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This study aims to improve the availability of regenerative braking for urban metro vehicles by introducing a sensorless operational temperature estimation method for the braking resistor (BR) onboard the vehicle, which overcomes the vulnerability of having conventional temperature sensor.

In this study, the energy model based sensorless estimation method is developed. By analyzing the structure and the convection dissipation process of the BR onboard the vehicle, the energy-based operational temperature model of the BR and its cooling domain is established. By adopting Newton's law of cooling and the law of conservation of energy, the energy and temperature dynamic of the BR can be stated. To minimize the use of all kinds of sensors (including both thermal and electrical), a novel regenerative braking power calculation method is proposed, which involves only the voltage of DC traction network and the duty cycle of the chopping circuit; both of them are available for the traction control unit (TCU) of the vehicle. By utilizing a real-time iterative calculation and updating the parameter of the energy model, the operational temperature of the BR can be obtained and monitored in a sensorless manner.

In this study, a sensorless estimation/monitoring method of the operational temperature of BR is proposed. The results show that it is possible to utilize the existing electrical sensors that is mandatory for the traction unit’s operation to estimate the operational temperature of BR, instead of adding dedicated thermal sensors. The results also validate the effectiveness of the proposal is acceptable for the engineering practical.

The proposal of this study provides novel concepts for the sensorless operational temperature monitoring of BR onboard rolling stocks. The proposed method only involves quasi-global electrical variable and the internal control signal within the TCU.

To address the problem that the current train operation mode that train selects one of several offline pre-generated control schemes before the departure and operates following the scheme after the departure, energy-saving performance of the whole metro system cannot be guaranteed.

A cooperative train control framework is formulated to regulate a novel train operation mode. The classic train four-phase control strategy is improved for generating specific energy-efficient control schemes for each train. An improved brute force (BF) algorithm with a two-layer searching idea is designed to solve the optimisation model of energy-efficient train control schemes.

Case studies on the actual metro line in Guangzhou, China verify the effectiveness of the proposed train control methods compared with four-phase control strategy under different kinds of train operation scenarios and calculation parameters. The verification on the computation efficiency as well as accuracy of the proposed algorithm indicates that it meets the requirement of online optimisation.

Most existing studies optimised energy-efficient train timetable or train control strategies through an offline process, which has a defect in coping with the disturbance or delays effectively and promptly during real-time train operation. This paper studies an online optimisation of cooperative train control based on the rolling optimisation idea, where energy-efficient train operation can be realised once train running time is determined, thus mitigating the impact of unpredictable operation situations on the energy-saving performance of trains.

In manufacturing, dedicated machine tools and flexible machine tools are failing to satisfy the ever-changing manufacturing demands of short life cycles and dynamic nature of products. These machines are limited when new product designs are introduced. The solution lies in developing responsive machines that can be adjusted or be changed functionally when these change requirements arise. These machines are reconfigurable machines which are becoming the new focus, as they rapidly respond to product variety and volume changes. A sheet metal working machine known as a reconfigurable guillotine shear and bending press machine (RGS&BPM) has been developed. The purpose of this paper is to present a methodology, function-oriented design approach (FODA), which was developed for the design of the RGS&BPM.

The design of the machine is based on the six principles of reconfigurable manufacturing systems (RMSs), namely, modularity, scalability integrability, convertibility, diagnosability and customisability. The methodology seeks to optimise the design process of the RGS&BPM through a design of modules that make up the machine, enable its conversion and reconfiguration. The FODA is focussed on function identification to select the operational function required. Two main functions are recognised for the machine, these being cutting and bending; hence, the design revolves around these two and reconfigurability.

The developed design methodology was tested in the design of a prototype for the reconfigurable guillotine shear and bending press machine. The prototype is currently being manufactured and will be subjected to functional tests once completed. This paper is being presented not only to present the methodology by to show and highlight its practical applicability, as the prototype manufacturers have been enthusiastic about this new approach.

The research was limited to the design methodology for the RGS&BPM, the machine which has been designed to completion using this methodology, with prototype being manufactured.

This study presents critical steps and considerations in the development of reconfigurable machines. The main thrust being to explore the best possibility of developing the machines with dual functionality that will assist in availing the technology to manufacturer. As the machine has been development, the success of the design can be directly attributed to the FODA methodology, among other contributing factors. It also highlights the significance of the principles of RMS in reconfigurable machine design.

