An experimental methodology to support development of yaw damper prototypes based on a hardware-in-the-loop test bench

Abstract

Research and development of innovative suspension components for rail vehicles have involved huge investments in recent years. Research efforts have focussed on designing and optimising suspension systems to deal with the new challenges introduced in railway dynamics by the continuous increase in vehicle speed. In particular, yaw dampers have been a relevant research topic due to their influence on vehicle stability. In this context, this paper aims to propose a Hardware-In-the-Loop (HIL) methodology for testing yaw dampers under experimental conditions close to real operating scenarios, comparing the influence of different prototypes on the stability of high-speed rail vehicles. A reduced vehicle model is proposed for real-time integration in HIL tests. This model provides a reference stroke to be imposed on the prototype tested, considering the actual damping force provided by the device being analysed. Two yaw damper prototypes are introduced to validate the proposed methodology by means of comparative analysis at different vehicle speeds. The experimental results provided by the HIL test bench are then compared with corresponding analysis done using Multi-Body (MB) simulations. The proposed HIL methodology has proved to be able to test physical prototypes and define guidelines to assist damper manufacturers developing and optimising yaw damper components.

KEYWORDS:

• Hardware-in-the-loop
• rail dynamics
• yaw damper
• real-time testing
• high-speed stability

Acknowledgements

This study is part of a research project involving Politecnico di Milano and Koni BV. The authors gratefully acknowledge Koni for providing the support and data necessary for this work.

Disclosure statement

No potential conflict of interest was reported by the author(s).