advices proposed have be adopted in the development and tests of Long and Big Cargo Freight Cars.
4. for the applications of rigid-flex coupling techniques, a methodology of vibration fatigue analysis was presented based on flex-rigid coupling simulation in order to analysis the influencing extent of structural vibration effects on fatigue life. Taking the case that the container flatcar's vertical vibration acceleration is on the high side as a topical analysis paradigm, the friction damping contrast analysis based on flex-rigid coupling simulations reveals that the dynamical interaction of the wedge's stick-slip friction in the bolster suspension is playing a very important role in generating the excitation of carbody's elastic vibration. With the post-processing data such as dynamic stress recovery, the influencing extent of carbody vibration to structural fatigue was determined by means of the correlation between dynamical stress and modal vibration, and the stress range histograms by which the amplitude and number of cycle stress on critcal points are contrasted stastically among the multi-condition.
The research works in this paper are suppoted as follows:
1.863 National High-Tech. R&D Program for Integrative-platform Development and Application of Complex Products' Collabrative Design, Simulation and Optimazition, No. 2006AA04Z160;
2.863 National High-Tech. R&D Program for Reseach and development of Hign-speed MagLev Vehicle, PART I, No.2004AA505240;
3. National Key Technology R&D Program in the 11th Five Year Plan of China for Concurrent Integrating Manufactory System of 300km/h High-speed Trainset, No. 2006BAF01A01
从系统集成设计能力出发,通过多种类型轨道车辆动态仿真研究,以及与试验对比的经验累积,本文提出了协同仿真与设计方法体系(CSDM, Collaborative Simulation and Design Methodologies)。这一方法体系具有如下两个特点：①以控制器模型移植和瞬时工作点线性分析作为MBS与CACE (Computer Aided Control Engineering Software)接口处理技术对策；②以几何约束构建主要约束、弹性内力约束逼近辅助约束作为柔性体对MBS接口处理对策。按照上述接口关系所建立的协同仿真平台更加强调了多专业知识的集成、协同设计的交互和分析工具的互补。
基于上述协同仿真与设计方法体系(CSDM),以四个典型工程案例为研究对象,本文进一步开展了如下基于多体系统的协同仿真及刚柔耦合应用研究与验证：
1.为了提高磁浮车辆电磁悬挂(EMS, Electro-Magnetic Suspension)的轨道适应性及鲁棒稳定性,采用上述MBS与CACE接口处理对策,提出了单轨正交模型及2-DOF主动控制策略。侧滚摄动可以转换为两侧沉浮摄动,因此悬浮单元的2DOF主动控制实质上具有沉浮、点头、横移、摇头和侧滚等5DOF摄动的鲁棒稳定性。由于电磁铁模块运动模态截取误差的适度降低,2DOF主动控制的悬浮与导向稳定性得到提高。主动导向控制以导向电流差动方式实现了悬浮单元的轨道对中控制。在高速磁浮列车模块化组装的协同环境下,对曲线通过性能、线路匹配性能和车桥耦合机制等3个专题进行了深入研究,其中,端部横向力敏感变化及端部减载问题得到了测试数据的证实。
2.为使轨道客车横向稳定仿真分析更好地体现其特殊的自激振动意义,提出了一种基于轮轨匹配的横向稳定性分析新方法。以某出口地铁编组车辆作为研究对象,基于MBS的多车编组非线性协同优化方式,确定了既有线路UIC54/ORE提速120km/h的优化方案。在空簧装车特性的虚拟测试与试验对比基础上,利用模板建模仿真技术,给出了一列8车编组的舒适性评价。在考虑空簧高度阀的位移滞后特性情况下,弹性联结抗侧滚扭杆的改进方案可以形成适当的抗侧滚等效刚度以确保乘坐舒适性。
3.以新型DQ35钳夹车作为大型刚柔耦合系统研究对象,进行了重载横向稳定性、重载曲线通过安全性和空车回送速度等刚柔耦合动态仿真。仿真结果表明：由于采用了上述柔性体接口处理技术对策,大型刚柔耦合动态仿真结果具有试验可比性,如导向销横向力的动荷系数和空载短联挂回送速度等均与线路动力学试验相吻合。对于重物摩擦约束稳定性和重载小半径曲线通过等运行安全性问题,刚柔耦合动态仿真进一步给出了其动力学解释,其所提出的改进建议已在长大货车的研制与试验中被采纳。
4.在刚柔耦合技术应用领域,为了分析结构振动对疲劳寿命的影响程度,进一步提出了一种基于刚柔耦合仿真的振动疲劳分析方法。以集装箱平车车体垂向振动加速度偏大作为是典型分析案例,基于刚柔耦合动态仿真的摩擦减振对比分析揭示了在车体弹性振动激励形成过程中,摇枕悬挂的斜楔摩擦低频卡滞是一个非常关键的影响因素。基于动应力恢复等后处理数据,通过危险点动应力的模态相关性分析和循环应力的幅频统计对比,确定了车体振动对结构疲劳的影响程度。
本文的课题研究工作得到如下项目资助：
1、国家“863”高技术研究发展计划项目：《复杂产品协同设计、仿真、优化一体化平台研究开发及其应用》(项目编号：2006AA04Z160)；
2、国家“863”高技术研究发展计划项目：《高速磁浮车辆研制(一)》(项目编号：2004AA505240)；
3、“十一五”国家科技支撑计划：300KM/H高速动车组现代集成制造系统(项目编号：2006BAFO1A01)。
For the complex mechatronic systems of modern railway vehicles, the integration design capability based on Multi-body System (MBS) is very crucial. To improve the systemic integration capability needs the support of the three following factors:design concept with creative thoughts, multi-discipline software tools and their interface transaction technologies, in which the interface transaction technologies between the different disciplinary software tools are the keys to represent the creative thoughts.
