DLR tests reveal aerodynamic solutions for efficient freight trains

DLR tests reveal aerodynamic solutions for efficient freight trains
by Robert Schreiber
Berlin, Germany (SPX) Dec 13, 2024

A specialized measurement container developed by the German Aerospace Center (DLR) has traversed Europe's rail networks, collecting extensive aerodynamic data to improve freight train performance. The FR8-LAB, short for "freight laboratory," has journeyed thousands of kilometers, delivering insights crucial to enhancing the efficiency, safety, and flexibility of rail freight transport.

James Bell of the DLR Institute of Aerodynamics and Flow Technology explained the critical role of aerodynamics in freight rail. "The faster freight trains travel, the more critical their aerodynamics become," Bell said. "When their speed doubles, aerodynamic drag quadruples. This significantly affects energy consumption and safety. For the first time, the FR8-LAB allows us to analyze these factors in detail."

Advanced sensors delivering precise data

Disguised as an ordinary container, the FR8-LAB features cutting-edge technology, including hundreds of sensors to measure pressure, acceleration, and vibration. Infrared and laser-based sensors capture environmental factors such as proximity to other containers, tunnels, and trains. Power is supplied by a combination of batteries and solar panels on the container's roof.

The FR8-LAB offers a seamless testing platform, traveling as a standard container without requiring special licensing. "This approach allows cost-effective and straightforward testing under real-world rail conditions over long distances," Bell noted. Data gathered is compared with simulations and wind tunnel studies, providing an unprecedented view of freight train aerodynamics.

Enhanced efficiency through wagon alignment

Initial findings show that reducing gaps between wagons significantly enhances aerodynamic efficiency. Traditional freight train assembly methods, often manual and inflexible, create unnecessary drag. Advances in digital rail systems, such as automated coupling technology, could optimize wagon arrangements. "Smaller gaps of up to one meter have minimal aerodynamic impact, but larger gaps greatly increase drag. Improved alignment could save energy by double-digit percentages," Bell summarized.

Addressing safety at high speeds

The FR8-LAB also investigates the safety challenges posed by faster freight trains. Aerodynamic phenomena such as slipstreams and pressure surges in tunnels are well-documented for passenger trains but remain less understood for freight configurations. Data collected by the FR8-LAB helps evaluate these effects, ensuring infrastructure like lighting and ventilation systems withstand the pressures caused by high-speed freight trains.

The findings could have broader applications, including adaptations for road transport to address aerodynamic challenges for trucks. "The FR8-LAB data enables us to advance our research and support the rail industry's efforts to modernize freight transport," Bell concluded.