Cover assembly with onboard generator for rail vehicles and axle assembly including the same.

Abstract

A cover assembly is disclosed. The cover assembly can be mounted in an axle assembly, the axle assembly including an axle that rotates using power transmitted from a power source, a housing surrounding one end of the axle, and a bearing disposed between the one end of the axle and the housing to rotatably support the axle to the housing. A generator that generates electricity by utilizing the rotation of the axle as a whole is integrally formed on the axle assembly to power data detection, signal conversion, and wireless communication. Therefore, sufficient data can be obtained for frequency analysis, and anomalies in the axle assembly can be diagnosed in real time.

Description

Technical Field

[0001] The present invention relates to a cover assembly with an onboard generator for a rail vehicle and an axle assembly including the cover assembly, and more specifically, to a cover assembly with an onboard generator for a rail vehicle and an axle assembly including the cover assembly, the cover assembly supplying power generated by the rotation of the axle to at least one sensor that detects physical quantities of the axle assembly to ensure sufficient data for frequency analysis. Background Technology

[0002] Regular diagnostics are performed on components currently used in rail vehicles, and repairs or replacements are carried out when abnormalities are detected. However, because the rail system is a bulk transportation system, accidents involving the rail system have a high potential to escalate into major incidents. To prevent rail vehicle accidents, axle assemblies become a primary focus of monitoring.

[0003] Defects in a diagnostic object can be identified through heat, sound, vibration, and other methods. Using heat or sound diagnostic methods, users can easily identify defects, even after the defect has progressed significantly. Because vibration diagnostic methods can predict defects most quickly, they are frequently used in related technologies.

[0004] However, because the data sampling time is set to be very short and data needs to be collected to utilize diagnostic methods using vibration, the power consumption for data sampling is very high.

[0005] Typically, in the case of rail vehicles, multiple vehicles are interconnected, and the operation of these vehicles is controlled by a single locomotive. Multiple axle assemblies are mounted on multiple vehicles. When powering sensors used to detect physical quantities in multiple axle assemblies via wired connections and receiving data from the sensors via wired connections, the wiring harnesses can be complex and prone to frequent failures. Therefore, in recent years, schemes have been adopted where sensors and servers transmit and receive data wirelessly. According to these wireless communication schemes, batteries are arranged within the axle assemblies, and their power is used to perform data detection, signal conversion, and wireless communication. As mentioned above, since the power consumption for data sampling is very high in order to utilize diagnostic methods using vibration, high-capacity batteries should be used. However, due to the limited installation space of the axle assemblies, batteries with sufficient capacity cannot be used. Therefore, monitoring may be performed only once per hour, and it is difficult to obtain sufficient data for fault diagnosis.

[0006] The information disclosed in this background section is intended only to enhance the understanding of the background of the invention and therefore may contain information that does not constitute prior art known to those skilled in the art in this country. Summary of the Invention

[0007] Technical issues

[0008] An exemplary embodiment of the present invention is intended to provide a cover assembly with an on-board generator for a rail vehicle, wherein a generator capable of generating electricity by rotating the axle is integrally formed on the axle assembly to supply power for data detection, signal conversion and wireless communication.

[0009] Another exemplary embodiment of the present invention is dedicated to providing an axle assembly including a cover assembly.

[0010] Another exemplary embodiment of the present invention aims to provide a cover assembly and an axle assembly that are easy to install on rail vehicles.

[0011] Another exemplary embodiment of the present invention is dedicated to providing a cover assembly and an axle assembly that facilitate the replacement of faulty components.

[0012] Technical solution

[0013] An exemplary embodiment of the present invention provides a cover assembly that can be installed in an axle assembly, the axle assembly including an axle that rotates by using power transmitted from a power source, a housing surrounding one end of the axle, and a bearing disposed between the one end of the axle and the housing to rotatably support the axle to the housing.

[0014] The cover assembly may include: a bearing cover having a space; a generator including a rotor operatively connected to and rotating with the axle; a stator surrounding the rotor in a radial direction while maintaining a predetermined gap with the rotor in the same radial direction; a printed circuit board (PCB) electrically connected to the generator, applying input to the stator and receiving output from the rotor; at least one sensor mounted on the PCB and detecting at least one physical quantity of the axle assembly; and a wireless antenna mounted on the bearing cover and capable of wirelessly transmitting data corresponding to the at least one physical quantity detected by the at least one sensor, wherein the generator, the PCB, and the at least one sensor may be located within the space formed by the bearing cover.

[0015] The at least one sensor may include: an acceleration sensor for measuring the acceleration of the axle assembly and a temperature sensor for measuring the temperature of the axle assembly.

[0016] The cover assembly may further include: a power control system mounted on the PCB and controlling the input applied to the stator and the output of the rotor; a battery mounted on the PCB and receiving the output of the rotor and charging it through the power control system; and a wireless communication module mounted on the PCB and capable of exchanging data wirelessly.

[0017] In some aspects, an encoder that rotates together with the rotor may be mounted on the rotor, and an encoder sensor that detects the rotation of the encoder may be mounted on the stator.

[0018] In some aspects, the cover assembly further includes: a ground cover mounted on one side of the bearing cover; and a ground rotor connected to one end of the axle and rotating with the axle, and extending into the ground cover by penetrating the bearing cover.

[0019] The rotor and the stator can be configured to generate 10W or more of power.

[0020] The at least one sensor can be configured to detect at least one physical quantity of the axle assembly at a sampling rate of 10 kHz or higher.