The RGS&BM machine is an answer for the small-to-medium enterprises (SMEs), as the machine replaces two machines with one, and the methodology ensures its affordable design. It contributes immensely to the machine availability by eliminating trial and error approaches.

This study presents a new approach to the design of reconfigurable dual machines using principles of RMS. As the targeted market is the SME, it is not limited to that as any entrepreneur may use the machine to their advantage. The design methodology presented contributes to the body of knowledge in dual reconfigurable machine tool design.

The brake controller is a key component of the locomotive brake system. It is essential to study its safety.

This paper summarizes and analyzes typical faults of the brake controller, and proposes four categories of faults: position sensor faults, microswitch faults, mechanical faults and communication faults. Suggestions and methods for improving the safety of the brake controller are also presented.

In this paper, a self-judgment and self-learning dynamic calibration method is proposed, which integrates the linear error of the sensor and the manufacturing and assembly errors of the brake controller to solve the output drift. This paper also proposes a logic for diagnosing and handling microswitch faults. Suggestions are proposed for other faults of brake controller.

The methods proposed in this paper can greatly improve the usability of the brake controller and reduce the failure rate.

The electromechanical brake system is leading the latest development trend in railway braking technology. The tolerance stack-up generated during the assembly and production process catalyzes the slight geometric dimensioning and tolerancing between the motor stator and rotor inside the electromechanical cylinder. The tolerance leads to imprecise brake control, so it is necessary to diagnose the fault of the motor in the fully assembled electromechanical brake system. This paper aims to present improved variational mode decomposition (VMD) algorithm, which endeavors to elucidate and push the boundaries of mechanical synchronicity problems within the realm of the electromechanical brake system.

The VMD algorithm plays a pivotal role in the preliminary phase, employing mode decomposition techniques to decompose the motor speed signals. Afterward, the error energy algorithm precision is utilized to extract abnormal features, leveraging the practical intrinsic mode functions, eliminating extraneous noise and enhancing the signal’s fidelity. This refined signal then becomes the basis for fault analysis. In the analytical step, the cepstrum is employed to calculate the formant and envelope of the reconstructed signal. By scrutinizing the formant and envelope, the fault point within the electromechanical brake system is precisely identified, contributing to a sophisticated and accurate fault diagnosis.

This paper innovatively uses the VMD algorithm for the modal decomposition of electromechanical brake (EMB) motor speed signals and combines it with the error energy algorithm to achieve abnormal feature extraction. The signal is reconstructed according to the effective intrinsic mode functions (IMFS) component of removing noise, and the formant and envelope are calculated by cepstrum to locate the fault point. Experiments show that the empirical mode decomposition (EMD) algorithm can effectively decompose the original speed signal. After feature extraction, signal enhancement and fault identification, the motor mechanical fault point can be accurately located. This fault diagnosis method is an effective fault diagnosis algorithm suitable for EMB systems.

By using this improved VMD algorithm, the electromechanical brake system can precisely identify the rotational anomaly of the motor. This method can offer an online diagnosis analysis function during operation and contribute to an automated factory inspection strategy while parts are assembled. Compared with the conventional motor diagnosis method, this improved VMD algorithm can eliminate the need for additional acceleration sensors and save hardware costs. Moreover, the accumulation of online detection functions helps improve the reliability of train electromechanical braking systems.

For billing purposes, heavy-haul locomotives in Sweden are equipped with on-board energy meters, which can record several parameters, e.g., used energy, regenerated energy, speed and position. Since there is a strong demand for improving energy efficiency in Sweden, data from the energy meters can be used to obtain a better understanding of the detailed energy usage of heavy-haul trains and identify potential for future improvements.

To monitor energy efficiency, the present study, therefore, develops key performance indicators (KPIs), which can be calculated with energy meter data to reflect the energy efficiency of heavy-haul trains in operation. Energy meter data of IORE class locomotives, hauling highly uniform 30-tonne axle load trains with 68 wagons, together with additional data sources, are analysed to identify significant parameters for describing driver influence on energy usage.

Results show that driver behaviour varies significantly and has the single largest influence on energy usage. Furthermore, parametric studies are performed with help of simulation to identify the influence of different operational and rolling stock conditions, e.g., axle loads and number of wagons, on energy usage.

Based on the parametric studies, some operational parameters which have significant impact on energy efficiency are found and then the KPIs are derived. In the end, some possible measures for improving energy performance in heavy-haul operations are given.