Estimating the wheel lateral position of a mechatronic railway running gear with nonlinear wheel–rail geometry

The “Next Generation Train” (NGT) is a double-deck high speed train concept in light-weight design that has been established as a technical and project framework in which the German Aerospace Center gathers its long-term railway vehicle research. To reduce wheel and rail wear and to enhance the passenger capacity, a mechatronic running gear with independently rotating wheels (IRW) is a key vehicle component under research. This running gear requires an advanced control of the lateral dynamics in order to fully exploit its potential in minimizing wear and noise, but this relies on information on its lateral position relative to the track. In daily railway operation it is difficult to directly measure this displacement of the wheel-pair. However, according to previous work it is possible to design an appropriate observer to estimate the lateral position, but its estimation accuracy highly depends on the chosen sensor configuration. Nevertheless, it was shown that the lateral dynamics of the running were not completely reproduced by the system description especially at suddenly changing directions in the movement of the IRW. In this work the system description is complemented by a nonlinear description of the wheel–rail geometry. Therefore, an observability analysis and an observer synthesis to estimate the lateral position for the nonlinear system of the 1:5 scaled hardware running gear is carried out. For validation purposes an extended Kalman filter with the U-D formalism is implemented at the real-time environment of the testbed and the estimation accuracy of the observer configurations is compared.