[0021] In some aspects, the cover assembly may further include: a retainer mounted on the stator and electrically connecting the PCB to the generator, and the PCB may be mounted on the retainer.

[0022] The retainer may include a first retainer and a second retainer that are detachably connected to each other, and the PCB may be disposed between the first retainer and the second retainer and mounted on the retainer by connecting the first retainer and the second retainer.

[0023] The first retainer may include a first protrusion and a second protrusion that are spaced apart from each other in the radial direction and each protrudes to one side in the axial direction. The PCB may be disposed between the first protrusion and the second protrusion, and the second retainer may be connected to the first protrusion and the second protrusion.

[0024] The PCB can be detachably mounted on the retainer.

[0025] The cover assembly may further include a protective layer mounted on the PCB.

[0026] In some aspects, the PCB can be divided into two or more functional modules and can be detachably mounted on the retainer.

[0027] In some aspects, the retainer may further include at least two spokes connecting the first protrusion and the second protrusion to each other, the PCB may be divided into two or more functional modules and can be detachably mounted in the space formed by the first protrusion and the second protrusion and the spokes.

[0028] The cover assembly may further include a protective layer mounted on the PCB, and a filler dam may be disposed between the protective layer and the periphery and spokes of the second retainer.

[0029] Another exemplary embodiment of the present invention provides an axle assembly that may include: a cover assembly according to an exemplary embodiment of the present invention; and a retainer mounted on a stator and electrically connecting a PCB to a generator. The PCB may be mounted on the retainer. The axle assembly may further include: an extension operatively connected to one end of the axle and extending axially; a bearing cap coupled to the retainer and having the generator and the PCB disposed therein; an axle housing mounted on an inner circumferential surface at one end of the housing; and a connection adapter for mounting the retainer on the axle housing, wherein the PCB may be mounted on the retainer, and the extension and the rotor of the generator may be spline-connected.

[0030] One end of the extension can penetrate the bearing cover without causing rotational interference with the bearing cover.

[0031] In some aspects, the axle assembly may further include: a speed plate mounted at one end of the extension, and a speed sensor housing mounted at one end of the axle housing.

[0032] In some aspects, the axle assembly may further include: a grounding rotor mounted at one end of the extension, and a grounding cover mounted at one end of the axle housing.

[0033] The axle assembly may further include: a gearbox that changes the power rotation speed of a power source through multiple gears and transmits the power of the changed rotation speed to the axle; a gearbox sensor module configured to detect at least one of the acceleration, rotation speed, and temperature of the multiple gears; and a wired connector mounted on the bearing cover and connected to the PCB for power supply.

[0034] The measured values ​​of the gearbox sensor module can be wirelessly transmitted to the PCB via a wireless antenna or wiredly transmitted to the PCB via a wired connector.

[0035] Beneficial effects

[0036] According to an exemplary embodiment of the present invention, a generator that generates electricity by utilizing the rotation of the axle as a whole is integrally formed on the axle assembly to provide power for data detection, signal conversion, and wireless communication. Therefore, sufficient data can be obtained for frequency analysis, and axle assembly malfunctions can be diagnosed in real time.

[0037] Furthermore, the use of a wireless communication scheme allows for the convenient use of wire harnesses.

[0038] In addition, data detected through wireless communication between axle assemblies is sequentially transmitted to the server to reduce the generator's capacity.

[0039] The PCB is assembled to the cover assembly via a retainer to protect the PCB from external impacts.

[0040] Because the PCB is divided into multiple functional modules and assembled onto the cover assembly, only the faulty functional module can be separated from the cover assembly and replaced. Therefore, components can be easily replaced, and maintenance costs can be reduced.

[0041] Furthermore, the effects that can be obtained or predicted by the exemplary embodiments of the present invention are disclosed, directly or implicitly, in the detailed description of the exemplary embodiments of the present invention. That is, various effects predicted according to the exemplary embodiments of the present invention will be disclosed in the detailed description below. Attached Figure Description

[0042] Exemplary embodiments of the invention will be more readily understood by referring to the following description associated with the accompanying drawings, in which similar reference numerals indicate the same or functionally similar elements.

[0043] Figure 1 This is a schematic diagram illustrating a rail vehicle according to an exemplary embodiment of the present invention.

[0044] Figure 2 This is a schematic cross-sectional view illustrating an axle assembly according to an exemplary embodiment of the present invention.

[0045] Figure 3 This is a schematic diagram illustrating some components of an axle assembly according to an exemplary embodiment of the present invention.

[0046] Figure 4 This is a schematic diagram illustrating some components of an axle assembly according to another exemplary embodiment of the present invention.

[0047] Figure 5 This is a schematic cross-sectional view illustrating the construction of a cover assembly according to an exemplary embodiment of the present invention.

[0048] Figure 6 This is a schematic plan view of the cover assembly according to an exemplary embodiment of the present invention.

[0049] Figure 7 This is a schematic plan view of a cover assembly according to another exemplary embodiment of the present invention.

[0050] Figure 8 Example edge Figure 7 A portion of the cross-sectional view taken by line AA in the image.

[0051] Figure 9 This is a schematic plan view of a cover assembly according to yet another exemplary embodiment of the present invention.

[0052] Figure 10 Example edge Figure 9 The section view is a portion of the cross-sectional view captured by line BB.

[0053] Figure 11 This is a cross-sectional view illustrating some components of an axle assembly according to an exemplary embodiment of the present invention.

[0054] Figure 12 This is a cross-sectional view illustrating some components of an axle assembly according to another exemplary embodiment of the present invention.

