This presentation gives an overview of rail related problems ESTEQ can help to solve. It is a combination of work from MSC Software, VI-Grade and ESTEQ

1. Solving Your Rail Related Problems

2. Solving Your Rail Related Problems
Rail vehicle simulations
Dynamics, stability, derailment…
Detailed Rail-Wheel interaction, wear…
Control systems, brake systems, traction…
Wagon interaction, buffer impact…
Permanent way simulations
Rail stresses, deformation…
Substructure stresses, deformation…
Component simulations
Stress, Fatigue…

3. The Solution Triangle

4. The Technology

5. Virtual Prototyping Defined
Functional simulation of real-world systems
Reduces time-intensive, costly, hardware build-
test-refine cycles
Improves quality (cut warranty and
repair/maintenance costs)

6. Virtual Prototyping Defined
Functional simulation of real-world systems
Reduces time-intensive, costly, hardware build-
test-refine cycles
Improves quality (cut warranty and
repair/maintenance costs)

7. Virtual Prototyping Defined
Thermal Comfort and Air
Quality in Carriages
Functional simulation of real-world systems
Reduces time-intensive, costly, hardware build-
test-refine cycles
Improves quality (cut warranty and
repair/maintenance costs)

8. VI-Rail
Applications

9. The Functional Digital Train
Full Railway System
Bogie Body Accessories Permanent Way
Suspensions Interference Buffers Track beams
Wheels / Contact Packaging Brakes Ballasts
Dampers Passenger Safety Engine groups Bridges
Active devices
Pantographs

10. The Functional Digital Train
Full Railway System
Bogie Body Accessories Permanent Way
Suspensions Interference Buffers Track beams
Wheels / Contact Packaging Brakes Ballasts
Dampers Passenger Safety Engine groups Bridges
Active devices
Pantographs

11. Integration Platform
CAD
FEA
Integration Platform
Durability Controls
Vibration In-House
Solutions

12. VI-Rail
Vehicle Stability
• Automatic Stability Analysis
• Specification of critical damping to determine stability (0%, 5%,...)
• Specification of conicity range for automatic generation of stability map

13. VI-Rail
Traction/Braking
• Friction coefficient variability
• With track distance
• With creepage
• With lateral coordinate on rail / wheel
Friction Coefficient

14. VI-Rail
Traction/Braking
• Application: detailed drive simulation during traction maneuver
• Oscillations in drive system can be carefully tracked down and eliminated

15. Packaging/Interference
• DMU/Replay integrates ADAMS/PPT into CATIA v5
to perform virtual collision check and envelopes
calculation
• Conceptual collision detection also available in the
ADAMS environment

16. Integrated Flexibility/Durability
Flex body representation
Stress recovery calculation
and color map visualized
into ADAMS/PPT

17. Integrated Vibration Analysis
Frequency response optimization of ride
indexes according to
Equivalent conicity
Suspension stiffnesses
Damper characteristics
Immediate information about qualitative
influence of design changes on running
comfort

18. Integrated DOE/Optimization
Through the use of ADAMS/Insight:
The scaling factors for all VI/Rail components
are automatically defined
Several design changes can be automatically
investigated
Results are formatted in 3D response
surfaces, animations, and HTML pages which
can be directly published for the whole
engineering team
Lat Acc RMS
0,65
0,6
0,6-0,65
0,55
0,55-0,6
0,5-0,55 0,5
0,45-0,5 0,45
0,4-0,45 1,4
0,4
1
0,6 PS ZStiff
0,8
1 0,6 Factor
PD Damping Factor 1,2 1,4

19. VI-Rail
Detailed Wheel/Rail Contact
Real Lift-Off Representation

20. VI-Rail
Detailed Wheel/Rail Contact
Flanging with Multi-Point-Contact

21. VI-Rail
Detailed Wheel/Rail Contact
Allows to switch between different profiles along the track
Implemented for WRGEN contact element

