Session: 14-04-01: Reliability and Safety in Transportation Systems I

Paper Number: 144439

144439 - Analysis and Design Improvements for an Inter-Vehicle Barrier Failure Between Rail Vehicles 

The inter-vehicle barrier is a component extensively utilized on railway vehicles, installed externally to bridge the gap between coupled vehicles without gangways. Without such structures, visually impaired passengers could potentially get trapped into the gap during boarding and alighting. ,  as such, similar feature with inter-vehicle barrier  was mandated for installation between vehicles in 1990 under  Federal code 49 C.F.R. § 38.85, which is derived from ADA act.

 

This study presents a recent analysis of inter-vehicle barrier tangling failures on railway vehicles. The investigation delves into the potential factors behind structural failure. Initially, the investigate focused on  safety straps utilized for restraint the barriers, the material properties, fading, UV exposure, and elongation characteristics were tested to verify compliance to the industry standards. Results shows that the safety strap adheres to design specifications. Subsequently, different scenarios where the two barriers may have potential interference during yard and mainline operations of the vehicle were simulated and enumerated, the analysis covers scenarios such as small horizontal curve radius, small curve-to-straight line maneuvers, and S curve maneuvers. contribution factors such as roll angle, and vertical curves radius are also taken into consideration. These conditions were assessed through single-factor and multifactor combination simulations to analyze the quasi-static relative position and motion trajectories of inter-vehicle barriers. Failure analysis pinpointed the most plausible failure scenario to occur during vehicle maneuvers, where vehicles transitioned from minimal horizontal curves into straight lines combined with special roll angle and include angle. All these factors combined lead to exacerbating interference at the barrier edges, resulting in barrier tangling, safety strap tearing, and structural failure during separation.

 

Based on the failure analysis, several potential structural improvements were proposed and subjected to multi-condition simulation analyses to determine feasibility. A solution involving the addition of guiding diagonal bars was deemed optimal. Finite element analysis results of the von-mise stress distribution meets the design  at both the weld and rivet joint area. In addition, the number of safety straps was increased while their length was reduced to increase the  stiffness and the clearance between vehicle barriers. Upon confirming structural integrity, prototypes were fabricated for on-vehicle testing, and deployed into revenue service after passing testing. Results indicate that enlarging the barrier gap reduces barriers’ contact occurrences, while the addition of guiding diagonal bars mitigates post-contact tangling, ensuring safe service of the vehicles.

this study endeavors to provide practical references for future railway vehicle design endeavors. Emphasizing the significance of predicting and analyzing extreme cases during the design phase, highlighting the importance of continuous improvement in safety measures and reliability for railway vehicles.

Presenting Author: Yanbo Yin CRRC MA Corporation

Presenting Author Biography: Dr. Yin Yanbo's academic journey commenced with the attainment of his bachelor's and master's degrees from Tsinghua University. His pursuit of scholarly excellence led him to North Carolina State University in the United States, where he completed his Ph.D. in 2007. Dr. Yin's professional trajectory began at Bombardier Transportation, where he contributed to the research and development endeavors in rail vehicle technology. Notable projects under his purview included the Long Island Rail Road (LIRR), Metro-North Railroad (MNR), and the John F. Kennedy Airport Express (JFK) in the United States, as well as various transportation initiatives across Canada, Malaysia, and South Korea.

In 2012, Dr. Yin transitioned to ABB, assuming the role of a technical project manager. Here, he played a pivotal role in market development and oversaw the implementation of ABB traction inverters in North America. Noteworthy accomplishments during his tenure include the successful refurbishment of Newark Liberty International Airport, the Dallas Area Rapid Transit (DART) project, and the auxiliary inverter project for MPI locomotives. Dr. Yin spearheaded technology transfer initiatives from Europe to North America, facilitating localized production to align with regional manufacturing standards.

Subsequently, in 2015, Dr. Yin joined Wabtec (later Faiveley), focusing on the development of rail vehicle door systems and air conditioning technology. His contributions extended to pivotal projects such as the Boston subway, New York City intercity railway, and Ottawa light rail vehicle initiatives in Canada. Notably, he played a key role in the implementation of intelligent maintenance systems for subway vehicle door systems.

In 2019, Dr. Yin assumed a pivotal role at CRRC MA, where he engaged in diverse activities ranging from bidding processes to research, development, production, and manufacturing of rail vehicle projects. Leading the center's foundational research and development endeavors, Dr. Yin delved into areas such as smart manufacturing, intelligent maintenance, additive manufacturing, and intelligent driving, cementing his reputation as a leading figure in the field of rail vehicle

Authors:

Long Zhang CRRCMA
Yanbo Yin CRRC MA Corporation
Qiubo Chen CRRCMA
Zijing Wu CRRCMA
Baide Feng CRRCMA
Yanhua Cao CRRCMA
Lvxian Wu CRRCMA
Peng Lu CRRCMA