1. Pantograph Catenary Interaction Framework for Intelligent Control Amiens, France, December 8 th, 2011 Numerical and Hardware-in-the-Loop Simulation of Pantograph-Catenary Interaction Stefano Bruni, Giuseppe Bucca, Andra Collina, Alan Facchinetti

2. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens 2  The assessment of the performance of a given pantograph- catenary system is usually based on line measurements  Experimental test runs are extremely time-consuming and expensive  The availability of simulation tools for pantograph-catenary dynamic interaction is essential or at least can reduce the number of required line tests for: design of new systems optimisation of existing systems interoperability analyses virtual homologation (PantoTRAIN) … Introduction

3. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens 1.Mathematical model and numerical simulation of pantograph-catenary interaction 2.Hybrid simulation of pantograph-catenary interaction 3.Comparison of the simulation tools with line measurements 4.Effect of contact strip deformability 5.Effect of contact dynamics on contact wire wear 6.Concluding remarks Contents of the presentation 3

4. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens  The development of a mathematical model for pantograph- catenary dynamic interaction started at Politecnico di Milano several years ago  Cooperation with Italferr and former FS (Italian State Railways), now RFI (Rete Ferroviaria Italiana)  Simulation tool mainly intended for the assessment of current collection quality, continuously updated  Software was successfully applied: to the design of the new Italian 25 kV a.c. high speed line for the upgrading of the existing Italian 3 kV d.c. line for the design of several applications world-wide, in support of the main overhead line suppliers. Mathematical model of pantograph-catenary interaction 4

5. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens 5 Mathematical model: the catenary model  Finite element schematisation of the contact wire and of the messenger wire  Droppers included as non linear element (non-linear characteristic obtained from laboratory tests) Traditional wire droppers Elastic ring dropper

6. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens 6 Mathematical model: the pantograph model  Pantograph represented as a non-linear lumped parameter system (identification from experimental FRF)  Bending deformability of the collectors introduced by modal superposition approach (impact tests on the single collector)

7. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Catenary motion Collector motion Contact law (penalty method) FcFc Mathematical model: the interaction model FcFc 7

8. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens 8 Hybrid (HIL) simulation of pantograph-catenary interaction Real-time catenary model 8

9. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens 9 Hybrid simulation: the HIL test-rig Lateral actuation (stagger) Electromechanical up to ±400mm @ 360 km/h Vertical actuation 2 independent hydraulic actuators up to 25 Hz Load cells 9

10. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens 10 Hybrid simulation: the catenary model traction compression  3-5 spans (periodic structure)  CW and MW represented through modal superposition approach (tensioned beams)  Effect of droppers’ slackening  “Shift forward” procedure

11. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Comparison of numerical simulation with line measurements 11 ATR95 pantograph - C270 catenary (25 kV a.c.) V = 300 km/h Time histor of the contact force (approximately 3 spans) 1/3 octave band frequency spectra of the contact force CW irregularity was considered in the numerical simulation

12. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Comparison of hybrid simulation with line measurements 12 ATR95 pantograph - C270 catenary (25 kV a.c.) V = 300 km/h Time history of the contact force (approximately 3 spans) 1/3 octave band frequency spectra of the contact force

13. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Comparison with line measurements 13 ATR95 pantograph - C270 catenary (25 kV a.c.) V = 300 km/h σ F [N] σ F 0-2 Hz [N] σ F 7-18 Hz [N] Line tests - average47.117.140.2 Line tests – max.48.920.941.5 Line tests – min.46.115.139.3 Hybrid simulation43.717.637.8 % deviation7.3%1.6%6.1% Numerical simulation37.016.829.4 % deviation21.5%2.1%27.0%

14. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Effect of contact strip deformability (numerical simulation) 14 Exp. freq. [Hz]FE freq. [Hz] 60.1 Hz60 Hz 76.9 Hz76.2 Hz 136 Hz

15. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens 15 Effect of contact strip deformability (numerical simulation) without deformability with deformability Spectra of the vertical accelerations of the front collector Contact losses percentage V=270 km/h V=330 km/h

16. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Numerical simulation of the pantograph- catenary interaction FcFc Wear model A=f(F c,i,V) A Evolution of CW irregularity (single passage) V Initial irregularity N pass. i Effect of contact dynamics on contact wire wear (numerical simulation) Procedure for the estimation of wear evolution 16

17. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Heuristic model of contact wire wear, tuned on the basis of experimental data A = worn area, F c = contact force, i = current intensity, V = sliding speed, H = hardness of CW material, F 0, i 0, V 0 = reference value, R(F c ) = electrical contact resistance α, β, k 1 and k 2 identified from experimental data The wear model Wear model A=f(F c,i,V) Mechanical contribution Electrical contribution 17

18. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens The test-rig enables the testing of full scale collectors at speeds up to 200 km/h, imposing electrical current intensity up to 1200 A dc, 500 A ac 16 2/3 Hz and 350 A ac 50 Hz. Test rig for the study of wear behaviour of contact strip and contact wire 18

19. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens 19 Test rig for the study of wear behaviour of contact strip and contact wire

20. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Rotating fibre-glass disk (R = 2 m) Contact wire 19 Test rig for the study of wear behaviour of contact strip and contact wire

21. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Collector Hydraulic actuator 19 Test rig for the study of wear behaviour of contact strip and contact wire

22. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Ventilation apparatus 19 Test rig for the study of wear behaviour of contact strip and contact wire

23. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Contact resistance vs contact force Results from wear tests: contact resistance 20

24. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens V lm = volume of lost material [mm 3 ] s = travelled distance [km] F C = Contact force [N] CW SWR vs contact force CW SWR vs current Results from wear tests: Contact wire Specific Wear Rate 21

25. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens k 1, k 2,  and β Results from wear tests: Contact wire Specific Wear Rate 22

26. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Comparison between numerical results for two different values of the mechanical tension of the contact wire, i.e. 17 kN and 20 kN mid Evolution of the worn area of the contact wire 23

27. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens Concluding remarks  The numerical simulation and hybrid co-simulation represent useful means to investigate the pantograph-catenary dynamic interaction before line-testing  The degree of accuracy that can be obtained with these two techniques is more than satisfactory  Mathematical models can also give some insight into some of the phenomena involved in pantograph-catenary interaction, e.g. the effects of collector deformability and wear process concerning contact wire and collector strip 24

28. A. Facchinetti PACIFIC’2011, December 18 th, 2011, Amiens 28