A double-row double-side chain self-powered wireless monitoring system device and method based on freight train wheelsets

Abstract

The present application relates to a kind of based on freight train wheel pair's double-row double-side chain type self-powered wireless monitoring system device and method, belong to rail transit wireless monitoring technical field.The present application discloses a kind of based on freight train wheel pair's double-row double-side chain type self-powered wireless monitoring system device and method, including the flexible strain sensor module and double-row double-side chain being set on rotating axle;The double-row double-side chain is equipped with turbofan rotor power generation module and high-efficiency flow increasing module and bluetooth communication module, power rectifier module is equipped in the high-efficiency flow increasing module and bluetooth communication module;The alternating current generated by the turbofan rotor power generation module is converted into ac after passing through power rectifier module, and high-efficiency flow increasing module and bluetooth communication module provide stable voltage.The present application directly utilizes host computer real-time monitoring the sensing signal of flexible strain sensor module, realizes the acquisition, storage, real-time, transmission of sensor data, improves generator system innovation.

Description

Technical Field

[0001] This invention relates to a double-row, double-sided chain self-powered wireless monitoring system device and method based on freight train wheelsets, belonging to the field of wireless monitoring technology for rail transit. Background Technology

[0002] Wheel axles are widely used in energy, transportation, and manufacturing sectors due to their functions of power transmission, motion support, and energy conversion. Freight trains, in particular, have numerous wheel axles, and capturing the kinetic energy of the relative motion of the airflow near the outer side of the wheel axle to drive a generator and power low-power components is considered a viable solution. Current energy harvesting technologies primarily include piezoelectric, electrostatic, and electromagnetic methods. However, using these technologies to harvest energy from wheel axles faces several common constraints, such as low energy conversion efficiency at low speeds and limited output power. It is noteworthy that energy harvesting in rotating environments also requires addressing challenges such as strong centrifugal forces, energy and signal transmission difficulties, and space and weight limitations.

[0003] Currently, several novel rotary energy harvesters have been proposed. One such harvester utilizes a cantilever beam and a magnetostrictive / piezoelectric (ME) layered transducer structure. This harvester features a magnetic loop at the free end of the cantilever beam, with an ME transducer developed in the air gap region of the loop. When mounted on a main structure rotating around a horizontal axis, the magnetic loop vibrates along its lateral direction due to gravity. This vibration generates an alternating magnetic field that is applied to the magnetostrictive / piezoelectric layered transducer, causing it to generate electrical energy. However, this harvester is screwed to the shaft cross-section, making it impossible to fix to the shaft surface, thus limiting its application. Therefore, there is a need for an energy harvester that can be easily mounted on the shaft surface and has high harvesting efficiency. Summary of the Invention

[0004] In order to overcome the shortcomings of the existing technology, the present invention aims to provide a device and method for a double-row double-sided chain self-powered wireless monitoring system based on freight train wheelsets.

[0005] The technical solution provided by this invention to solve the above-mentioned technical problems is: a double-row, double-sided chain self-powered wireless monitoring system device based on freight train wheelsets, including a flexible strain sensor module and a double-row, double-sided chain installed on the rotating axle; the double-row, double-sided chain is equipped with a turbofan rotor power generation module, a high-efficiency current boosting module, and a Bluetooth communication module, and the high-efficiency current boosting module and Bluetooth communication module are equipped with a power rectification module; the AC power generated by the turbofan rotor power generation module is converted from AC to DC by the power rectification module to provide a stable voltage for the high-efficiency current boosting module and Bluetooth communication module.

[0006] A further technical solution is that the rotating axle is made of high-quality medium carbon alloy steel.

[0007] A further technical solution is that the double-row double-sided chain is provided with heterogeneous double-row curved plates.