From the viewpoint of the integration design capability, and with the groundwork of the accumulated experiences in the dynamical simulations and test contrasts of the various-type railway vehicles, Collaborative Simulation and Design Methodologies (CSDM) are proposed in this paper, which are characterized as the two following features:(1) specifying the migration of the controller model and the linearization on the working point as the interface transaction between MBS and CACE (Computer Aided Control Engineering Software); (2) representing the main constraints constructed by the geometric pairs and the slave ones approached with the elastic inner-force restrictions as flex-body interfacing to MBS. And the platform formed by these above interface transactions has emphasized more the integration of multi-discipline knowledge, the reciprocity of collaborative design, and the complementarity of analysis tool.
With the CSDM, the four typical cases about the industrial applications of collaborative simulations based on MBS were further studied and validated in this paper.
1. in order to improve the adjustability and robust-stability of Electro-Magnetic Suspension in MagLev vehicle to railway, Mono-rail Ortho-Model and 2-DOF active control strategy were presented by the above interface transaction technology between MBS and CACE. Since the rolling disturbance can be converted the bouncing disturbances on both sides,2-DOF active control of levitating unit has actually the rubost control stability to 5-DOF disturbances, i.e. bouncing, pitch, lateral, yaw and roll. Because of the reasonable reduction in the error of electro-magnet module's kinematic modal truncation, the 2-DOF active control stability of levitation and guidance can be gotten improved. Meanwhile the rail centering of levitating unit is achieved by the guiding active control in the differential guiding current mode. Under the collaborative environment with the modeling modularization of high-speed MagLev trainset, the three following special topic studies were furthermore investigated:the curve negociation performance, track match performance and vehicle-bridge coupling mechanism, in which the sensitive variation of lateral forces and unloading problems in both ends are received by the measuring data validation.
2. in order that the simulation analysis of railway passenger vehicle's lateral stability may better represent the uncommon significance of self-excited vibration, a novel analysis methodology of lateral stability was proposed based on wheel/rail match. For an export tram marshalling plan, with the non-linear collaborative optimization mode of multi-vehicle trainset based on MBS, the optimization scheme was determined for increasing velocity 120km/h on existing line condition (UIC54/ORE). After the virtual measuring of assembled air-spring's characteristics and contrasting with testrig data, the comfort indices of the 8-vehicle trainset, which are assembled by template-based modeling technique, were evaluated. Under the condition of considering the displacement lag feature of air-spring's leveling valve, the suitable anti-roll equivalent stiffness can be formed by the improved solution of elastic-joined anti-roll torsion bar to ensure the ride comfort quality.
3. As a large-scale rigid-flex coupling system, the new-built 350T Schnabel Wagon were investigated on laden lateral stability, laden curve negociation safty and tare returning velocity. These contrast simulation analyses show that:due to the application of the above flex-body interface transaction technology strategy, the large-scale flex-rigid coupling simulation has comparability with testing data, e.g., the dynamic load coefficient of lateral force of guide pin and the returning velocity of tare short-trailer, etc., are consistent with line dynamic test. For the laden run-time safty problems, e.g., the stability of the weight's friction constraints and the laden small-radius curve negociation, etc., the dynamic explainations were given by flex-rigid coupling simulations, and the improving advices proposed have be adopted in the development and tests of Long and Big Cargo Freight Cars.
4. for the applications of rigid-flex coupling techniques, a methodology of vibration fatigue analysis was presented based on flex-rigid coupling simulation in order to analysis the influencing extent of structural vibration effects on fatigue life. Taking the case that the container flatcar's vertical vibration acceleration is on the high side as a topical analysis paradigm, the friction damping contrast analysis based on flex-rigid coupling simulations reveals that the dynamical interaction of the wedge's stick-slip friction in the bolster suspension is playing a very important role in generating the excitation of carbody's elastic vibration. With the post-processing data such as dynamic stress recovery, the influencing extent of carbody vibration to structural fatigue was determined by means of the correlation between dynamical stress and modal vibration, and the stress range histograms by which the amplitude and number of cycle stress on critcal points are contrasted stastically among the multi-condition.
The research works in this paper are suppoted as follows:
1.863 National High-Tech. R&D Program for Integrative-platform Development and Application of Complex Products' Collabrative Design, Simulation and Optimazition, No. 2006AA04Z160;
2.863 National High-Tech. R&D Program for Reseach and development of Hign-speed MagLev Vehicle, PART I, No.2004AA505240;
3. National Key Technology R&D Program in the 11th Five Year Plan of China for Concurrent Integrating Manufactory System of 300km/h High-speed Trainset, No. 2006BAF01A01
引文
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