[0055] It should be understood that the accompanying drawings are not illustrated to scale, but rather present a simplified representation of various preferred features illustrating the basic principles of this disclosure. For example, specific design features of this disclosure, including particular dimensions, orientations, locations, and shapes, will be determined in part according to the specific intended application and the specific environment of use. Detailed Implementation

[0056] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to limit this disclosure. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. When the terms “include” and / or “including” are used in this specification, it should be understood that the terms specify the presence of the stated features, integers, steps, operations, components, and / or parts, but do not exclude the presence or addition of at least one of other features, integers, steps, operations, components, parts, and / or combinations thereof. As used herein, the term “and / or” includes one or all random combinations of the associated listed items.

[0057] As used herein, terms such as “vehicle” or “of vehicles” or other similar terms are understood to include automobiles in addition to rail vehicles, including sport utility vehicles (SUVs), buses, trucks and various commercial vehicles.

[0058] Furthermore, one or more of the following methods or aspects are understood to be performed by at least one control unit (e.g., an electronic control unit (ECU), controller, or control server). The terms "control unit," "controller," or "control server" can refer to a hardware device including a memory and a processor. The memory is configured to store program commands, and the processor is specifically programmed to execute the program commands to perform one or more processes described in more detail below. The control unit, controller, or control server can be a control unit, module, component, device, or similar component thereof. Furthermore, it should be understood that the following methods can be performed by a device including a control unit or controller and one or more other components recognized by those skilled in the art.

[0059] Furthermore, the control unit, controller, or control server according to this disclosure can be implemented as a non-transitory computer-readable recording medium comprising executable program commands executed by a processor. Examples of computer-readable recording media include, but are not limited to, ROM, RAM, optical disc (CD) ROM, magnetic tape, floppy disk, flash drive, smart card, and optical data storage device. The computer-readable recording medium is also distributed on a computer network, and the program commands can be stored and executed through a distribution scheme such as a telematics server or a controller area network (CAN).

[0060] Figure 1 This is a schematic diagram illustrating a rail vehicle according to an exemplary embodiment of the present invention.

[0061] like Figure 1 For example, rail vehicle 1 includes multiple vehicles connected to each other. The vehicles are configured to carry passengers or cargo, and multiple bogies 10 are mounted on the underside of the vehicles to enable them to move on the tracks. An engine room may be formed in one of the multiple vehicles, and a control server 200 may be located in the engine room.

[0062] The bogie 10 typically consists of two or three axle assemblies 100 and supports the vehicle body. The bogie 10 includes a bogie frame, axle assemblies 100 mounted on the bogie frame, a buffer device, a braking device, a traction motor, etc.

[0063] Since the bogie 10 is well known to those skilled in the art, a more detailed description will be omitted.

[0064] Control server 200 controls the operation of rail vehicle 1 and monitors components included in rail vehicle 1. For example, control server 200 may be configured to receive signals corresponding to physical quantities of axle assembly 100 from at least one sensor included in axle assembly 100, and diagnose the state of axle assembly 100 based on the received signals. Furthermore, control server 200 may be configured to receive signals from a sensor mounted on gearbox 110 (see...). Figure 2At least one sensor in the gearbox 110 receives a signal corresponding to a physical quantity of the gearbox 110 and diagnoses the state of the gearbox 110 and the state of the track based on the received signal.

[0065] Figure 2 This is a schematic cross-sectional view illustrating an axle assembly according to an exemplary embodiment of the present invention.

[0066] like Figure 2 For example, the axle assembly 100 includes an axle 102. The axle 102 is connected to a power source (e.g., a traction motor, etc.) and rotates by receiving power from the power source.

[0067] A gearbox 110 may be disposed between a power source and an axle 102. The gearbox 110 includes a plurality of gears that mesh with each other to change the rotational speed of the power source and transmit the changed power to the axle 102. A gearbox sensor module 112 is mounted on the gearbox 110 and is configured to detect at least one of the acceleration, rotational speed, and temperature of the plurality of gears.

[0068] The control server 200 can diagnose the state of the gearbox 110 based on the physical quantities of the gearbox 110 detected by the gearbox sensor module 112.

[0069] Wheels 104 are fixedly mounted on both sides of axle 102. Wheels 104 can be fixed to axle 102 by various methods including extrusion, welding, splines, etc. Each wheel 104 is rotatably mounted on a track. When axle 102 rotates by receiving power from a power source, wheel 104 rotates on the track. Therefore, the rail vehicle 1 can move.

[0070] Bearings 120 are mounted at both ends of axle 102. Each bearing 120 supports the axle 102 and enables it to rotate relative to the vehicle body. Bearing 120 includes an inner ring, an outer ring, and multiple rolling elements. The inner ring is fixed to the axle 102 and rotates with the axle. The outer ring surrounds the inner ring outside its radius and is fixed to the vehicle body. The multiple rolling elements are configured to rotate between the inner and outer rings. The multiple rolling elements allow the inner ring to rotate relative to the outer ring.

[0071] Cover assembly 130 is installed at both ends of axle 102. Cover assembly 130 primarily prevents foreign substances such as water or dust from entering bearing 120.

[0072] Figure 3 This is a schematic diagram illustrating some components of an axle assembly according to an exemplary embodiment of the present invention.

[0073] like Figure 3For example, the axle assembly 100 according to an exemplary embodiment of the present invention further includes a housing 140 surrounding the axle 102. The housing 140 may be formed separately from and connected to the vehicle body or integrally formed with the vehicle body. As described above, a bearing 120 is disposed between the housing 140 and the axle 102. The inner ring of the bearing 120 is fixed to the axle 102 by various methods including extrusion, welding, etc., and the outer ring of the bearing 120 is fixed to the vehicle body or the housing 140 by various methods including extrusion, welding, etc., and a plurality of rolling elements are disposed between the inner ring and the outer ring.

