Lu Bingyang and Sun Lichao, reporters of the China Business Daily "Contour Line", reported in Beijing
This is a cool "Fuxing" EMU, in all 4153 EMUs on Chinese railways, "She" is unique and distinctive.
"She" is surrounded by ice blue, and 24 snowflakes are dotted in the middle, with flowing feathers and white ribbons, dancing softly. "She" is currently the only EMU in China painted with blue and blue as the keynote, in order to highlight the exclusive temperament of "she", people gave her a beautiful nickname - Ruixue Yingchun.
Ruixue Yingchun "Fuxing" CR400BF-C intelligent EMU
This is a train tailored for the Beijing Winter Olympics. Since January 21, a total of 10 new 350 km/h Winter Olympic trains, including "Ruixue Yingchun", have served the 2022 Beijing Winter Olympics and the Beijing Paralympic Winter Games for 55 days. "They" carry athletes, coaches and staff from all over the world, running in the Beijing-Zhangjiakou high-speed railway Beijing, Zhangjiakou and Yanqing three major competitions.
Ruixue Yingchun "Fuxing" CR400BF-C intelligent EMU crossed the Great Wall
All 10 Winter Olympic trains are independently developed, manufactured and maintained by CRRC Changchun Railway Bus Co., Ltd. (hereinafter referred to as "CRRC Changke"). Starting from the 2017 project bid, which lasted 4 years, the Winter Olympic train jumped from the drawings to reality.
The three elements of "wind", "snow" and "Olympics" have given the Olympic spirit of "Rejuvenation" through abstract art design, and let the heavy equipment of the country bloom out of the beauty of industry. In the promotional video played before the opening ceremony of the Winter Olympic Games, "Ruixue Yingchun" drove out of the ice and snow at a rapid pace, which was a gift from China's high-end rail transit equipment industry to the Winter Olympics.
Paint "Ruixue Welcomes Spring"
The "Ruixue Yingchun" Fuxing train is not only unique within the scope of China's railway EMUs, but even among the 10 Winter Olympic trains, "she" is also the most beautiful "boy".
The 10 EMUs tasked with the Winter Olympic and Paralympic Winter Games consist of three Olympic configuration (CR400BF-C) EMUs and seven standard configuration (CR400BF-G) EMUs. Dou Lei, an engineer at CRRC Changke Chemical Technology Office, told the "Contour Line" reporter: "'Ruixue Yingchun' enjoyed the blue-blue snowflake painting in the 3 Olympic edition trains. ”
Dou Lei and his team, the third from the right in the back row is Dou Lei
"Ruixue Yingchun" painting with blue and blue and the Great Wall gray as the color base, blue and gray form a gradient transition, the front of the car on both sides of the snowflake image octagonal decorative pattern, taken from the winter Olympic area of Zhangjiakou Chinese traditional intangible cultural heritage - paper-cut art snowflake window flower modeling, the body is decorated with a total of 24 abstract snowflakes, symbolizing the 24th Winter Olympics.
Dou Lei said that "Ruixue Yingchun" adopts a gradient painting scheme, which is the difficulty of painting the Winter Olympics train, and neither the "Harmony" nor the "Fuxing" has used this coating scheme before.
In order to meet the coating effect required by the gradient coating scheme and improve the aesthetics of the train, "Ruixue Yingchun" did not choose the traditional mechanical spraying method of "Fuxing", but adopted a fully manual spraying method.
Dou Lei revealed to the "Contour Line" reporter that the CRRC long-distance passenger craft team began to prepare for the winter Olympic train spray painting work in 2018. Because there is no relevant experience in large-area gradient spraying in China to adopt, he and his colleagues can only explore from scratch.
The jet painting team of CRRC changke continues to investigate automobile companies in various places and learn spray painting technology from paint companies. Even THE LONG PASSENGER of CRRC also prepared a 1:1 model car for the painting team, which was specially designed for the workers to simulate the spray painting effect.
The process of the spray painting test is cumbersome and complex. "We first do the color mixing in the laboratory, and then spray test on the model car. After each spray, the team commented on the effect and proposed improvement and improvement plans. Then the model car is painted and polished off, and sprayed again according to the new scheme. After dozens of times of polishing the old paint and then spraying the new paint, after hundreds of tests, it was finally confirmed that the gradient spraying process using 6 colors of paint was confirmed. Dou Lei said.
