DIGITAL TWIN-DRIVEN WEAR PREDICTION METHOD FOR PANTOGRAPH STRIP IN URBAN RAIL VEHICLES

Aiming at the deficiencies of current monitoring approaches for pantograph strip wear in urban rail vehicles, such as the time-consuming and labor-intensive nature of manual inspection and the low reliability of image recognition-based methods, this study takes the pantograph–catenary system of Chongqing Rail Transit Line 1 as the research object and proposes a novel wear prediction method for pantograph strips driven by digital twin technology. First, the overall framework of the digital twin system for pantograph strip wear prediction is constructed. This framework elaborates in detail the composition of the twin system, the interaction mechanisms among its components, and the step-by-step process of predicting strip wear. Secondly, the rigid-flexible hybrid dynamics model of the urban rail vehicle pantograph-catenary coupling system is established by using the multi-body dynamics method and the finite element method to obtain the dynamic characteristics between the pantograph and catenary, and its surrogate model is established to achieve lightweight simulation. Furthermore, based on adhesive wear theory and electrical contact theory, a mathematical formula for calculating the wear rate of pantograph strips is derived. The parameter identification and calculation accuracy verification of the wear rate calculation formula are completed through current-carrying friction and wear simulation tests for the pantograph-catenary system. By integrating the dynamic surrogate model with the strip wear rate calculation formula, a comprehensive prediction model for pantograph strip wear profile is established. This model takes into full account the dynamic characteristics of the pantograph–catenary system during operation. Finally, taking the pantograph strip on actual lines as a case study, the wear profile of the pantograph strip under actual operating conditions is predicted. According to the actual wear monitoring data of the pantograph strip, the result verification and parameter calibration of the wear prediction model is completed, providing theoretical guidance for the replacement and maintenance of pantograph strips in actual operations.