[0074] The axle assembly 100 includes a cover assembly 130 mounted between the housing 140 or the vehicle body and the axle 102. The cover assembly 130 allows the axle 102 to rotate relative to the housing 140 or the vehicle body. The cover assembly 130 is attached to one end of the housing 140 to prevent foreign substances such as dust or moisture from entering the housing 140. The cover assembly 130 may be detachably mounted on the housing 140.

[0075] The cover assembly 130 can be connected to the axle 102 via an extension 132. The extension 132 is operatively connected to the axle 102 and extends axially. Therefore, the cover assembly 130 includes a component connected to the axle 102 and capable of rotation, and a component connected to and fixed therein to the housing 140. As a fixed component, the cover assembly 130 further includes a bearing cover 150. The bearing cover 150 is directly or indirectly connected to the housing 140 and has space for housing components.

[0076] The cover assembly 130 may further include an axle sensor unit 160 disposed inside the bearing cover 150 and a wireless antenna 162 mounted on the bearing cover 150.

[0077] Figure 4 This is a schematic diagram illustrating some components of an axle assembly according to another exemplary embodiment of the present invention.

[0078] like Figure 4 For example, the axle assembly 130' according to another exemplary embodiment of the present invention further includes a grounding rotor 172 and a grounding cover 170.

[0079] The grounding rotor 172 is connected to one end of the extension 132 and is able to rotate together with the extension 132.

[0080] One end of the grounding rotor 172 is positioned inside the grounding cover 170 by penetrating the bearing cover 150.

[0081] The grounding rotor 172 is guided to the grounding cover 170 by brushes installed therein.

[0082] The ground cover 170 is mounted on a surface of the bearing cover 150, the housing, or a separate structure connected to the housing 140 or the bearing cover 150.

[0083] The rail vehicle 1 forms a circuit in which the current collector (pantograph) is set as the (+) pole and the track is set as the (-) pole. Since the bearing 120 is located between the vehicle body electrically connected to the current collector and the wheel 104 electrically connected to the track, the current collector, vehicle body, track, wheel 104, axle 102, and bearing 120 form a closed circuit. However, when a high-voltage current passes through the bearing 120, the contact area between the inner ring, outer ring, and rolling elements is small, resulting in sparks or electrolytic corrosion at the contact points.

[0084] To prevent this from happening, the current should be conducted directly from the grounding rotor 172, which rotates together with the axle 102, to the grounding cover 170 via brushes.

[0085] Figure 5 This is a schematic cross-sectional view illustrating the construction of a cover assembly according to an exemplary embodiment of the present invention. Figure 6 This is a schematic plan view of a cover assembly according to an exemplary embodiment of the present invention.

[0086] like Figure 5 and Figure 6 For example, the cover assembly 130 according to an exemplary embodiment of the present invention includes an axle sensor unit 160 and a generator 180 inside a bearing cover 150.

[0087] The generator 180 includes a rotor 182 and a stator 184. The rotor 182 is fixed to an extension 132 of the axle 102 and is rotatable with the axle 102. The stator 184 surrounds the rotor 184 in the radial direction while maintaining a gap with the rotor 182 in the radial direction. Therefore, the stator 184 and the rotor 182 face each other in the radial direction. Each of the rotor 182 and the stator 184 is wound with a coil, and when a current is applied to the coil of the stator 184 to form a magnetic field, an induced current is generated in the coil of the rotor 184 rotating in the magnetic field. In one exemplary embodiment, the rotor 184 is described as being fixed to the extension 182, but the invention is not limited thereto. The rotor 184 may also be fixed to the axle 102 depending on the size of the bearing cap 150 and the power generation capacity. The phrase "fixed to axle 102" in this specification and claims should be understood to include "directly fixed to axle 102" or "fixed to an extension 132 connected to axle 102".

[0088] In some exemplary embodiments, encoder 183 may be mounted on the outer peripheral surface of rotor 182, and encoder sensor 185 may be mounted on stator 184. In encoder 183, N poles and S poles are arranged alternately circumferentially, and encoder sensor 185 faces encoder 183 with a predetermined air gap between them to detect changes in the magnetic field that occur when encoder 183 rotates. Therefore, encoder sensor 185 can detect the rotational speed of encoder 183, i.e., the rotational speed of axle 102.

[0089] At least one printed circuit board (PCB) is mounted on the outer periphery of the stator 184. PCB 186 is electrically connected to the stator 184 and the rotor 182. Therefore, PCB 186 can apply an input (e.g., current) to the stator 184 and receive an output (e.g., current) from the rotor 182. In addition, PCB 186 is electrically connected to an encoder sensor 185 to receive a signal corresponding to the rotational speed of the axle 102 detected by the encoder sensor 185.

[0090] An axle sensor unit 160, including an acceleration sensor 192 and a temperature sensor 194, is mounted on a PCB 186. The acceleration sensor 192 may be a triaxial acceleration sensor capable of measuring the acceleration of the axle 102 or axle assembly 100 in the x, y, and z axes.

[0091] Temperature sensor 194 can measure the temperature of axle 102 or axle assembly 100.

[0092] The axle sensor unit 160 further includes a power control system 197, a battery 198, and a wireless communication unit 199 mounted on a PCB 186.