In order to achieve the effect of blending gradients from blue and blue to the Great Wall gray and the fluttering snowflake image pattern, the "Ruixue Yingchun" adopts a three-layer spray painting process, while the ordinary "Fuxing" train only needs to spray a practical topcoat.
Dou Lei told the "Isobath" reporter that the spray painting process must first spray silver gray primer on the outer layer of the train metal, which is the base color of "Great Wall Gray"; the second layer of paint began to spray gradient color, and the gradient color was completed by 6 kinds of gradient color paint. The first time is sprayed in the forward color separation according to the color gradient law, and the second time is sprayed in reverse at the 6 color transitions, so as to finally achieve the natural transition of different colors of paint.
When the gradient effect is complete, spray snowflakes and streamers are also painted. In order to achieve a sense of depth distance and three-dimensionality between the 24 snowflakes, each snowflake is not only different in size and style, but also the depth of the snowflake white is also different, and the 24 snowflakes use different color paints and hand spray painting.
"The second spray painting is very cumbersome, and it is the most critical step to achieve the overall appearance effect of the vehicle, relying on the many years of experience and superb technology of the spray painting workers." Dou Lei said. After the completion of this process, a third layer of varnish is sprayed to improve gloss and clarity, enhance the hardness of the paint surface and improve wear resistance, at which time the spray painting work is completed.
In addition to 1 "Ruixue Yingchun" painting, the remaining 9 Winter Olympic trains are composed of two "Golden Phoenix" paintings and 7 "Dragon Phoenix Chengxiang" painting "Fuxing". The hand-painted work of these 10 Winter Olympic trains was all responsible for Dou Lei and his team.
Dou Lei revealed to the "Contour Line" reporter that compared with "Ruixue Yingchun" and "Longfeng Chengxiang" under the three-layer spray painting process, the amount of paint used is not much different, but the amount of paint used in "Ruixue Yingchun" is much more than that of "Longfeng Chengxiang". "'Dragon and Phoenix Chengxiang' is completed with a total of 8 kinds of paint, while 'Ruixue Yingchun' doubled to 16 kinds." He said.
At the same time, the manual spray painting of man-hours will also increase significantly, Dou Lei told reporters that in the case of overtime work by the team, the spray painting "Ruixue Yingchun" head car still needs 21 days, while the machine sprays the ordinary Revival number, and the normal working hours only need 13 days.
As a member of China's high-end rail equipment industry, Dou Lei is proud to have the honor of participating in the support work of the Winter Olympics. He took out the "Revival" painted by his 6-year-old daughter and showed it to reporters: although a few sketches of jane were not childish, a large snowflake pattern stood out on the front of the car. "'Ruixue Welcoming Spring' was made by my father and was my daughter's mantra during the Winter Olympics, which makes me very proud." Dou Lei said.
Smart Assurance
During the Winter Olympics, passengers who take the "Ruixue Yingchun" and "Longfeng Chengxiang" Fuxing EMUs to and from various competition areas in Beijing and Zhangzhou can feel the "intelligence" everywhere in all aspects of the ride. 5G race live broadcast, full vehicle WIFI coverage, intelligent lighting and temperature regulation, mobile phone wireless charging, vending machines that support online payment, these intelligent configurations provide passengers with a more convenient and comfortable ride experience.
Zhang Guoqin, head of the electrical system design of crusade long-distance intelligent EMU, told the "Contour Line" reporter that youth is a major feature of the design team of the Beijing-Zhang high-speed rail intelligent EMU project, and this design team has 136 young designers under the age of 35, which is the main force of the design team. Relying on this young team, the Beijing-Zhangjiang high-speed rail intelligent EMU has achieved a number of "domestic firsts" in terms of intelligent driving, intelligent services, intelligent operation and maintenance, new material application and new technology development.
Zhang Guoqin and her team, the fourth from the left is Zhang Guoqin
Zhang Guoqin recalled that when the Beijing-Zhang high-speed rail intelligent EMU project was preparing to bid, the design team closed the office for 3 months. Every day everyone is crowded in a conference room, decomposing tasks, the front of the locomotive electrical system alone has made 42 sets of programs, listed more than 1800 technical specifications for various systems of the whole vehicle, and drew more than 5000 design structure drawings...