22. VI-Rail
Detailed Wheel/Rail Contact
Possibility to change wheel radius along circumference
Available when using WRGEN contact element
Different radii specified in wheel configuration matrix

23. From Concept to Prototype
• Functional Virtual Prototyping as a complete solution for railway
engineering
• Confirmed by several customers and several applications
• Enabling communication between the engineering tools
• Rely on railway expertise and powerful, specialistic tools through strategic
relationships

24. REFERENCES

25. Deutsche Bahn AG
Business: European railway operator
Challenge: Evaluate stresses developing in
rail bridges from high speed trains
Solution: Using ADAMS/Rail in combination
with FE to virtually estimate the
bridge mid-span stress time
histories
Value: Enables prediction of stress
histories without expensive
physical testing
“A high flexibility in modeling different types of vehicles has
been reached by taking advantage of the template-builder
structure… to build up different ICE assemblies by referencing
simply to an ICE bogie and an ICE car body template.”
--Manfred Zacher,
Deutsche Bahn AG

26. RDSO
Business: Research arm of the Indian
Ministry of Railways
Challenge: Develop a flat rail car for safe
operation at 100 km/h
Solution: Using ADAMS/Rail and
NASTRAN with field wheel/rail
measurements to virtually
evaluate acceptance criteria
Value: Virtual tests demonstrated that
design shall pass the field
criteria of Indian Railways
“ADAMS/Rail is for RDSO a necessary virtual prototyping tool to
ensure good financial health of the organization and reduction in
cost of development and testing of a new design.”
-- Nitin Chowdary
Director, Vehicle Dynamics Group

27. Trenitalia
Business: European railway operator
Challenge: Implement braking device in
experimental railway vehicle
Solution: Behavior of the WSPD (Wheel
Slide Protection Device)
active system is investigated
using ADAMS-Matlab Co-
Simulation
Value: Able to optimize slide
protection device with the help
of virtual prototyping
“The proposed model has a behaviour qualitatively and
quantitatively analogous to the on line tests.”
-- P. Presciani
Manager, UTMR Trenitalia

28. Bombardier
Business: Railway rolling stock
manufacturer
Challenge: Rapidly develop an optimized
traction control system
Solution: Using MSC.Patran/Nastran,
ADAMS/Rail with
ADAMS/Controls + MATLAB as
integrated virtual prototyping
solution for mechatronics
Value: Increased confidence in product
“Commissioning of traction control could be finished in a short
time with very good results to the satisfaction of our customer,
even though the conditions were very difficult.”
-- Peter Haese
Traction Systems Engineering

29. Alstom
Business: European railway vehicles
manufacturer
Challenge: Investigate poor performance
caused by car body torsion
interaction with bogie hunting
Solution: Integrated VI/Rail bogie model
with FE carbody
Value: Overall comfort performance
optimize, resulting in wide
commercial success
“A complete DOE analysis enabled the engineers to test the
dynamic behaviour of the complete system and to find out the
optimal parameter settings which restricts the vibration of the
construction and therefore optimises the comfort behaviour.”
-- Pascal Geoffroy
Manager, Rolling Stock

30. Alstom
Business: Railway vehicles manufacturer
Challenge: Optimize new streetcar
for rollover stability and
derailment avoidance
Solution: Evaluated the vehicle behavior
virtually to optimize the design
Value: Improved safety; greater
confidence
“The simulation produced results in agreement with all
service conditions and the overall dynamic behavior.
Derailment and rollover stability measurements have
been matched with a maximum error of 3%.”
-- Massimo Lenti
Manager R&D, Alstom IPS

31. Case Study:
GE Transportation
Business:
North American locomotive manufacturer
Challenge:
Investigate the effect of wheel back-to-back
distance on locomotive stability and safety
Solution:
Parametric model built in ADAMS/Rail and
run through standard suite of maneuvers
Value:
Met customer critical-to-quality
requirements on locomotive design
“We have done a lot of wonderful work using ADAMS.”
-- Jingjun Zhang
Control and Auxiliary Systems

