Aiming at preventing frequently occurred coupler jack-knifing in slave control locomotives of 20,000-tonne heavy-haul trains, a theoretical and experimental research on enhancing the coupler stability has been carried out. Field tests are conducted to ascertain the load characteristics of the slave control locomotive, and the coupler stability mechanism of the locomotive is studied. A dynamic simulation model considering the locomotive, adjacent wagons, and attached coupling devices is established and validated. Based on the model, countermeasures for improving the coupler stability are studied. The field test results indicate that: 1) the slave control locomotives suffer from sustained compressive forces less than 1500kN at the braking stage of cycle braking, while the maximum short-term impact force at the release stage exceeds 2000kN; 2) The coupler jack-knifing mostly occurs at the braking stage, and the yaw angles of the middle couplers are larger than the front and rear couplers. According to the theoretical analysis and dynamic simulation results, the coupler stability can be improved by increasing the stiffness of secondary lateral bump stops and reducing its clearance. Moreover, the proposed countermeasure of setting up lateral bump stop to locomotive couplers is proved to be effective to prevent the coupler jack-knifing.

In addition to the discontinuity of the rail profile of a normal turnout, the unique S-shaped curve of a crossover significantly affects the negotiation performance of a train. For heavy-haul freight trains, the in-train forces generated during the braking process may further deteriorate the running safety. Investigating the dynamic behaviour of the train passing through the crossover under braking forces, therefore, can provide a reasonable basis for ensuring train safety. This paper analyses the dynamic response and wheel wear of a three-vehicle train negotiating a single crossover under variable conditions, including variable braking forces, wheel-rail friction coefficient, and crossover layout forms. The results show that the three factors have considerable influences on train safety. If one of the three factors keeps an ideal level, the safe probability of empty wagons can be significantly improved. Considering that there are still some crossovers with tight curves in the existing railway system, avoiding large braking or lubricating the wheel flange in the crossover is still an effective solution to improve the vehicle's performance. In addition, for a new single crossover, a 600-m-radius curve is a good option for balancing permissible train speeds and construction costs of the crossover.

The friction draft gear with hysteresis characteristics is one of the typical nonlinear elements in longitudinal train dynamics (LTD). Due to the nonlinear hysteresis of friction damping, the discontinuity between loading and unloading envelopes becomes a mathematical integration issue when adopting look-up table methods to establish draft gear models. It might cause integration divergence and wrong results if ignored. To solve this discontinuity, three different transitional strategies (velocity-dependent, intermediate slope, and smoothing approximation) are applied to building draft gear models, and the one-dimensional (1D) longitudinal train model adopting the ‘Zhai’ integration method is used. To ensure accurate results, the international benchmark cases of LTD are studied, and three draft gear models with different transitional strategies are compared in this paper. The results show that these three models can successfully work with ‘Zhai’ method in the LTD simulation to achieve the force agreement with benchmark cases. Compared to the other two models, the velocity-dependent model doesn’t exhibit good buffer deflection agreement and requires a smaller step size to achieve convergent results. Therefore, it is recommended that adopting the intermediate slope method or smoothing approximation approach avoids discontinuity problems of modelling draft gears in LTD.

Recently, composite brake blocks have been widely adopted in European railway systems to replace cast iron brake blocks in order to reduce braking noise. However, the poor heat dissipation of composite materials has caused more wheel tread damage, including wheel flats (WFs). The WF, as an undesirable tread defect in railway vehicles, can cause severe wheel/rail impact and increase the damage probability of wheelset components and track structures. Early detection of WFs is vital to ensure operational safety and reduced maintenance costs. In this work, to help understand the dynamic impact caused by WFs, a single WF with a length of 20 mm is artifically produced on a wheel of a tank wagon, and field experiments are performed. The influence of the WF on the axle box accelerations (ABAs), vertical accelerations of the bogie frame and vertical accelerations of the car body is discussed in the time and time-frequency domains. On the other hand, the angular domain synchronous averaging (ADSA) method is used to detect WFs by averaging the ABA signals in the angular domain over a fixed time interval, and it requires ABA data and the axle rotational speed as inputs. This method can greatly reduce the amount of measured data by averaging it in the angle domain and can eliminate the short-time influence of interference signals caused by switches and crossings, rail joints, and so on. The results show that the ADSA of a defective wheel with the WF has a clear peak with an amplitude of 21–104 m/s² while that of a healthy wheel fluctuates around zero in the polar coordinate. Also, the waveform of defective signals can be well presented in polar coordinates. The effectiveness of this method is compared with the envelope spectrum technology in three scenarios and its application to three journeys is presented.