Winter Olympics train CR400BF-C belongs to the intelligent EMU, as a high-speed rail designer, on the one hand, to consider whether the train can meet the needs of users, so that users feel intelligent; on the other hand, to continuously improve the optimization of the system at the same time, more consideration of the compatibility between the various systems.
For example, Zhang Guoqin said, such as lighting systems, they determine the color temperature, illuminance and logic of automatic adjustment according to the environment according to the relationship between color, atmosphere and human feelings in different modes. The lighting system of the Winter Olympic train can be automatically adjusted according to the changes in the external environment, and the lighting color and shape are also different in different carriages and functional areas.
It is worth mentioning that the Winter Olympic train innovatively set up a power battery system with two-way charging function, without relying on the high-voltage power supply system, the train can also travel 20 kilometers at a speed of 30 km / h, with the ability to emergency walk to the nearest station in any section of the Beijing-Zhang high-speed rail line.
Zhang Guoqin told reporters that the "emergency self-propelled walk" program is the first in China, and it is stronger than the existing vehicle emergency walking capability abroad. "The emergency travel capacity of the N700 series EMUs on the Japanese Shinkansen is 8 kilometers, and we have achieved more than 20 kilometers, which is equivalent to the stronger support capacity of the train." She said.
In addition, CRRC Long Passenger has also added a guidance device to the "Emergency Self-Propelled Walk" program. Through the guidance device, in the event of an emergency, the system can automatically prompt the driver whether he should go forward, or backward, or turn on the emergency air conditioner and wait in place according to the remaining power of the vehicle and the location.
The Winter Olympics train in the world for the first time to achieve a speed of 350 kilometers per hour automatic driving, through the on-board sensors, speed radar, positioning antenna and other equipment to collect location and vehicle information, the train can achieve automatic departure at the station, automatic operation of the section, automatic parking at the station, automatic opening of the door and other functions, parking accuracy within 0.5m.
Autonomous driving can reduce the work intensity of drivers by more than 40%. For example, Zhang Guoqin said that in manual driving mode, the driver needs to frequently operate the controller handle; in the automatic driving mode, the driver no longer needs to operate the handle. Depending on the set speed, the vehicle automatically pulls and brakes. For ordinary passengers, in the automatic driving mode, the vehicle's frustration is reduced, and the comfort and accuracy are further improved.
The Tiancheng protection team collects passenger suggestions and handles and feedback as soon as problems are found
Zhang Guoqin also revealed that at present, some intelligent technologies of the Winter Olympic trains have begun to be applied on ordinary intelligent EMU trains, such as the automatic identification system for toilet lights, which have been used on the "Fuxing" train.
Before the end of the Winter Olympic Games and the arrival of the Winter Paralympic Games, CRRC long-distance passengers modified 4 of the 10 "Winter Olympic cars". Two seats are removed from each car and wheelchair holders are installed in the vacated space to facilitate the ride of disabled athletes and passengers in the Winter Paralympic Games.
In addition to passengers, the mechanics on the train can also feel the "friendliness" of the intelligent system. Zhang Guoqin said that the mechanics of the Winter Olympic intelligent EMU can now realize the "multi-screen integration" of pantograph video, carriage video, safety monitoring and other systems by relying only on a display screen. Vehicle condition monitoring can also be carried out via a handheld terminal. Behind the simple screen fusion is the support of intelligent O&M systems based on big data technology.
The security personnel and mechanics confirm the discovery of faults
The Winter Olympic trains use Gigabit Ethernet control cars, and more than 2700 monitoring points are set up in the whole car, which is 200 to 300 more than the previous EMUs. "And each monitoring point often requires more than one sensor, resulting in a significant increase in the amount of equipment added to the whole vehicle." Zhang Guoqin said.
In addition, in order to realize the transformation from pure technology application to data plus technology application, the Winter Olympic Intelligent EMU also uses cloud computing, big data, artificial intelligence and other technologies to build an integrated intelligent operation and maintenance system of "vehicle-air-ground". 136 early warning and prediction models for seven major systems such as high pressure and traction were designed.
"We believe that intelligent operation and maintenance technology based on big data is the development direction of intelligent EMUs in the future," Zhang Guoqin said, adding that the intelligent EMU of the Beijing-Zhang high-speed railway is now an intelligent EMU type 1.0, and there is still a lot of room for development. "For example, let the train achieve self-learning iteration and realize unmanned driving, that is a smart train." She said.