[0093] The power control system 197 can control the input applied to the stator 184 and the output of the rotor 182. That is, the power control system 197 can control the current applied to the stator 184 and receive current from the rotor 182 to charge the battery 198. Furthermore, the power control system 197 supplies power to the battery 198 and also supplies power to the encoder sensor 185, the acceleration sensor 192, and the temperature sensor 194, enabling the sensors 185, 192, and 194 to detect physical quantities of the axle assembly 100.

[0094] In addition, the power control system 197 supplies power from the battery 198 to the wireless communication unit 199 to enable wireless communication with the control server 200 or the surrounding axle assembly 100.

[0095] The battery 198 can be charged using electricity generated by the generator 180 and supplies power to each component of the axle sensor unit 160 under the control of the power control system 197. The battery 198 can be a rechargeable and dischargeable secondary battery.

[0096] The wireless communication unit 199 converts the physical quantities detected by the encoder sensor 185, accelerometer 192, and temperature sensor 194 into signals capable of wireless communication. It then communicates these converted signals with the control server 200 or the peripheral axle assembly 100 via wireless communication protocols such as Bluetooth, Zigbee, WiFi, or LTE. The signals converted by the wireless communication unit 199 are transmitted to the control server 200 or the peripheral axle assembly 100 via the wireless antenna 162. Furthermore, signals can be received from the peripheral axle assembly 100, the control server 200, or the gearbox sensor module 112 via the wireless antenna 162.

[0097] The wired connector 163 can be further installed in the bearing cover 150. The wired connector 163 is electrically connected to a component on the PCB 186 to apply external power and transmit / receive data, or is wired to the gearbox sensor module 112 included in the axle assembly 100 to power the gearbox sensor module 112 or transmit / receive signals to the gearbox sensor module 112.

[0098] According to an exemplary embodiment of the present invention, when considering the size of the bearing cover 150 and the average rotational speed of the axle 102, the generator 180, which can be installed in the cover 150, can generate approximately 10 W or more of power. When using 10 W of power, the triaxial acceleration (or vibration) of the axle assembly 100 (75,000 data points), the temperature of the axle assembly 100 (1 data point), and the rotational speed of the axle 102 (1 data point) are measured wirelessly at a sampling rate of 75,002 data points per second or 25 kHz. To perform frequency analysis using the vibration of the axle assembly 100, the data should be sampled at a sampling rate of at least 10 kHz or higher, preferably 12.5 kHz. According to an exemplary embodiment of the present invention, sufficient data for frequency analysis can be obtained by using the capacity of the generator 180, which can be installed in the bearing cover 150, for data sampling at a sampling rate of 25 kHz or higher, and for wireless communication.

[0099] Furthermore, according to an exemplary embodiment of the present invention, both the generator 180 and the axle sensor unit 160, including sensors 185, 192, and 194, are disposed within the bearing cover 150, and the extension 132 of the rotor 182 connected to the generator 180 protrudes to the outside of the bearing cover 150. Therefore, when the bearing cover 150 is connected to the housing 140 and the extension 132 is connected to the axle 102, the cover assembly 130 according to an exemplary embodiment of the present invention can be installed in the axle 102. Thus, the cover assembly 130 according to an exemplary embodiment of the present invention can be applied without making special modifications to existing axle assemblies of rail vehicles.

[0100] Simultaneously, data detected by one axle assembly 100 can be transmitted wirelessly to another axle assembly 100 located near the control server 200. In this scheme, the axle assembly 100 closest to the control server 200 can wirelessly transmit all data from each axle assembly 100 to the control server 200. Therefore, the power consumption of wireless communication can be reduced, and the capacity of the generator 180 can be reduced.

[0101] Furthermore, since data is transmitted via wireless communication, wire harnesses may be convenient.

[0102] Figure 7 This is a schematic plan view of a cover assembly according to another exemplary embodiment of the present invention. Figure 8 Example edge Figure 7 A portion of the cross-sectional view taken by line AA in the image.

[0103] like Figure 7 and Figure 8 For example, the cover assembly 130 according to another exemplary embodiment of the present invention may include a generator 180 and an axle sensor unit 160, and the axle sensor unit 160 may be mounted on the stator 184 of the generator 180 by a retainer 300.

[0104] In one example, the retainer 300 may be an annular shape surrounding the generator 180. In this case, the retainer 300 may be mounted on the stator 184. In another example, the retainer 300 may be an annular shape surrounding the axle 102 and may be located on one side of the generator 180. In this case, the retainer 300 may be mounted on one side of the stator 184.

[0105] The retainer 300 includes a first retainer 302 and a second retainer 304 that are detachably connected to each other.

[0106] The first retainer 302, which has an annular disk shape, includes an outer peripheral surface and an inner peripheral surface.

[0107] Since the outer diameter of the first retainer 302 is smaller than the inner diameter of the housing 140, the axle sensor unit 160 can be installed in the housing 140, and when the inner diameter of the first retainer 302 is larger than the outer diameter of the generator 180 or the axle 102, the first retainer 302 can surround the generator 180 or the axle 102.

[0108] In the first retainer 302, a first protrusion 314 and a second protrusion 316 are formed, which are spaced apart from each other in the radial direction, and each of the first protrusion 314 and the second protrusion 316 protrudes along one side in the axial direction. PCB 186 is disposed between the first protrusion 314 and the second protrusion 316.

[0109] The second retainer 304 has an annular disc shape and has dimensions corresponding to each of the first protrusion 314 and the second protrusion 316. After the PCB 186 is positioned between the first protrusion 314 and the second protrusion 316, the second retainer 304 is coupled to the first protrusion 314 and the second protrusion 316 to mount the PCB 186 onto the retainer 300.