[0008] A further technical solution is that the turbofan rotor power generation module includes blades, a generator shaft, a coil rotor, a stator housing, and a generator guide base mounted on a double-row double-sided chain; the stator housing is mounted on the generator guide base; the coil rotor is mounted on the left end of the generator shaft, the blades are mounted on the right end of the generator shaft, the left end of the generator shaft is mounted inside the stator housing, and one end of the coil rotor containing the permanent magnet assembly is disposed in the stator housing.

[0009] A further technical solution is that the high-efficiency current boosting module and Bluetooth communication module include a high-efficiency current boosting module, a communication module cover plate, a Bluetooth communication module, and a streamlined housing mounted on a double-row double-sided chain; the high-efficiency current boosting module and Bluetooth communication module are disposed inside the streamlined housing, and the communication module cover plate covers the streamlined housing.

[0010] A further technical solution is that the high-efficiency current boosting module consists of a gas discharge tube, an inductor, a capacitor, and a control IC. It is first connected to a diode rectifier via leads, and then connected to a Bluetooth communication module.

[0011] A further technical solution is that the Bluetooth communication module consists of a voltage acquisition unit and a Bluetooth communication unit. The voltage acquisition unit consists of an analog circuit, an analog-to-digital converter, a microcontroller, and a communication interface. The key components of the Bluetooth communication unit include a wireless radio frequency unit, a baseband / link control unit, and a link management unit.

[0012] A further technical solution is that the flexible strain sensor module includes an outer layer, a middle layer, and an inner layer arranged from top to bottom. The outer layer serves as a protective structure for the module; the middle layer is a key component that converts physical signals into electrical signals; and the inner layer is a channel for placing the middle layer. The channel directly contacts the upper middle layer, and by controlling the deformation of the channel, the shape and size of the middle layer change, thereby changing the resistance.

[0013] A further technical solution is that the power rectification module includes a rectifier diode chip, a DC constant voltage source, a bypass capacitor, and a magnetic field winding output terminal.

[0014] A double-row, double-sided chain self-powered wireless monitoring method based on freight train wheelsets includes the following steps: Step S1: Install a double-row, double-sided chain self-powered wireless monitoring system device based on freight train wheelsets on the rotating axle; Step S2: When the rotating axle starts to rotate, the double-row double-sided chains on the rotating axle also rotate, further driving the turbofan rotor power generation module to perform circular motion, thereby providing a stable voltage for the high-efficiency current boosting module and Bluetooth communication module. Step S3: Front-end signal collection stage; The flexible sensor module converts the deformation of the outer surface of the rotating axle into a change in resistivity based on the piezoresistive sensing principle, thereby outputting a sensing signal that is linearly proportional to the magnitude of the strain. This sensing signal is routed to a high-efficiency current booster module for front-end conditioning and gain amplification to improve the signal-to-noise ratio and meet the requirements of subsequent communication links. Step S3, Signal Transmission and Packaging Stage; The analog sensing signal output from the front end is converted into a discrete signal by the analog-to-digital converter circuit inside the Bluetooth communication module, and then the data is framed to construct a data packet adapted to the link layer protocol; the data packet is transmitted to the host data analysis platform by applying Bluetooth data link technology. Step S4: Signal analysis and algorithm processing stage; After receiving the data packet, the host data analysis platform first decodes the frame structure to obtain valid strain waveform timing data; then it executes digital signal processing algorithms. Step S5: Fault diagnosis and decision output stage; The feature attribute vector after algorithm processing is loaded into the pre-calibrated fault identification model. The diagnostic model performs consistency checks based on the threshold method, pattern recognition classification algorithm and benchmark state database, and evaluates the service status of the rotating axle in real time. The service status classification mainly includes: standard health status, fatigue crack initiation stage, overload status and potential structural damage. The evaluation results are dynamically displayed on the data monitoring panel through a visualization interface. If there is a difference between the sensed signal and the standard signal, a hierarchical alarm is triggered according to the preset conditions.

