High-speed railway wheel life cycle intelligent management system

In recent years, China's high-speed railway has achieved rapid development, and the new concept of "green, intelligent, safe and humanistic" leads the innovative development of high-speed railway in the future. Railway is an important national infrastructure, the main artery of the national economy and a popular means of transportation. It plays an irreplaceable role in supporting the sound and rapid development of my country's social economy and national defense. The large-scale development of high-speed railways with the advantages of large capacity, safety and comfort, all-weather transportation, environmental friendliness and sustainability is the only way and inevitable choice to promote the formation of a large number of high-tech and related industries and manufacturing industries.

 

 

According to relevant data, by the end of 2020, the total mileage of China's high-speed railway will exceed 38000km, accounting for more than 2/3 of the world. By 2035, the total mileage of high-speed rail is expected to reach 70000 kilometers, and the "four vertical and four horizontal" will be upgraded to the "eight vertical and eight horizontal" high-speed rail main channel. By 2050, it will be fully built into a modern railway power. China will develop into one of the countries with the fastest development speed and the largest total mileage of high-speed railway.
Among the many factors affecting railway safety, the study of wheel-rail relationship is one of the most important factors, which affects the safety of vehicle operation and the life of the whole vehicle. Today, please follow the footsteps of Xiaobian to learn about our hospital.Wheel/Rail Relationship and Maintenance Research Center(hereinafter referred to as "Wheel/Rail Center") over the years of research and development innovation results:Intelligent management system for the whole life cycle of high-speed railway wheels.

 

science and technology research and development

Zhai Wanming, an academician of the Chinese Academy of Sciences and chief scientist of the Wheel and Rail Center, proposed in 2015 that China's high-speed rail urgently needs to establish an operation and maintenance standard system. It mentioned that compared with the source countries of high-speed rail such as Japan, Germany, and France, my country's high-speed rail operation time is very short. Practical experience is still lacking, and basic research is also weak. Therefore, in view of the characteristics of China's high-speed rail, we should start from the three aspects of basic source, key technology and operation practice to find the most suitable operation and maintenance mode for China's national conditions.
Based on the wheel rail center over the years, together with a number of brother units, we are committed to developing a set of high-speed railway wheel life cycle intelligent management system, from the design and production, operation management and maintenance and other stages of system management wheel state.

 

 

　　The existing wheel monitoring system monitoring means is relatively simple, and not perfect, can not effectively and comprehensively monitor the state of the wheel and diagnose the type of wheel damage.In addition, there is a lack of capacity to fully manage the full life cycle of the wheel and an effective link with wheel manufacturing and spinning.

Main types of wheel damage

 

　　

Wheel not round tread stripping tread stripping

 

Based on the investigation of the current situation of wheel monitoring and maintenance, the wheel rail center and a number of domestic universities and scientific research institutions jointly developed a set of high-speed railway wheel life cycle intelligent management system.Through the integration of wheel manufacturing, processing and assembly, the use of maintenance and other life cycle information, the construction of high-speed railway wheel life cycle intelligent management system. It realizes the functions of timely monitoring of the health status of high-speed rail wheels, research and judgment of defect trend, fault prediction and early warning, etc.

 

 

science and technology innovation

innovation point
■ For the first time at home and abroad, the research on fault prediction and health management technology of high-speed train wheels is proposed, and the project will realize the information query, data statistical analysis, comprehensive assessment of health status, residual life prediction and preventive rotation repair scheme for the whole life cycle of high-speed train wheels.
■ Innovative design of high-speed train wheel health management model, comprehensive wheel use status and service history information, quantitative given wheel health status.
■ Vehicle-track coupling dynamics calculation, wheel-rail wear model, wheel wear history data and other data as an expert database, tread spin repair parameter calculation method as a judgment rule, the whole road wheel collection data for comprehensive analysis, the development of preventive spin repair program.

Research Overview

 

Technology Roadmap

01 Basic Theory: Vehicle-Track Coupling Dynamics
As the basis of this research, the vehicle-track coupling dynamics theory founded by Academician Zhai has created a new field of railway system dynamics and has been widely recognized internationally.