32. Patentes Talgo
Business: Railway rolling stock
manufacturer
Challenge: Meet UIC518 acceptance
requirements when operating
on tracks with different gauges
Solution: Virtual comfort and safety
studies for different system
configurations
Value: Fulfilled UIC518 requirements
“The results achieved have been coherent
regarding tilting in curves, accelerations on car
bodies, contact forces, and guidance system.”
-- Emilio Garcia,
Manager, Talgo

33. Patentes Talgo
Business: Railway rolling stock manufacturer
Challenge: Investigate dynamic behavior of high-
speed train
Solution: VPD and MSC.ADAMS/Rail
Value: Simulation enables to virtually
perform design certification with less
cost and to investigate system
behavior through tests which cannot
be performed physically
“Simulation reduces the cost of design. It is a
fundamental tool to present technical information
to our customers and ensure the viability of our
products. It facilitates the investigation of design
issues like comfort and derailment safety.”
-- Emilio Garcia,
Manager, Talgo

34. Skoda Loc
Business: Railway vehicle manufacturer
Challenge: Establish locomotive bogie
design between different variants
Solution: ADAMS/Rail detailed models of
locomotives with different
traction devices
Value: Recommend for implementation
better arrangement for running
gear thanks to simulation results
“Thanks to simulation it has been possible to
choose the most cost-effective design for the
locomotive bogies, by evaluating the behavior of
all different variants.”
--Vaclav Kraus
Skoda Locomotive

35. VUKV
Business: Railway vehicle manufacturer
Challenge: Position itself successfully in a
global market
Solution: Following an extensive
benchmarking, implemented the
state-of-the-art simulation
technology from MSC.Software
Value: Show competence presenting
highly sophisticated solutions to
their customers
“By using MSC.Software products we have been
able to acquire new customers and, most
significantly, open new markets. Our initial
estimate of a three-year payback period proves
to be significantly shorter.”
-- Zdenek Malkovsky
VUKV

36. Case Study:
Association of American Railroads
Challenge:
Perform crash tests on railcar prototype
Solution:
VPD from MSC.Software (based on LS Dyna)
Value:
After correlation with physical testing, VPD can be used to
perform virtual crash tests with enormous cash saving

37. Voith Turbo
Business: Supplier for locomotive drive
systems
Challenge: Optimize the complete
locomotive + drive assembly
Solution: Nastran and ADAMS Functional
Digital Train with FE
components enabled them to
improve traction/braking and
impact performance
Value: Improved collaboration with
customer. Better information
earlier in the process

38. Fiat CRF
Business: European service provider
Challenge: Develop a semi-active lateral
suspension for a new tilting train
Solution: Integrating train model in
ADAMS/Rail with MATLAB model
of sky-hook suspension design
Value: Increased low-frequency ride
comfort
“Tilting system modifications investigated with the
integrated virtual prototype enabled us to reach
reduction of nearly 50% of the lateral ride figures.”
-- Mauro Montiglio
Manager, Vehicle Engineering Projects

39. Fiat CRF
Business: European service provider
Challenge: Develop innovative railway
wheelsets with outstanding
reliability performances
Solution: ADAMS/Rail model of railcar
including MSC.Nastran flexible
wheelsets
Value: Predict load spectra with
simulation: increase confidence
in design Average service (400 km)
“Significant developments in the design of railway
wheelsets in terms of improved durability, reduced noise
and vibration impact, and lower life cycle costs are straight
Vertical force
expected to be the final result of the project.” curve
total
-- K. Bel Knani
Manager, HIPERWHEEL Project, Fiat CRF
0 1 2 3 4 5
10 10 10 10 10 10

40. Case Study:
Warsaw University
Challenge:
Buffer impact simulation
Solution:
VPD from MSC.Software (based on ADAMS/Rail
detailed buffer model mounted on complete
vehicles)
Value:
Guarantee safe performance of buffer

