Analysing the root causes of bracket vibration and proposing a solution to avoid the resulting failures.
Analysing the root causes of bracket vibration and proposing a solution to avoid the resulting failures.
Failure of a wheel lubricator bracket due to strong vibration.
The work started with a finite element analysis (FEA) to determine the actual loads. In particular, vibrations were analysed in detail. The data obtained was used in post-processing using: fast Fourier transform (FFT) and white noise elimination. The acquired data were transferred to the FEA model and correlated with the FEA test.
The solutions used allowed the stiffness and mass topology to be optimised. Thanks to a comprehensive approach – including root cause analysis, thorough examination of the acquired data and optimisation of the topology – it was possible to deliver an error-free, robust solution. The result was an improved design used to produce an implementation-ready product, remaining in use from its initial implementation.
Rolling stock OEMs can reduce prototype risk by defining the validation scope early, connecting design with FEM analysis, checking critical joints and interfaces, and preparing traceable evidence before manufacturing begins. Simulation does not remove the need for physical testing. It helps make the prototype a confirmation of a mature design rather than the first place where major structural weaknesses are discovered.
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