Forward design
Since the former Ministry of Railways launched the international bidding and procurement of 140 EMUs with a speed of 200 kilometers per hour in 2004, China's high-speed railway equipment manufacturing has undergone a process of introduction, digestion, absorption and re-innovation. "At present, in many fields, we have entered the 'no man's land' of independent innovation of high-speed EMUs, there is no ready-made solution to refer to, and many problems need to be tested and explored by ourselves, that is, the so-called 'forward design'." Zhang Guoqin said.
The airtightness verification of the Winter Olympic train is a typical positive design case.
The Beijing-Zhangjiang high-speed rail line has many bridges, long tunnels, mountains and ravines, and 30/1000 ramps are difficult to climb, resulting in higher airtightness requirements for trains than ordinary "Fuxing".
The so-called train airtightness refers to the control indicators that ensure the stability of the air pressure in the car under the action of wind pressure in the high-speed operation of the vehicle, if the air tightness is not done well, the air pouring into the car will continue to impact the eardrums of passengers, causing continuous discomfort.
Zhao Jinlong, senior engineer of CRRC Changke, told the "Contour Line" reporter that the Beijing-Zhang high-speed railway Prince Edward City station is 1600 meters above sea level, while the lower garden station is only 560 meters above sea level, the altitude difference is more than 1000 meters, and the pressure difference is more than 10,000 pa. When the train passes at a speed of 350 kilometers per hour, the air pressure difference between the human ear and the aircraft is almost the same as when the plane lands. "Make sure that the train doesn't get a lot of air into the car the moment it goes downhill quickly or in and out of the tunnel. This was a huge challenge for the design team. He said.
Zhao Jinlong (first from the right)
One of the challenges comes from the holes that dot all corners of the train. Zhao Jinlong said that a fuxing train has tens of thousands of wiring harnesses, to enter the car through hundreds of holes, any one of the holes is not well sealed, or the equipment outside the car is not installed in place, it will lead to vehicle "leakage". Whether the air tightness index can be completed, one of the keys is to rely on the aperture interface process and operation technology.
"We assign air tightness indicators to each hole and each piece of equipment, and conduct full air tightness verification before and after loading, and strive to achieve tight seams and keep air flow out." Zhao Jinlong said.
However, it is not enough to seal the vehicle, because the vehicle is not a stationary object, and the impact from the environment outside the vehicle is more complex under high-speed operating conditions. To this end, Zhao Jinlong and his colleagues decided to develop a personalized database for the Beijing-Zhang high-speed railway.
In order to collect data, Zhao Jinlong's team boarded the bus at 5 a.m. in Beijing Every day, traveled back and forth to Prince Edward City and Zhangjiakou several times a day, and got off at 23:00 at night. Through instruments and personal experience, they recorded the pressure data and feelings of entering different tunnels at different times, explored the characteristics of the lines of each tunnel, analyzed the damper action rules at different times, continuously optimized, repeatedly verified, and finally designed a set of best control strategies and software logic for the dampers after more than 100 follow-up tests.
With this set of personalized data support, combined with the tunnel pressure difference, the software can dynamically adjust the train inlet and exhaust air control at any time during the high-speed operation of the vehicle, so as to ultimately ensure the balance of air pressure inside and outside the car, achieving excellent air tightness performance.
The air tightness index of the Winter Olympic train has increased by more than 20% compared with the ordinary "Fuxing", and it has increased several times more than the "Harmony". "Maybe everyone won't feel these improvements when they're on the bus, everything is unconscious, but in terms of airtightness, not feeling it is the biggest recognition of our work." Zhao Jinlong said.
The localization rate has increased again
While the "Winter Olympic Train" is constantly improving in technology, comfort and aesthetics, the localization rate is also increasing. The chief guest of the CRRC told the "Contour Line" reporter that after the advent of the Fuxing EMU in 2017, the localization rate has reached more than 90% so far, and it is still improving.
For example, he said, as mentioned above, two of the three CR400BF-C "Fuxing" trains serving the Winter Olympics are currently fully assembled with Chinese-funded enterprise wheel alignment products. "Enterprises in the high-speed rail equipment industry chain are constantly improving their independent innovation capabilities, and we hope to take the first time the Winter Olympics held in China as an opportunity to continue to improve the localization rate of the 'Fuxing'." He said.
