Design of instrumented wheelset for measuring wheel-rail interaction forces

The paper presents the design of a specific type of instrumented wheelset intended for continuous measuring of lateral and vertical wheel-rail interaction forces and , in accordance with regulations EN 14363 and UIC 518. The platform is a standard heavy wheelset BA314 with an axle-load of 25 tons. The key problems of smart instrumentalization are solved by the use of the wheel’s numerical FEM model, which provides a significant cost reduction in the initial stage of development of the instrumented wheelset. The main goal is to ensure high measuring accuracy. The results of the FEM calculations in ANSYS are basis for identification of the distribution of strains on the internal and external side of the wheel disc. Consequently, the most convenient radial distances for installation of strain gauges of Wheatstone measuring bridges are determined. In the next stage, the disposition, number and ways of interconnection of strain gauges in the measuring bridges are defined. Ultimately, an algorithm for inverse determination of parameters and based on mixed signals from the measuring bridges is developed. The developed solution is validated through tests on specific examples, using a created numerical FEM model. A high accuracy of estimation of unknown parameters and is obtained with an error of less than 4.5%, while the error of estimation of their ratio is less than 2%. Therefore, the proposed solution can be efficiently used in the instrumentalization of the considered wheelset, while the problems of its practical implementation will be the subject of further research.