Wagon Design Research Articles

Realization and testing of the Extended Market Wagon

The Extended Market Wagon (EMW) (see article start image) is an advanced lightweight freight wagon that was developed as part of the Fr8Rail 4 project in Europe’s Rail in the Shift2Rail IP-5 programme. In a previous article, the lightweight design developed for the EMW by the German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt, DLR) within the Competitive Freight Wagon (CFW) consortium was described [1]. In the following article, the subsequent manufacture of the final wagon design will be described, as well as the display of the wagon at the InnoTrans 2022 in Berlin and its testing under real world conditions in Velim in Czechia.

INTEGRATED RESEARCH OF MULTI-PURPOSE STANCHION BASKETS FOR TRANSPORTING TIMBER AND CONTAINERS

Analyses of cargo transport in 2021 show that despite the increased volume of cargo transported by all types of transport compared to 2020, road transport is still dominant compared to rail transport. Therefore, all actions aimed at improving these unfavorable relations (rail transport vs. road transport) in transport, particularly cargo transport, should be considered purposeful and justified. One such activity is the ongoing work on the design and construction of freight wagons for specialized transport. Unlike universal wagons, specialized wagons are characterized by a limited ability to transport a wide range of material groups. An example is the transport of timber. However, the development of new transport technologies, and above all, technical and organizational progress, force the organizers of these transport modes to look for new logistic and rolling stock solutions. The aforementioned transport of timber is an example of this. The transport of wood does not constitute a large volume of transport, but taking into account its transport issues (transport with large truck tractors, high axle loads, and high risks for other road users), it is a classic example of the fact that it should not be carried out by road over long distances. Therefore, all actions aimed at reducing these issues and improving efficiency by using rail transport are desirable and even necessary. The article presents an innovative design solution in the form of a stanchion basket installed on flat wagons, allowing the use of standard wagons of this type to transport both containers and timber as well as loads such as beams and pipes. Such a solution will allow the use of empty runs of these wagons after unloading wood at the destination station for further transport of containers and vice versa. The considerations described in the article show the research process at the construction stage and testing the prototype of the built basket and the wagon with the stanchion basket structure placed on it.

Analysis of the Strength of the Supporting Structure of a TwoSection Hopper Wagon under Operating Loading Conditions

It is proposed to improve hopper wagon design to provide the possibility of simultaneous transportation of different types of cargo. This improvement consists of dividing the body into two separate sections, interacting with each other through a vertical wall and horizontal connecting belts. A calculation by using the FEM in the SolidWorks Simulation has been carried out to determine the strength of the construction of the two-section hopper wagon. The results of the research showed that the maximum load of the hopper wagon occurs in the first design mode (impact). However, the obtained stresses were lower than permissible by 30%. To calculate the indicators of the wagon dynamics, modeling was carried out. All received dynamics indicators were within the permissible limits. For transporting a hopper wagon on railway ferries in international traffic, it is suggested to use units for the fastening chain. Research of the dynamic load of the hopper wagon supporting structure was carried out through mathematical modeling. The strength analysis of the hopper-wagon-bearing structure was carried out. It was found out that the stresses in the hopper wagon structure did not exceed the normative values. The results of the research will contribute to the increased profitability of railway transport. Additionally, the results of the work can be useful in the creation of modern designs of wagons, including for international traffic.

Method for designing freight wagons for use in industry and engineering teaching

The transport of goods on the Brazilian railway networks has been growing over the last decades, reflecting growth in industries in this segment, including those related to the design of railway wagons. The general objective of this paper is to propose a method for designing railway wagons capable of developing the usual wagon models and meeting specific design demands, which can be applied in industrial environments and education. The proposed method combines practices identified in the literature on the design of railway wagons with traditional product development methods. It was structured in three phases: Informational Design, Conceptual Design, and Detail Design. The proposed method was evaluated by wagon manufacturers in Brazil and applied in teaching environments, demonstrating its feasibility. The method proposed for the design of railway wagons presented in this work has a high affinity with the practices adopted by the industry and is easy to apply in the academic environment, helping both in the training of human resources and in the execution of new wagon design projects.

