Electric Test System for Simulating and Measuring Performance
Moog has developed a complete electric test system named the European Railway Train Monitoring System (ERTMS) for the Italian Railway Company, Trenitalia. This system tests the speed of the train and simulates the behavior of the train equipment during normal use on the line. Data on behavior is based on over 300 conditions collected by Trenitalia using a special black box installed on the trains. This test system makes it possible to verify what might happen when a particular condition is encountered. This unique ability to test and measure simultaneously is one of the key benefits of the Moog Solution
The Moog Solution involved the development of two different electric simulators and one pneumatic:
- Ground Railway Simulator
- Wheel Simulator
- Brake Simulator
By replicating real conditions and certifying components using the same testing machinery it is possible to ensure safety and quality of the train under numerous possible conditions, while saving time and operating costs.
Ground Railway Simulator
This electric testing apparatus is able to simulate the movement of the train with the ground. It is based on 2 electric servomotors working on 2 parallel axes that move 13 belts. The rotation of the belts is able to simulate the velocity between the train and the ground. This test machine has 2 columns where it is possible to install the radar and the instrumentation.
This testing apparatus is enclosed in a sound-proof cabinet to ensure safety and noise protection, The maximum speed reached from the test bench is 180 km/h with an acceleration and deceleration of 3 m/sec². The velocity closed-loop system is made using the Moog DS2000 servodrive and brushless servomotors.
Wheel Simulator
The Wheel Simulator Testing apparatus simulates 2 wheels of the train and uses Moog's brushless servomotors and a T200 Moog Servodrive for motion control. Simulation of a complete train requires 4 test benches as 8 wheels correspond to the complete locomotive.
One advantage of this machine is the ability to measure the speed of the wheels by simulating the velocity of the train and verifying the measurement of the sensors used on the train. As the Ground Railway Simulator approaches the velocity set (which correspond to the velocity of the wheels) a mathematical model of the complete train is applied.
Brake Simulator
The Brake Simulator Testing apparatus uses 8 pneumatic actuators to simulate the actuation of the brakes. Specially developed mechanical springs are used to create the load on the actuators. When the train is braking the wheel simulator will reduce the speed. For example, when simulating the train stopping at the station, the Ground Railway Simulator will reduce the velocity of the belts (both the test systems are correlated by a mathematical model) and the hardware for the brake will make the train stop.
Summary
To complete this project, Moog in Italy collaborated with Trenitalia and the University of Firenze who prepared all the specifications. Moog designed and manufactured the complete test system in its facility in Italy. Moog was invited to participate in this project and has an agreement for further cooperation continuing in the future. This project was an ideal example of how collaboration results in the development of a superior solution. In this case the result is a test system capable of replicating.
Author
Bruno Fazzari is currently the Sales Manager for Testing and Systems for Moog in Italy. He is an Electrical Engineer and has been taught Physics at the University of Milan. In addition Bruno's background includes working as a System Engineer at Magnaghi Aerospace.