[0110] The retainer 300 can be electrically connected to the generator 180 and the axle sensor unit 160. For example, the retainer 300 may include a first connector electrically connected to the generator 180, a second connector electrically connected to the PCB 186, and internal wiring electrically connecting the first and second connectors. Therefore, when the PCB 186 is mounted on the retainer 300, the connector pins of the PCB 186 can be connected to the second connector of the retainer 300, thus establishing an electrical connection between the retainer 300 and the PCB 186. Furthermore, when the retainer 300 with the PCB 186 mounted is mounted on the outer periphery of the generator 180, the connector pins of the generator 180 can be connected to the first connector of the retainer 300, thus establishing an electrical connection between the PCB 186 and the generator 180.

[0111] Alternatively, the generator 180 and the axle sensor unit 160 can be wirelessly connected.

[0112] The retainer 300 protects the axle sensor unit 160, including the PCB 186, from external impacts. Specifically, the PCB 186, in the form of a thin plate, is mounted on the generator 180 via the retainer 300 to protect the PCB 186 and the axle sensor unit 160 mounted thereon from external impacts. The retainer 300 may further include a protective layer 310 mounted on the PCB 186 for further protection. After the PCB 186 is mounted on the retainer 300, the protective layer 310 can be formed on the PCB 186 using silicone or epoxy resin.

[0113] In one example, a protective layer 310 may be formed on the retainer 300 using silicone or epoxy resin before the PCB 186 is mounted on the retainer 300, and the PCB 186 may also be mounted thereon.

[0114] In one example, the first retainer 302 and the second retainer 304 may be threadedly connected. For this purpose, threaded holes 306 and 308 can be formed at positions corresponding to the first protrusion 314 and the second protrusion 316, and the second retainer 304, respectively. This specification illustrates a threaded connection between the first retainer 302 and the second retainer 304, but the connection of the first retainer 302 and the second retainer 304 is not limited to this. Various connection schemes that allow for detachable connection of the first retainer 302 and the second retainer 304 can be employed. Because the first retainer 302 and the second retainer 304 are detachably connected to each other, the axle sensor unit 160 can be easily replaced when it malfunctions.

[0115] To further facilitate the replacement of faulty components in the axle sensor unit 160, the PCB 186 can be divided into two or more functional modules and mounted on the retainer 300, such as... Figure 9 and Figure 10 Example.

[0116] Figure 9 This is a schematic plan view of a cover assembly according to yet another exemplary embodiment of the present invention. Figure 10 Example edge Figure 9 The section view is a portion of the cross-sectional view captured by line BB.

[0117] like Figure 9 As exemplified in the example, PCB 186 can be divided into four functional modules, such as wireless communication module 186a, power module 186b, operation module 186c and sensor module 186d.

[0118] The wireless communication module 186a may include a wireless communication unit 199 and circuitry supporting the wireless communication unit 199. The power module 186b may include a power control system 197, a battery 198, and circuitry supporting it. The operation module 186c may include circuitry supporting the wireless communication module 186a, the power module 186b, and the sensor module 186d. The sensor module 186d may include an encoder sensor 185, an acceleration sensor 192, a temperature sensor 194, and circuitry supporting them.

[0119] like Figure 10 For example, the retainer 300 further includes at least two spokes 313 that connect the first protrusion 314 and the second protrusion 316 to each other and divide the respective functional modules 186a, 186b, 186c and 186d, and form spaces therein in which the respective functional modules 186a, 186b, 186c and 186d can be installed, so as to easily separate the respective functional modules 186a, 186b, 186c and 186d from the retainer 300.

[0120] exist Figure 9 The example shows four functional modules 186a, 186b, 186c, and 186d, and four spokes 313, but the number of functional modules and spokes is not limited to four. For example, when two functional modules are provided, the number of spokes 313 can be two.

[0121] Furthermore, a filler dam 312 may be disposed between the protective layer 310 and the retainer 300 (e.g., the periphery of the second retainer 304 and the spokes 313) to easily separate each of the functional modules 186a, 186b, 186c, and 186d from the retainer 300. The filler dam 312 connects the protective layer 310 and the retainer 300 to easily separate the protective layer 310 (attached to each functional module) from the retainer 300. When the second retainer 304 is separated from the first retainer 302, the protective layer 310 and each of the functional modules 186a, 186b, 186c, and 186d are attached to the second retainer 304. When the filler dam 312 surrounding the protective layer 310 of the replaceable functional module is removed from the second retainer 304, the replaceable functional module and the protective layer 310 attached to the functional module can be separated from the second retainer 304. Subsequently, a new functional module is installed on the first retainer 302, and a second retainer 304 is connected to the first retainer 302. Then, a stuffing dam 312 is attached to the periphery and spokes 313 of the second retainer 300, and a protective layer 310 is formed on the functional module to replace it. Therefore, the functional module is easy to replace. Furthermore, since only the faulty functional module is replaced, maintenance costs are reduced.

[0122] As described above, retainer 300 may include electrical connection means for electrically connecting each of the functional modules 186a, 186b, 186c, and 186d of PCB 186 to generator 180. In one example, the electrical connection means may be a connector and connector pins.

[0123] The following is for reference. Figure 11 and Figure 12 The installation process of the axle assembly 100 according to an exemplary embodiment of the present invention will be described.

[0124] Figure 11 These are cross-sectional views illustrating some components of an axle assembly according to an exemplary embodiment of the present invention. Figure 12 This is a cross-sectional view illustrating some components of an axle assembly according to another exemplary embodiment of the present invention.