Lightweight design of the Extended Market Wagon

The Extended Market Wagon is a design concept for an advanced lightweight freight wagon and has been developed as part of the Fr8Rail 4 project in Europe’s Rail. Fr8Rail 4 is focused on improving the efficiency and capacity of rail freight through the use of modern technologies, design strategies and operational concepts. Using tools such as topology optimizations and FEM structural analysis, as well as the incorporation of design elements focused on the use of the DAC and single wheelset running rear, a new, innovative lightweight freight wagon design has been achieved.

Lightweight design of the Extended Market Wagon

The Extended Market Wagon is a design concept for an advanced lightweight freight wagon and has been developed as part of the Fr8Rail 4 project in Europe’s Rail. Fr8Rail 4 is focused on improving the efficiency and capacity of rail freight through the use of modern technologies, design strategies and operational concepts. Using tools such as topology optimizations and FEM structural analysis, as well as the incorporation of design elements focused on the use of the DAC and single wheelset running rear, a new, innovative lightweight freight wagon design has been achieved.

FUNDAMENTALS OF MODULAR DESIGN OF PROSPECTIVE NEW GENERATION PASSENGER SLEEPING WAGONS

Purpose. The aim of the work is to study the directions for creating promising competitive passenger sleeping wagons based on the application of the principles of their modular design. Methodology. The research is based on the analysis of literature sources, formation of a system of wagon modules and development on their basis of possible variants of modular design of passenger sleeping wagons and assessment of prospects for their application based on mathematical analysis of the degree of unification of car designs. Findings. In the course of research, it was established that the design of promising passenger sleeping wagons of the new generation should be based on the principles of significantly improving the quality and comfort of passenger transport based on the use of new layout schemes and relevant principles of modular design. The basic geometric module of passenger wagons of any functional purpose assumes increase in width of its body of 3,4 m. Systems of modular design of passenger sleeping wagons in several variants developed on the basis of the offered new layout schemes providing application of two lateral or only one vestibule located in one end wagons or in the middle of their bodies. The proposed layout schemes also provide for increasing the width of longitudinal passages in passenger rooms, equipping wagons with different numbers of bathrooms depending on the type of wagons for their intended purpose, equivalent in size parameters berths in reserved or compartment wagons of the appropriate class. Originality. The scientific novelty of the work is that for the first time, based on selected concepts, a system of modules for the design of passenger wagons for various functional purposes, their definitions and evaluation of the prospects of the proposed modular design systems for passenger wagons. Practical value. Developed systems of modular design of promising passenger sleeping wagons and compartment wagons of the new generation provide a significant increase in their comfort levels, improve the quality and safety of passenger transport, as well as significantly reduce the timing and amount of funding for cars of different classes and purposes, maintenance and repairs during operation.

Evaluation of interoperability to Ukrainian tank cars, as they are recognized for the transportation of non-healthy cargoes by railway transport

Ensuring safety during the transportation of goods by railway transport with the minimization of the level of risks is a priority task today. An analysis was made that shows that in Ukraine there are significant developments in the field of improving the design of wagons, their dynamic characteristics and safety. Manufacturers of railway cars strive to increase the number of new, high-quality and technically advanced (under the terms of interoperability) railway rolling stock in use. 11 interoperability specifications were considered: infrastructure; energy; management; noise; persons with limited mobility; safety in tunnels; freight cars; locomotives, passenger cars and rolling stock; freight transportation telematics; passenger transportation telematics; the movement of trains that are approved and currently in operation. The considered requirements and components of the Technical Certification of Interoperability and domestic normative documents for railway cars, namely: the requirements of the Technical Certification of Interoperability for freight railway cars; requirements of regulatory documents in Ukraine regarding tank cars; technical characteristics of tank cars produced in Ukraine. A comparative analysis was made of the conformity of the general technical parameters of tank cars manufactured in Ukraine, the principle of operation and design of brake systems of freight cars, the conformity of the dimensions of tank cars, regarding the determination of the dimensions of railway rolling stock (or the dimensions of rolling stock), the fulfillment of conditions under which it is possible the east of the rolling stock. Calculations were made for an empty car in the presence of a raised outer rail, as well as calculations of traffic safety criteria according to these standards. Taking into account the requirements for the production of modern rolling stock is a necessity, which is considered on the example of tank cars, which are currently produced for compliance with interoperability requirements, and the proposed priority measures to achieve the specified compliance

