ABSTRACT
I. Introduction ...................................................................................................................... 458
II. The History of Roller Rigs .............................................................................................. 459
III. The Test Technique and Classification of Roller Rigs ................................................... 460
IV. Examples of Roller Rigs.................................................................................................. 462
A. The Chengdu Roller Rig.......................................................................................... 462
1. Structure of the Chengdu Roller Rig ................................................................ 462
a. Degrees of Freedom of the Rollers............................................................. 462
b. Components of the Roller Rig .................................................................... 464
i. Test Unit............................................................................................... 464
ii. Driving System .................................................................................... 465
iii. Hydraulic System................................................................................. 466
iv. Monitoring System............................................................................... 466
v. Data Acquisition and Processing System............................................ 466
vi. Auxiliary System ................................................................................. 466
c. Function of the Roller Unit......................................................................... 467
d. Curve Simulation......................................................................................... 467
2. Characteristics of the Chengdu Roller Rig....................................................... 469
3. Scope of Test Function ..................................................................................... 469
B. Naples Roller Rig..................................................................................................... 470
1. Structure............................................................................................................. 470
a. Power Supply System.................................................................................. 470
b. Overhead Line Simulator ............................................................................ 471
c. Roller Test Bench........................................................................................ 471
d. Drive and Brake System ............................................................................. 472
e. Control System ............................................................................................ 472
f. Data Acquisition System............................................................................. 473
g. Lifting Equipment ....................................................................................... 473
2. Function ............................................................................................................. 473
C. The Tokyo Roller Rig (RTRI)................................................................................. 474
1. Roller Unit ......................................................................................................... 474
2. Flywheel Assembly ........................................................................................... 476
3. Driving Device .................................................................................................. 476
4. Hydraulic Power Source ................................................................................... 476
5. Bogie Holding Device....................................................................................... 476
6. Building and Foundations ................................................................................. 476
D. The Pueblo Roller Rig (TTC).................................................................................. 476
V. Operation and Results ...................................................................................................... 477
A. Test Methods............................................................................................................ 477
1. Status of the Test Vehicle ................................................................................. 478
2. Status of the Roller Rig..................................................................................... 478
3. Stability Test ..................................................................................................... 478
4. Dynamic Simulation Test.................................................................................. 479
5. Curve Simulation Test....................................................................................... 480
6. Power Test ......................................................................................................... 481
7. Modal Analysis Test ......................................................................................... 481
8. Storage Security Test ........................................................................................ 481
B. Differences between Roller and Track .................................................................... 481
1. Differences of Geometry Relationship ............................................................. 481
a. Calculation Method of Wheel-Roller Geometry Relationship ................. 481
b. Geometry Difference of Wheel-Rail Contact and
Wheel-Roller Contact ................................................................................ 484
2. Difference in Creep Coefficient ........................................................................ 487
3. Differences in Stability...................................................................................... 489
4. Difference in Vibration Response..................................................................... 491
5. Difference in Curve Simulation ........................................................................ 493
C. Influence of Setup Errors on Roller Rig Vehicle Stability ..................................... 494
1. Diameter of the Rollers ..................................................................................... 494
2. Gauge of the Rollers ......................................................................................... 494
3. Cant of the Rollers ............................................................................................ 494
4. Coefficient of Friction on the Contact Surface................................................. 496
5. Vehicle Position on the Roller Rig................................................................... 496
6. Yaw Angle between Wheelset and Roller Axle............................................... 497
D. Examples of Comparison Results with Theoretical Analysis................................. 497
1. Stability Test ..................................................................................................... 498
a. Stability Tests and Theoretical Analysis of a Freight Car ......................... 498
b. Stability Test and Theoretical Analysis of a Passenger Car ...................... 500
2. Ride Comfort Test and Theoretical Analysis of a Passenger Car ................... 502
VI. Conclusions ...................................................................................................................... 504
References..................................................................................................................................... 504
Experience teaches us that the complete development cycle (design, prototype, railway line tests,
industrialisation, production start up, in service adjustment, and corrective action) for a new vehicle
featuring a significant level of systems and technological innovation is very time-consuming. The
duration and efficiency of prototype experimentation activities is a key element in the development
of new rolling stock, and is instrumental in terms of technical and economic success. An awareness
of this technological and competitive development has led the railway industry or research
institutes to commit extensive financial and technical resources to the creation of test facilities. The
main objectives are to reduce the time (and therefore the cost) of testing new vehicles, to make as
wide a range of tests available as possible, in order to achieve maximum levels of performance,
reliability, and availability in the shortest possible time.
