Keywords: next generation train, running gear, roller rig, software-in-the-loop, rapid-control-prototyping, multi-body simulation.

A full-scale prototype of the Next Generation Train (NGT) running gear with a roller rig installation bench will be built as proof of concept of the running gear and its suitability for high-speed traffic. It will be available as the research platform “Forschungsinfrastruktur NGT-Fahrwerk” (FuN) for the German Aerospace Center (DLR) internal and external research activities. This work presents an innovative method and tool chain to develop application software for the automation of a mechatronic running gear (prototype). The methodology, development, and simulation tools that offer a consistent tool chain from model creation to real-time software and measurement data processing are presented. The model and software structures that are necessary for the software environment are described. The software-in-the-loop environment couples the existing multi-body simulations for the development process with signal-based simulation software using a co-simulation interface. The resulting software-in-the-loop simulation environment contains a novel interface layer that translates the mechanical states of the multi-body simulation to pseudo-electrical signals that are read or written by the application software. This makes it possible to develop real-time applications and software structures in software-in-the-loop architectures. The real-time software contains a dedicated model structure of input, processing and output submodels, which is based on signal flow and distinct assignment of tasks. On the rapid-control-prototyping hardware, the real-time software is investigated with a virtual installation bench simulation.

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