Konzeptentwicklung eines neuartigen Bremsenprüfstandes für Schienenfahrzeuge

This master thesis deals with the development of a new brake test bench for rail vehicles. The braking system is a safety-relevant component and is exposed to high loads due to the large vehicle mass and the high speeds.
The development of new lightweight-chassis, with a weight reduction of almost 50%, has led to an increased demand for new test benches.
The concept of the existing flywheel brake test benches, in which isolated single components can be tested separately, provides only very incomplete statements on the vibrational interaction of the braking system with the bogie-frame. But these interactions are from great interest, especially due to the new lightweight-design.
Currently, very cost-intensive and time-consuming on-track tests have to be carried out. The intention to reduce these on-track tests led to the motivation to develop an innovative brake test bench. This master thesis deals with the concept development of such a test rig. The state of the art at the brake test stand sector was collected and the existing test bench concepts were analysed. Subsequently, a series of solution variants were developed, and a final concept was chosen from a group of potential design concepts.
The final solution, which meets all the requirements, has been found in the form of a roller dynamometer, which is driven by two flywheel test benches. With these two component test stands single component tests, as well as complete chassis tests, with the integrated drive and brake system, can be carried out. Because of this, a combination of adhesion-dependent brakes and non-adhesion dependent brakes can be tested.
On the basis of the defined technical parameters, a preliminary dimensioning of the drive motor, the flywheels, the roller set and the drive train was carried out.