 

  

 

02 Information acquisition system and wheel-rail force real-time dynamic test system

Collect wheel information:It is equivalent to establishing its own "ID card" for each wheel ". The system manages information about the wheels from birth to death.
wheel rail force dynamic measurement system:Through the acting force and reaction force between wheel and rail, the wheel state can be grasped in real time.

 

 
 

 

03 Big Data Platform: Wheel Health Linked Data Center
The wheel-rail force is input as an important parameter, combined with track information, rotation information and other parameters, and the application of big data technology for data screening, data training, and finally establish the wheel health factor.

 

 

04 Expert System: Wheel Life Cycle Health Management System
Through the wheel health factor, the wheel fault and fault type are judged, and the wheel rotation mileage is optimized and the fault development trend is predicted in combination with historical data.

 

 

High-speed railway wheel life cycle health management system advantages

1. The wheel information acquisition system realizes the wheel electronic label:Through the birth of the wheel information, wheel assembly information, wheel status real-time monitoring information, operating line track design, maintenance information, wheel maintenance information to achieve the electronic labeling of the wheel, to achieve real-time tracking and monitoring.
2. The big data platform grasps the quality and running status of each wheel in real time:Wheel life cycle information database to achieve wheel resume management, quality tracking, life management. Monitor the operation process within the life of the wheel.
3. Ensure the safety of vehicle operation:Through defect generation and development rate analysis and wheel trace tracing, the class ensures the safety of vehicle operation.
4. Reduce operation and maintenance costs and extend service life:Reduce operation and maintenance costs by predicting the remaining life of the wheel and providing an economic spin repair scheme.

 

application value

scientific research value
Combing the influence factors and interaction relationship in the whole life cycle of the wheel;
■ Compare the historical data of wheel status and wear trend of each line and vehicle to provide the basis for the optimization of vehicle and track design and maintenance work;
Accumulate a large amount of wheel wear data to provide a data base for preventive maintenance research;
economic value
■ Realize the information management of the whole life process data of high-speed train wheels;
■ Improve the service life of wheels and reduce maintenance costs;
■Realize the dynamic management and effective allocation of wheel status, improve the operation efficiency of the entire high-speed railway system, and realize the further improvement of economic benefits;
■ High traceability of abnormal failure wheels to improve vehicle safety;
 

industrialization process

■ The intelligent management system has established a system framework;
■ The prototype of the wheel-rail force real-time dynamic test system was manufactured and entered the test stage, and the subway system was tested, and its accuracy and response time met the expected standards;
■ Build big data algorithms.

 

 

The industrialization of rail transit is a long and complex process due to the multidisciplinary and interdisciplinary nature and the complexity of the verification process. In the future, the wheel rail center will adhere to the spirit of "continuous self-improvement and moral integrity" of Tsinghua University, continue to promote the rapid landing of industrialization, and help China's rail transit industry to a new level.

Wheel/Rail Relationship and Maintenance Research Center
The Research Center for Wheel/Rail Relationship and Maintenance was led by Professor Zhai Wanming, an academician of the Chinese Academy of Sciences. Academician Zhai Wanming has been engaged in the research of dynamics and vibration of rail transit engineering for a long time, and has opened up a new field of railway system dynamics research. The research center relies on the team's scientific research advantages in the direction of rail transit and the accumulation of scientific research results over the years to carry out scientific research, achievement transformation, product services and other work on railway and urban rail transit preventive maintenance theory and maintenance equipment. The core technologies include vehicle-track coupling dynamics theory; wheel-rail state perception technology: wheel-rail force ground perception system, force measuring wheel set, track state perception system; heavy-duty train safety, model control, evaluation and intelligent driving technology; heavy-duty train dynamics analysis, bogie technology and CAE analysis of key components.

 

Source | Wheel/Rail Relationship and Maintenance Research Center
Editor | Wang Xiao
The final interpretation right of the above related technologies belongs to the Wheel/Rail Relationship and Maintenance Research Center.