Eco-innovations in rail transport

The importance of sustainable development and eco-innovation in modern economies has been rising in recent years. The idea of eco-innovation is to introduce new solutions and thus gain a competitive advantage, but without or with minimal detriment to the quality of the natural environment. This aim of this paper is to explore the eco-innovations in rail transport by presenting the case study of modified coal wagons. Therefore the main research question is: how the modifications in the coal wagon design can impact the effectiveness of cargo transport and contribute to reducing the damage to the quality of the natural environment? The presented case study shows that the introduction of some seemingly minor design changes to the wagons, taking into account the application of legal restrictions of rail transport, are of great importance in the case of handling large flows of cargo over long distances, and thus contribute to the reduction of a carbon footprint.

The Dynamic and Strength Analysis of an Articulated Covered Wagon with the Circular Pipe Design

An articulated covered wagon design was developed. The wagon feature is that the body-bearing elements are made of circular pipes. This technical solution made it possible to reduce the tare weight of the wagon while ensuring the strength conditions. Mathematical simulation of the dynamic loading of the developed articulated covered wagon design was carried out under the main operating conditions. In the calculations of the observed quantities, an application of symmetry with regard to the longitudinal axis of the wagon was used. The accelerations, as the components of the dynamic load acting on the wagon, were determined. The dynamic loading computer simulation results of the developed wagon design are also presented. The strength analysis of the articulated covered wagon supporting structure made it possible to conclude that the strength indexes were within the allowed limits. The wagon bearing structure was analyzed for fatigue strength. The weld strength analysis results of the most loaded part of the wagon-bearing structure are presented. The results obtained for the desired quantities revealed their symmetrical distribution in the wagon structure. This research will contribute to improving the efficiency of railway transport operation.

Educational tool based on a morphological matrix for design alternative generation for use in railway wagon design

Over the past 20 years, undergraduate railway engineering education has been on the rise in Brazil. However, a long period without investments in the sector led to the absence of up-to-date material in Portuguese to back up the teaching of specific courses in the program. To help bring the program up to speed, this work presents the development of a wagon design support tool, based on the principles of the design methodology process. The proposed tool combines data from the national railway sector with classic tools such as functional modeling and the morphological matrix. As the result, an instrument that directs the student to a more realistic solution for the design possibilities is presented to support wagon design. One of the observed benefits is the focus shift from the search to the analysis of the technical possibilities arising from using the working principles presented.

Examination of structural properties of a new railway wagon design for flammable substance transportation

The article covers information from the field of static strength tests of freight wagons, in this case the static strength test was performed on a Zans 95 m3 tank wagon. The introduction of the article contains the division and significance of freight wagon tests. Various types of test load in static tests which affect the vehicle structure are also mentioned. Subsequently, the test requirements are written together with the technical parameters of the tested wagon. The next chapter deals with measured quantities and the instruments used for measurement, as well as a schematic sketch of the location of some sensors. The final chapter contains a description of the individual tests, where the procedure of loading, stay, unloading and reading of values for all static tests examined within the article are given. In the conclusion, verbal opinion is added to the summary of measurement results and the wagon construction is evaluated in terms of meeting the required strength conditions. The article contains graphs and tables from the outputs of some measurements.

