Session: 12-03-05: General: Mechanics of Solids, Structures and Fluids

Paper Number: 144441

144441 - Feasibility Study of Self-Lubricated Load Bearing Design for Plug Sliding Door System on Railway Vehicles 

Currently, urban rail vehicles rely heavily on essential load-bearing components within the plug sliding door systems, mainly constructed from metal materials. The imperative for regular maintenance to ensure door safety and operational efficiency is recognized within the industry. And the door system on modern railway vehicles is a crucial key to ensuring smooth operation and passenger safety. The regular metal loading bearing of the plug sliding door system needs to be regularly maintained. The repairers need to remove the old lubricant grease and apply new one. This procedure increases the cost of the door system’s maintenance and potentially cause environmental pollution. In response to this, car builder and the door supplier embark on an initiative to explore the feasibility of replacing these key metal components with non-metal alternatives. This change is aimed at potentially obviating the need for lubrication during a single vehicle overhaul period. This article underscores a strategic approach towards enhancing the reliability and cost-effectiveness of urban rail vehicle operations.

The integrity of the door structure design is paramount for ensuring the safe operation of railway vehicles. Accordingly, meticulous market research, with past experience, is conducted to validate the practicality and efficacy of this innovative approach. Subsequently, the door hanger roller, low arm rollers, drive screw mid support block, and bump roller are identified as prime specimen for replacement with non-metal counterparts.

The rollers and drive screw mid support block are manufactured using PA12C self-lubricating non-metal material for casting. Manufactory processes are well designed and strictly followed to ensure the precise fabrication of these crucial components, setting the stage for comprehensive testing and evaluation.

A pivotal phase of the experimentation involves the installation of the lubrication-free components onto standardized metro-style doors, followed by subjecting them to an endurance test comprising one million cycles. Prior to the durability test, measurements of the dimensions and weight of the lubrication-free components are conducted. Upon the completion of the durability test, these measurements are reiterated. And a conclusive finding shows the sustained operational efficacy. The non-metal components can operate over the prescribed duration of opening, holding position, and closing sequences.

Along with the physical testing, modeling and stress analysis utilizing finite element analysis techniques are employed to exam the performance of bump rollers and lower arm rollers under different load conditions. The resulting insights affirm the suitability of non-metal materials for articulated joints, validating their ability to fulfill the requisite of lubrication-free operation within one overhaul timeframe.

Using synthesizing research data, endurance testing, and finite element analytical methodologies, this study corroborates the efficacy and feasibility of utilizing PA12C self-lubricating non-metal material for critical components within the plug sliding door system. Beyond its technical merits, this transition is poised to confer significant cost efficiencies, and to reduce environmental pollution. Thereby enhancing the overall competitiveness of urban rail vehicle door systems and laying the groundwork for the widespread adoption of lubrication-free technology in future iterations for more potential application scenarios on the railway vehicles.

Presenting Author: Hang Lu CRRCMA

Presenting Author Biography: Hang Lu is a newly joined mechanical engineer within the railway vehicles industry. She completed her bachelor’s degree at Rensselaer Polytechnic Institute, where she spent four years studying various fundamental aspects of mechanical engineering. Subsequently, she pursued advanced academic studies in the integration of mechanical engineering, electrical engineering, and software at Columbia University, earning her master’s degree.

Her entry into the industry commenced with CRRC MA, marking her initial step. Here, she developed a profound interest in door systems. Under the guidance of knowledgeable door system engineers, she applied her knowledge to address authentic industry challenges and was inspired to seek enhancements.

Authors:

Liangliang Zhang CRRC Changchun
Long Zhang CRRCMA
Peng Sun IFE-Victall Railway Vehicle Door Systems(Qingdao)Co.,Ltd
Tao Zhang IFE-Victall
Hang Lu CRRCMA
Dongdong Chen CRRC Changchun
Lvxian Wu CRRCMA
Yanbo Yin CRRC MA Corporation