[0125] Figure 11 The axle assembly 100 illustrated further includes an axle housing 320, a vehicle speed sensor 330, a connection adapter 340, and a speed sensor housing 350.

[0126] First, the extension portion 132 is connected to the axle 102. That is, the extension portion 132 is provided at one end of the axle 102, and the axle 102 and the extension portion 132 are connected by a connecting device such as a bolt 134. A spline 135 may be formed at a designated position on the extension portion 132.

[0127] Subsequently, the generator 180 and the axle sensor unit 160, which are connected to each other via the retainer 300, are coupled to the axle housing 320. Here, the generator 180 and the axle sensor unit 160 are disposed in the bearing cover 150, and the bearing cover 150 is connected to the retainer 300. The axle housing 320 has a generally cylindrical shape, and the generator 180 and the axle sensor unit 160 are mounted on the inner circumferential surface of the axle housing 320. A connecting adapter 340 is used to connect the retainer 300, which connects the generator 180 and the axle sensor unit 160, to the axle housing 320. For this purpose, the connecting adapter 340 includes a cylindrical portion 342 and a disc portion 344. The cylindrical portion 342 can be coupled to the inner circumferential surface of the axle housing 320 by a coupling device such as a bolt 346, and the disc portion 344 can be coupled to the retainer 300 by a coupling device such as the connecting device 346. Therefore, the axle sensor unit 160 is connected to the generator 180 via the retainer 300, and the disc portion 344 of the connecting adapter 340 is connected to the retainer 300. Subsequently, the cylindrical portion 342 of the connecting adapter 340 is connected to the inner circumferential surface of the axle housing 320.

[0128] After the generator 180 and the axle sensor unit 160 are connected to the axle housing 320, the axle housing 320 is mounted on the inner circumferential surface of the housing 140. The axle housing 320 can be press-fitted onto the housing 140 or connected to the housing 140 by a connecting device such as bolts. During the press-fitting of the axle housing 320 onto the housing 140, the generator 180 is operatively connected to the extension 132. For this purpose, a spline 136 is formed on the inner circumferential surface of the rotor 182 of the generator 180, and the spline 136 of the rotor 182 is spline-connected to the spline 135 of the extension 132. Therefore, when the axle 102 and / or the extension 132 rotate, the rotor 182 also rotates. Furthermore, a predetermined gap is formed between the bearing cap 150 and the outer circumferential surface of one end of the extension 132. One end of the extension 132 penetrates the bearing cap 150 without causing rotational interference with the bearing cap 150.

[0129] Subsequently, a speed plate 330 is formed on one end of the extension 132. Speed ​​teeth 332 are formed at equal intervals on the outer peripheral surface of the speed plate 330, and the speed teeth 332 can generate a current change proportional to the rotational speed in the speed sensor (not shown). The speed plate 330 is mounted on the bearing cover 150 without interfering with its rotation, and is connected to the extension 132 by a connecting device such as a bolt 334. Therefore, the speed plate 330 can rotate together with the extension 132.

[0130] Finally, the speed sensor housing 350 is mounted on one end of the axle housing 320.

[0131] Figure 12 The axle assembly 100 illustrated further includes an axle housing 320, a grounding rotor 172, and a connection adapter 340.

[0132] Figure 12 The wheel and axle assembly 100 illustrated further includes a wheel and axle housing 320, a grounded rotor 172, and a connection adapter 340.

[0133] First, the extension portion 132 is connected to the axle 102. That is, the extension portion 132 is provided at one end of the axle 102, and the axle 102 and the extension portion 132 are connected by a connecting device such as a bolt 134. A spline 135 may be formed at a designated position on the extension portion 132.

[0134] The generator 180 and the axle sensor unit 160, connected to each other via a retainer 300, are coupled to the axle housing 320. The axle housing 320 has a generally cylindrical shape, and the generator 180 and the axle sensor unit 160 are mounted on the inner circumferential surface of the axle housing 320. The retainer 300, which connects the generator 180 and the axle sensor unit 160, is connected to the axle housing 320 using a connecting adapter 340. For this purpose, the connecting adapter 340 includes a cylindrical portion 342 and a disc portion 344. The cylindrical portion 342 can be coupled to the inner circumferential surface of the axle housing 320 by a coupling device such as a bolt 346, and the disc portion 344 can be coupled to the retainer 300 by a coupling device such as the connecting device 346. Therefore, the axle sensor unit 160 is coupled to the generator 180 via the retainer 300, and the disc portion 344 of the connecting adapter 340 is coupled to the retainer 300. Subsequently, the cylindrical portion 342 of the adapter 340 is attached to the inner circumferential surface of the axle housing 320.

[0135] After the generator 180 and the axle sensor unit 160 are connected to the axle housing 320, the axle housing 320 is mounted on the inner circumferential surface of the housing 140. The axle housing 320 can be press-fitted onto the housing 140 or connected to the housing 140 by a connecting device such as bolts. During the press-fitting of the axle housing 320 onto the housing 140, the generator 180 is operatively connected to the extension 132. For this purpose, a spline 136 is formed on the inner circumferential surface of the rotor 182 of the generator 180, and the spline 136 of the rotor 182 is splined to the spline 135 of the extension 132.

[0136] Therefore, when the axle 102 and / or the extension 132 rotate, the rotor 182 also rotates together.

[0137] Furthermore, a predetermined gap is formed between the bearing cap 150 and the outer peripheral surface of one end of the extension 132. One end of the extension 132 penetrates the bearing cap 150 without causing rotational interference with the bearing cap 150.