The Chinese-funded enterprise mentioned by the above-mentioned person is BVV (Bochumer Verein Verkehrstechnik GmbH). BVV is an international high-speed rail wheelset giant, one of the world's leading rail transit five wheelset manufacturers. In March 2017, BVV was acquired by a Chinese-funded enterprise, FULL HILL ENTERPRISES LIMITED (hereinafter referred to as "Hong Kong Toyama"), and Guangxi Zhaoying Venture Capital Co., Ltd. (formerly Chongqing Zhaoying Rail Equipment Co., Ltd.) is the controlling shareholder of Hong Kong Toyama. At this point, BVV has become a Chinese-funded enterprise.
The safeguards team checks the wheelset
BVV people confirmed the above statement of the CRRC captain's guest to the "Contour Line" reporter, he said that the wheels and axles installed on the Winter Olympic train were designed by China Railway Research Institute Group Co., Ltd., CRRC Changke provided drawings, and BVV completed the production and manufacture of wheels and axles according to the requirements of the above two enterprises. After that, the CRRC captain assembled the wheels and axles, and a pair of finished wheelsets was completed.
During the Winter Olympics and Paralympic Winter Games, the BVV team cooperated with CRRC Long Passenger to track and guarantee the wheel pairs of the Winter Olympic trains. "So far, the BVV Olympic car maintenance team has not received any calls from the user." BVV people told reporters, "For our protection team, the user did not contact us, that is, the best praise for the product." ”
Wheelset is one of the main and high-precision components of rail transit equipment, and it is also one of the nine key technologies of high-speed EMUs, and the most important guarantee for the safe and stable operation of vehicles. The key technologies for wheels and axles lie in the smelting technology of steel, the level of control of the heat treatment process, and the ability to process and form with high precision.
Previously, China's high-speed rail wheel and shaft market was occupied by the Italian Lucchini Steel Machinery Company (Lucchini) to occupy most of China's high-speed rail wheel and shaft market. In 2018, after BVV was acquired by a Chinese-funded enterprise, its market share increased steadily.
Xuan Ruiguo, the actual controller of BVV and chairman of Toyama in Hong Kong, told the "Contour Line" reporter that in order to continue to meet the needs of the Chinese market and expand production capacity, BVV's plan to build a wheel axle manufacturing and wheelset press-fitting plant in China is advancing. "After the BVV China plant is put into operation, the Chinese high-speed rail EMUs will use fully localized high-speed rail wheelsets. This will not only meet the needs of the Chinese market, but also sell back to the European and North American markets. He said.
In 2008, seven days before the opening of the 29th Summer Olympic Games, China's first self-designed and constructed high-speed railway with a speed of 350 kilometers per hour, the Beijing-Tianjin Intercity Railway, was officially opened, opening the era of China's high-speed rail. During the Beijing Olympic Games, heads of state, dignitaries, athletes and tourists of many countries can travel between Beijing and Tianjin in just 28 minutes on the Harmony train.
Eleven years later, on December 30, 2019, the Beijing-Zhang high-speed railway, an important supporting project of the 24th Winter Olympic Games, was opened. On January 6, 2022, less than a month before the opening of the Beijing Winter Olympics, when the Winter Olympic train "Fuxing" dressed in the "Ruixue Yingchun" livery ran on the Beijing-Zhangjiang high-speed railway for the first time at a speed of 350 kilometers per hour, Beijing completed the certification of the world's first "Double Olympic City".
All 10 Winter Olympic trains were independently developed by CRRC Changke
In the 14 years from the "Summer Olympics" to the "Winter Olympics", China's high-speed rail has achieved a perfect surpass from the breakthrough of "zero" to the construction of the world's most developed high-speed rail network of more than 40,000 kilometers. China's rail transit equipment industry is not only a witness to China's hosting of the Olympic Games, but also a participant. The process of independent innovation of China's high-speed rail equipment coincides with the pursuit of the Olympic spirit of "faster, higher, stronger and more united".
Many years later, when people recall the wonderful moments of the 2022 Beijing Winter Olympic and Paralympic Winter Games, there are either the athletes' athletic and heroic posture on the ice and snow field, or the opening Olympic rings breaking through the ice, and the torch that lights up the world " shimmering". But for China's "high-speed rail people", the Olympic "Fuxing" train that crossed the wind and snow and galloped on the centennial Beijing-Zhang line also has extraordinary significance.
(Editor: Hao Cheng Proofreader: Yan Jingning)