Support to the development of technical demonstrators for the next generation of brake systems - S2R-OC-IP1-03-2019

Deadline: Jun 18, 2019  
CALL EXPIRED

SPECIFIC CHALLENGE

In the first phase of Shift2Rail, the projects PINTA (GA730668), CONNECTA (GA730539) and PIVOT (GA777629) put their focus on the analysis of the status quo and approaches to cope with the new development challenges and comply with the new requirements for the railway subsystems and components. These activities resulted in specifications, design of new and more standardised brake components, as well as new methods and tools to improve maintenance and certification processes.

Based on this, the challenge of the technical demonstrator brake system (TD1.5) is to perform the development and implementation of brake systems with higher brake performance (e.g. in low adhesion condition), lower life cycle costs and noise levels. The development of the new generation of more compact and environmentally friendly brake components with enhanced diagnosis systems and electronics requires considerable analysis and test work.

SCOPE

Proposals should complement the brake developments and activities within the Shift2Rail (S2R) programme and especially within the S2C-CFM-IP1-01-2019. These activities are described globally in the S2R Multi-Annual Action Plan (MAAP) and the S2R-CFM-IP1-01-2019 topic description.

Proposals should address all work-streams described below, in line with the Shift2Rail Multi-Annual Action Plan (MAAP):

Work Stream 1: Improved adhesion management

To cope with the challenge of insufficient adhesion conditions, additional data shall be collected on a running train under real field test conditions. In this regard, the results of the action stemming from the topic S2R-CFM-IP1-01-2016 - D8.1 Adhesion Modelling Specification shall be considered. The data collection has to be aligned with the partners of the action stemming from the topic S2R-CFM-IP1-01- 2018 to ensure sufficient results and support. One of the main aspects is the conditions of collection of adhesion data from trains on tracks, in sliding condition.

The data collection runs should be done with trains on tracks under real field test conditions. The data should be transferred into a format that will be defined in the action stemming from the topic S2R- CFM-IP1-01-2018.

Proposals shall provide adhesion curves acquired during rolling stock wheels sliding caused by degraded adhesion conditions. The preferred rolling stock shall be a Multiple-Unit. Measurements shall be done by using different types of contaminants, in order to better understand the phenomenon. Measurement shall be done by properly instrumenting the train under test. These measurements will be inserted into a database that will be proposed by the complementary action stemming from the topic S2R-CFM-IP1-01-2018 to allow a comprehensive approach of the interpretation of the influence of the environmental conditions on the adhesion coefficient.

Proposals partners shall provide the train and the test track, the instruments for acquisition and shall collaborate with the complementary action stemming from the topic S2R-CFM-IP1-01-2018 partners for the tests setup and execution definition. Activites are expected to reach TRL4.

Work Stream 2: High safety relevant brake control functions in an advanced brake component HW- SW architecture

The objective is to support the safety analysis of brake subsystems with well-defined, easy to apply and efficient processes and methods. This requires a close cooperation with the partners of the complementary action stemming from the topic S2R-CFM-IP1-01-2018 - brakes part . The main aspect is the definition of user-friendly safety processes and methods.

Proposals should define a user-friendly safety process and methods which allow system engineers to execute safety analysis activities in their daily engineering exercise for railway subsystems, especially as concerns brakes. Modern model based system engineering methods and artefacts shall be used to allow system engineers to handle the complexity of the system using an integrated system- and safety engineering. Activites are expected to reach TRL3.

Work Stream 3: Innovative lightweight brake discs.

Ceramics disks are currently used in automotive industries, especially in sport or luxury cars. The use of this material provides a tremendous saving of weight and LCC costs. This technology shall now be investigated for the use for brake disks. Proposals should evaluate the usability of ceramics combined with conventional material in brake disks. The action shall be performed in close coordination with the complementary action stemming from the topic S2R-CFM-IP1-01-2018, especially the working area Friction Pairing. This working package includes the evaluation of ceramic layers for brake discs.

Proposals should perform activities to better understand the capability of a ceramic layer for braking applications. In particular proposal should evaluate if combined brake discs from metal based materials and a ceramic layer ceramic applications can be used for the railway industry.

The evaluation should be based on already existing standards for type testing, as the EN 14535. Scaled dynamometer testing is preferred. Activites are expected to reach TRL4.

An indicative scheduling of the deliverables is suggested below47 :
 Deliverable under workstream 1, 2 and 3 are expected by month 24

COMPLEMENTARITY

As specified in section 2.3.1 of AWP 2019, in order to facilitate the contribution to the achievement of S2R objectives, the options regarding 'complementary grants' of the S2R Model Grant Agreement and the provisions therein, including with regard to additional access rights to background and results for the purposes of the complementary grant(s), will be enabled in the corresponding S2R Grant Agreements.

The action that is expected to be funded under this topic will be complementary to the actions that are expected to be funded under the following topics:

 S2R-CFM-IP1-01-2019: Development of new technological concepts towards the next generation of rolling stock, applied to major subsystems such as Car body, Running Gear, Brakes, Doors, Modular interiors and HVAC

The action stemming from this topic will also be complementary to actions carried out within the following projects:

 PIVOT (GA 777629).

47 The scheduling of the deliverables is provided to facilitate the complementarity with the CFM actions and it is not binding. Additionally, each deliverable may have some flexibility in the scheduling

EXPECTED IMPACT

The most significant benefits from the action as a result of the new technology developments, methodologies and simulations besides the continues qualification of the brake related KPI’s are:

• -  Optimisation of adhesion conditions to reduce braking distances in low adhesion conditions and to reduce the LCC and overall train safety

• -  LCC reduction due to better diagnostics, lower energy consumption and introduction of life time brake components due to an advanced SIL3/4 compliant electronic hardware and software architecture for brake components

Reduction of weight and LCC costs by developing innovative friction pair solutions such as ceramic disks for lifetime operation.

Type of Action: Research and Innovation Action (RIA)