[0138] The grounding rotor 172 is guided to the axle housing 320 by brushes installed therein. The grounding rotor 172 is fixed to the extension 132 by a connecting device such as bolts 174. Therefore, the grounding rotor 172 can rotate together with the extension 132.

[0139] Finally, the ground cover 170 is installed at one end of the axle housing 320.

[0140] While the invention has been described in conjunction with exemplary embodiments now considered practically feasible, it should be understood that the invention is not limited to the disclosed embodiments. Rather, it is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A cover assembly mounted in an axle assembly, the axle assembly including an axle that rotates using power transmitted from a power source, a housing surrounding one end of the axle, and a bearing disposed between the one end of the axle and the housing to rotatably support the axle to the housing, the cover assembly comprising: The bearing cover has a space within it; A generator includes a rotor operatively connected to and rotating with the axle, and a stator surrounding the rotor in the radial direction while maintaining a predetermined gap with the rotor in the radial direction. A printed circuit board, electrically connected to the generator, applies input to the stator and receives output from the rotor; At least one sensor is mounted on the printed circuit board and detects at least one physical quantity of the axle assembly; A wireless antenna is mounted on the bearing cover and is capable of wirelessly transmitting data corresponding to at least one physical quantity detected by the at least one sensor; as well as A retainer, mounted on the stator, electrically connects the printed circuit board to the generator, wherein the printed circuit board is mounted on the retainer. The generator, the printed circuit board, and at least one sensor are located in the space formed by the bearing cover. The retainer includes a first retainer and a second retainer that are detachably connected to each other, and The printed circuit board is disposed between the first holder and the second holder, and is mounted on the holder by connecting the first holder and the second holder.

2. The cover assembly according to claim 1, wherein: An encoder that rotates together with the rotor is mounted on the rotor, and An encoder sensor that detects the rotation of the encoder is mounted on the stator.

3. The cover assembly according to claim 1, wherein: The at least one sensor includes: An acceleration sensor measures the acceleration of the axle assembly, and A temperature sensor measures the temperature of the axle assembly.

4. The cover assembly according to claim 1, further comprising: A power control system, mounted on the printed circuit board, controls the inputs applied to the stator and the outputs applied to the rotor; A battery is mounted on the printed circuit board and receives the output of the rotor and is charged through the power control system. as well as A wireless communication module is mounted on the printed circuit board and is capable of exchanging data wirelessly.

5. The cover assembly according to claim 1, further comprising: A grounding cover is installed on one side of the bearing cover; as well as A grounding rotor is connected to one end of the axle and rotates with the axle, and extends into the grounding cover by penetrating the bearing cover.

6. The cover assembly according to claim 1, wherein: The rotor and the stator are configured to generate 10W or more of power.

7. The cover assembly according to claim 1, wherein: The at least one sensor is configured to detect at least one physical quantity of the axle assembly at a sampling rate of 10 kHz or higher.

8. The cover assembly according to claim 1, wherein: The first retainer includes a first protrusion and a second protrusion spaced apart from each other in the radial direction, and each of the first protrusion and the second protrusion protrudes to one side in the axial direction. The printed circuit board is disposed between the first protrusion and the second protrusion, and The second retainer is connected to the first protrusion and the second protrusion.

9. The cover assembly according to claim 1, wherein: The printed circuit board is detachably mounted on the retainer.

10. The cover assembly according to claim 1, further comprising: A protective layer is mounted on the printed circuit board.

11. The cover assembly according to claim 10, wherein: The printed circuit board is divided into two or more functional modules and is detachably mounted on the retainer.

12. The cover assembly according to claim 8, wherein: The retainer further includes at least two spokes connecting the first protrusion and the second protrusion to each other, and The printed circuit board is divided into two or more functional modules and can be detachably installed in the space formed by the first protrusion, the second protrusion, and the spokes.

13. The cover assembly of claim 12, further comprising: A protective layer is mounted on the printed circuit board. The filler dam is disposed between the protective layer and the periphery of the second retainer and the spokes.

14. An axle assembly, comprising: The cover assembly according to claim 1; The extension is operatively connected to one end of the axle and extends in the axial direction; A bearing cap, connected to the retainer, and in which the generator and the printed circuit board are disposed; Axle housing, mounted on the inner circumferential surface of one end of the housing; as well as A connection adapter is provided for mounting the retainer onto the axle housing. The extension portion and the rotor of the generator are splined together.

15. The axle assembly according to claim 14, wherein: One end of the extension penetrates the bearing cap without causing rotational interference with the bearing cap, and The axle assembly further includes: A speed plate, mounted at one end of the extension, and The speed sensor housing is mounted on one end of the axle housing.

16. The axle assembly according to claim 14, wherein: One end of the extension penetrates the bearing cap without causing rotational interference with the bearing cap, and The axle assembly further includes: A grounded rotor is mounted at one end of the extension; and A grounding cover is installed at one end of the axle housing.

17. The axle assembly of claim 14, further comprising: The gearbox changes the rotational speed of the power source through multiple gears and transmits the changed power to the axle. The gearbox sensor module is configured to detect at least one of the acceleration, rotational speed, and temperature of the plurality of gears; as well as A wired connector is mounted on the bearing cover and connected to the printed circuit board for power supply.

18. The axle assembly according to claim 17, wherein: The measured values ​​of the gearbox sensor module are wirelessly transmitted to the printed circuit board via the wireless antenna or wiredly transmitted to the printed circuit board via the wired connector.

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