Повышение универсальности вагонов-цистерн для перевозки нефтехимических грузов

Objective: Characterise the methods for optimisation of tank wagon fl eet. Determine the advantages obtained by the proprietor from wagon modernization. Establish the opportunity for increasing universality of rolling stock on the example of modernisation of tank wagons designed to transport petrochemical cargoes. Methods: Parameters of tank wagons for petrochemical cargo transportation in operation were compared to those of a modernised wagon. Structural elements of a wagon that require modernisation to be consistent with current regulatory requirements were identifi ed. Results of calculations and tests were analysed, and wagon certifi cation was carried out. Results: Ways of modernisation of tank wagons are shown. Primary wagon structural elements that require modernisation are described. Strength, fatigue strength and stability calculations were carried out. Safety valve throughput capacity is calculated, and requirements for this index during transportation of petrochemical cargoes. Optimum design for a drain device is established. A series of engineering prototype verifi cation tests in situ was run, including durability tests which confi rmed the possibility of safe operation of a modernised wagon throughout its service life. The wagon was certifi ed for compliance with railway rolling stock safety requirements. Practical importance: The studies conducted confi rm possibility of modernisation of petroleum and oil tank wagons for transportation of a wide range of cargoes. This would allow create a project for tank wagon modernisation. The novel wagon type is included in the Cargo Wagon Design Reference Guide. Proprietor can implement modernisation of wagons in accordance with the developed modernisation project

Dynamic Load and Strength Determination of Carrying Structure of Wagons Transported by Ferries

A rapid development of economic relations between states has required an introduction of combined rail/ferry transportation. A feature of this type of transportation is the possibility of wagons traveling by sea on specially equipped ships—railway ferries. However, the transportation of wagons by sea is accompanied by damage to their structures. This follows from the fact that the wagons are not adapted to this type of transportation. In addition, the design of wagons does not consider the loads that can act on them during transportation by sea. In this connection, it is important to study the dynamic loading and strength of wagons during their transportation by sea. The current work investigated into dynamic load on the carrying structure of wagons transported by ferries using mathematical and computer modelling and defined accelerations on the wagon body. The adequacy of the models was checked with an F-test. The results of strength calculation for the carrying structure of a wagon made it possible to conclude that a typical fixation diagram does not provide the admissible range of strength parameters. The current work proposed an improved fixation diagram for cars on the deck with the viscous binder. The solution was substantiated by the results of the mathematical modelling of dynamic forces, strength, and stability of the carrying structure of a wagon on the deck. The results of the work will contribute to the creation of recommendations for the transportation of wagons on ferries. The research can contribute to safe transportation of wagons by ferries, and higher efficiency of the combined transportation

Development of Single and Externally Integrated Transport Area in Central Asia

Competently built strategy for development of international transport corridors passing through the countries of Central Asia ensures economic development of not only the states located in this region, but also of other countries participating in transportation processes. At the same time, the practices of development of international transport corridors reveal several problems which comprise inconsistency of regulatory acts of the parties involved, differences in technical standards, lack of uniformity of railway gauge, duration of customs clearance. The objective of the work was to study transport corridors of Central, Western and South Asia and the existing infrastructural, organizational, and technological limitations for their development. The methods of economic, statistical, and engineering analysis were used. The research has considered problems in development of international transport corridors and possible solutions there-of through organization of intermodal transportation by a single transport operator of Uzbekistan, as well as the current state of transport corridors linking Central, Western, South Asia and China with the EU countries, including development of China–EU railway corridors. In that context, the article suggests the analysis of several legal, organizational, technological factors , as well as of infrastructural restrictions using the example of the Kashgar (China)–Osh (Kyrgyzstan) railway section, prior to construction of which it is proposed to use intermodal transportation. The proposals refer to creating the Shanghai Cooperation Organisation (SCO) transport and logistics association and to developing the design of universal wagons with variable gauge wheel sets adapted for operation on railways of various gauges.

Static Lateral Pressure of Heavy Haul Wagon’s End Wall and Side Wall Based on Soil Mechanics

A new analytical method for calculating the static lateral pressure is introduced to obtain more accurate calculation method of the lateral pressure of end wall and side wall of heavy haul wagon. In the method, the influence of mechanical characteristics of the end wall is considered. For the end wall, a basis for lightweight design can be provided by deducing an analytical method of the lateral pressure which is closer to the experimental results. For the side wall, calculation formula which takes the cycloid curve as projection of rupture surface is derived. The correctness of the formula is verified by comparison with the experimental results. The nonlinear distribution of lateral pressure along the height direction is achieved. Further research is done on the relationship between key parameters of the heavy haul wagon design and the lateral pressure on the side wall.