41. Nedtrain Consulting
Business: Railway Services Consultant
Challenge: Improve railcar efficiency by
reducing delays due to technical
failure
Solution: Full virtual prototype of door
system (including electric and
pneumatic)
Value: Virtually improve operational
safety of door opening system
“The simulation results will be used to introduce
improvements in the door system operation.”
-- E.J.J. De Jong
Nedtrain Consulting

42. Nedtrain Consulting
Business: Railway Services Consultant
Challenge: Develop a compact system to
measure train weight and wheel
defects (GOTCHA)
Solution: Measuring site ADAMS model to
gain insight in the dynamic behaviour
of the measuring system
Value: GOTCHA already used to monitor
wheel tread quality on almost all
electrical NS rolling stock
“Using the model the processing of the
measuring signal was optimised resulting in a
high accuracy and reproducibility of the system.”
-- E.J.J. De Jong
Nedtrain Consulting

43. RTU
Business: Railway industry consultant
Challenge: Simulate UK freight wagon ride
acceptance tests
Solution: ADAMS/Rail model of freight
wagon with custom
simulation/postprocessing event
Value: Allow prediction of the results of
the UK vehicle acceptance test
within simulation environment
“With ADAMS/Rail the effects of modifications to the
vehicle can be evaluated before the actual test
procedure is carried out.”
--Yann Bezin
Rail Technology Unit, MMU

44. Corus - RTU
Business: Railway industry consultant
Challenge: Develop a methodology to
virtually investigate rolling
contact fatigue
Solution: ADAMS/Rail vehicle models in
combination with non linear FE
rail-ballast models
Value: Virtually predict the typical stress
response of rail when subjected
to vehicle loads
“The forces predicted from the vehicle dynamic
modelling using Adams/Rail are in broad agreement with
measured data from on site instrumentation. The
predicted forces can then be used with confidence in
both the global track and contact stress models.”
--Stephen Blair
Corus Rail Technologies

45. Transnet Freight Rail
Business: largest Railway company in
South Africa
Challenge: predict by simulation the loads in
the overhead system, and the
pantograph during operation, in
order to optimise the tension in
the overhead system to minimise
the forces.
Solution: MSC.Marc for a unique capability
of line/line contact approach
Value: The cost of the physical damage
is around € 250k, but the cost of
the lost revenue on the unsused
lines runs into millions.

46. How Can We Help You?

47. With The Right Tools…

48. With The Right Tools…
Product Lifecyle Management (PLM)
Computer Aided Drawing (CAD)
Finite Element Analysis (FEA)
Systems & Controls (S&C)
Multi Body Dynamics (MBD)
Computation Fluid Dynamics (CFD)
Test & Measurement (T&M)

49. Linking to the Rail Community
Which Tools does the Rail Community use?
MSC Masterkey
Access to Multiple specialised CAE tools
Flexible licensing system
All products integrate easily
VI-Rail
Rail focused MBD tool
Runs on top of MSC Adams
Integrates fully with MSC Masterkey products

50. Supporting the Rail Community
Consulting Services
VI-Rail Simulations
Thermal Simulations
Thermal Structural Analysis
(UIC510-5)

51. With The Right People…

52. With The Right People…
Product Training
Discipline Training
THRIP Program @ UP Chair in Railway
Engineering
University Program
Recruitment

53. With The Right Ways…

54. With The Right Ways…
Product Support
Service Level Agreement (SLA)
On-Site training
On-Site Mentoring
Knowledge Transfer
Internship program

55. ESTEQ is your solution!

56. Who is ESTEQ?
• Engineering Solutions focused
company
• Since 1994
• Head office in Gauteng, offices in
Western Cape & KwaZulu Natal
• 45 Employees
• 22 Mechanical Engineers
• 3 Industrial Engineers
• 1 Electrical Engineer
• 1 Civil Engineer
? • Brings World Class Technology to SA:
• SIEMENS, MSC Software, HBM, Mentor Graphics,
Endevco…
• Who do we help?
• Over 1500 local companies
• 16 local Universities
• Over 5 000 users