Train Door Testing Rig

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Group Design Project
Developing the train door rig into an advanced testing and fault detecting tool to assess the key components failure using advanced sensing techniques
Group Members
Kamran Esmaeili, Evangelos Selimos, Shuhan Sun, Peerapat Prakongtham, Hew Soon Pang, Kim Byung Jae, Cameron FitzGibbon

Supervisors
Dr. Ling Wang, Professor Suleiman Sharkh, Professor Robert Wood

Supporters
Siemens, National Training Academy for Rail (NTAR)

Train doors have evolved over the recent decades. As the technology involved developes from manually operated doors to electrically and pneumatically operated doors, it is important for manufacturers and operators to understand the nature of the components, which experience cyclic loading in day-to-day operations. A lack of proper understanding of the behaviour of these components can lead to frustrating delays and unnecessary costs.

This project follows last year’s construction of the train door test rig for the British Rail Class 450 train doors, as presented at the 2015 Design Show. The main aims of this year’s GDP are as follows:
1) To provide design improvements to the testing rig from the aspects of user experience and reliability. Enhancing the representativeness of the rig with respect to the actual operating conditions
2) To develop sensor and user interface (UI) systems.
3) To perform trial tests with the rig to demonstrate its capability.
In order to achieve the project aims, the previous testing rig design was examined and analysed. Recommendations for the structural improvements were drafted and carried out.
At the same time, the group performed a literature review on the common train door failure modes, and selected a number of them to investigate. Subsequently, the design and testing methodologies were considered and finalised. These included the sensors to be installed, a UI design, circuit wiring, an automation system, and software solutions for testing.

The design improvements to the train door test rig provide more stability to the test rig, which enhances the testing conditions. Removable stairs are added to allow easy access to the train doors’ drive while improving structural stiffness. The data from sensors installed on the train door components offered an insight into the potential of the current experimental set-up, and could potentially lead to more advanced research into the failures of train door components, or in the future, contribute towards a new design of train door system.

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