Operational and tegnological requirements for the profitable provision of rail freight transport

This article provides an overview of the most pertinent operational and design requirements of rail freight transport technology that could be instrumental in the profitable participation of rail transport in an economically deregulated freight transport market. The following three aspects are addressed: (1) The market segments that are serviced profitably by rail transport in industrial countries; (2) comparative cost of rail transport and the specific operational methods employed to make rail transport more cost advantageous; and (3) the most pertinent technological requirements set upon rail transport systems to operate commercially viably. Regarding technological requirements, the following aspects are elaborated upon: (1) train types and purpose-built wagons to appropriately serve specific market segments; (2) the type of freight terminals employed to effectively support rail transport operations; and (3) the types of handling equipment needed to enable rail transport to operate smoothly. The purpose-built wagon models and the types of train compositions to optimally adhere to rail transport operators’ specific needs, as well as the the most important factors that underlie wagon design, are discussed. Subsequently the functional requirements of the main terminal facilties that receive freight trains are discussed. Lastly, the handling equipment needed to load, unload and transload transportable freight on, from and between wagons and other modes of transport swiftly, safely and at lowest cost per freight unit are discussed.

Experimental confirmation of the theory of implementation of the coupled design of center girder of the hopper wagons for iron ore pellets

We present results and special features of the conducted experimental studies into proposed theory of implementation of the coupled design of a center girder of hopper wagons for iron ore pellets. The importance and relevance of the set scientific and practical task is predetermined by economic expediency. In particular, by the attained possibility of bringing down the cost of manufacturing such wagons by10 %. In addition, such approach could be used for the modernization (including scheduled repairs of different types) of wagons under study, which would make it possible to significantly reduce the cost of their operation.The research found that the coupled design of the center girder of hopper wagons for iron ore pellets would guarantee to ensure the required indicators for operational reliability over the rated service life of wagon of 15 years. We can highlight as the scientific results of the work conducted the developed and experimentally-confirmed comprehensive technique for the implementation of coupled designs of wagon beams. The practical importance of research results is demonstrated by the proposed and patented solutions of technical realization of the chosen direction, implemented at a number of Ukrainian wagon building companies. The new and valuable results of present work include a created adequate spatial finite-element computer model of the improved design of hopper wagons for iron ore pellets.The proposed methodical complex for reducing the manufacturing cost of hopper wagons for iron ore pellets by the conjugated design of their carrying beams is expedient for application in other types of freight wagons, as well as other means of transport engineering

The study of dynamic load on a wagon–platform at a shunting collision

In order to increase the volume of cargo transportation through international transport corridors that pass through Ukraine, container transportation has been developed. To ensure the safety of a wagon-platform with containers placed on it, the research of dynamic loads acting on them at shunting collision has been conducted in real operating conditions. The research results led to the conclusion that the largest values of acceleration acting on the wagon-platform with containers placed on it during a shunting collision occur in the presence of gaps between the fitting stops and fittings and amount, respectively, about 90 m/s² and 110 m/s². The approbation of obtained acceleration values was performed by computer simulation of the dynamics of a wagon platform with containers placed on it under the action of the longitudinal impact force of 3.5 MN on the back gauge of automatic coupling. Verification of the model was tested by the Fischer criterion. This revealed that the hypothesis of the adequacy of the model was not disputed. Conducted research will improve operational safety of the wagons in the combined transportation, and will motivate design of wagons of the new generation for use in combined international traffic.

Freight rail transport governance: An international issue

Since the economic deregulation of freight transport operations internationally, it has been necessary to have a workable knowledge and an understanding of the types of freight wagons that can help to be instrumental in the efficient and effective market participation of rail technology in the freight transport market. The article identifies and describes the most commonly used rail freight wagons for commercial purposes internationally. The investigation has indicated that subsequent to the economic deregulation of freight transport, there are nine rail wagon types manufactured and commonly used internationally. They are: (1) covered wagon/van; (2) refrigerated wagon/van; (3) flat wagon; (4) tank wagon; (5) container wagon; (6) open wagon; (7) hopper wagon; (8) side stanchion and centre partition wagon; and (9) motorcar wagon. The study revealed that the following three factors mainly dictate wagon design: (1) characteristics of the freight to be transported; (2) physical railway characteristics; and (3) the type of freight terminals and handling equipment necessary to efficiently and effectively accommodate and support rail freight transport.