[0015] The present invention has the following beneficial effects: 1. The present invention provides a double-row double-sided chain self-powered wireless monitoring system device based on freight train wheelsets. Based on the double-row double-sided chain structure, a novel flexible chain energy harvester is developed. Utilizing the extensibility and convenience of the chain, it can be applied to fields such as smooth round shafts, greatly expanding the application scenarios of the energy harvester. 2. When the flexible double-row double-sided chain of the present invention is wound around a rotating shaft and other scenarios, it can achieve non-destructive installation of the rotating shaft. Since the chain adopts a rigid structure, it also has extremely high safety and reliability. The chain structure is compact, has high space utilization, is stable in operation, and can significantly reduce load sway. 3. The micro wind turbine rotor generator in the turbofan rotor power generation module of the present invention adopts a modular stator and rotor motor, which has the advantages of simple structure, small size, low manufacturing cost, large power generation, low relative speed of starting airflow, and high utilization rate. It is very suitable for scenarios with high installation requirements, such as freight train wheelsets. 4. The high-efficiency current boosting module and Bluetooth communication module of the present invention adopt gas discharge tube, inductor, capacitor, control IC, Bluetooth communication unit and other modules. While boosting the circuit current, it can also directly use the host computer to monitor the sensing signal of the flexible strain sensor module in real time, realizing the acquisition, storage, real-time and transmission of sensor data, and improving the innovation of the generator system. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the wheelset support module of the present invention; Figure 3 This is a schematic diagram of the structure of the turbofan rotor power generation module of the present invention; Figure 4 This is a schematic diagram of the structure of the high-efficiency current booster module and Bluetooth communication module of the present invention; Figure 5 This is a schematic diagram of the flexible strain sensor module of the present invention; Figure 6 This is a schematic diagram of the power rectifier module of the present invention; Figure 7 This is a schematic diagram of the structure of the double-row double-sided chain of the present invention; Figure 8 This is a schematic diagram of the installation structure of the heterogeneous double-row bent plate of the present invention.

[0017] Figure Descriptions: 1. Wheelset; 2. Turbofan rotor generator module; 3. High-efficiency current booster module and Bluetooth communication module; 4. Flexible strain sensor module; 5. Power rectifier module; 10. Rotating axle; 11. Right wheel; 12. Right brake disc; 13. Left wheel; 14. Left brake disc; 15. Heterogeneous double-row curved plate; 16. Chain pin; 17. Double-row double-sided chain; 20. Blade; 21. Generator shaft; 22. Coil rotor; 23. Stator housing; 24. Generator current guide base; 30. High-efficiency current booster module; 31. Communication module cover plate; 32. Bluetooth communication module; 33. Streamlined housing; 40. Outer layer; 41. Middle layer; 42. Inner layer; 50. Rectifier diode chip; 51. DC constant voltage source; 52. Bypass capacitor; 53. Magnetic field winding output terminal. Detailed Implementation

[0018] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] like Figures 1-8 As shown, the present invention discloses a double-row, double-sided chain self-powered wireless monitoring system based on freight train wheelsets, comprising a flexible strain sensor module 4 mounted on a rotating axle 10 and a double-row, double-sided chain 17 symmetrically positioned along the axial direction at the geometric center; the double-row, double-sided chain 17 is equipped with a turbofan rotor power generation module 2, a high-efficiency current booster module, and a Bluetooth communication module 3, wherein the high-efficiency current booster module and Bluetooth communication module 3 contain a power rectifier module 5; the AC power generated by the turbofan rotor power generation module 2 is converted from AC to DC by the power rectifier module 5 to provide a stable voltage for the high-efficiency current booster module and Bluetooth communication module 3.

[0020] In this embodiment, the turbofan rotor power generation module 2, the high-efficiency current booster module, and the Bluetooth communication module 3 are respectively connected to the double-row double-sided chain 17 by screws, while the flexible strain sensor module 4 is conformally attached to the curved surface of the rotating axle 10 by pressure-sensitive adhesive tape to monitor its operation in real time.

[0021] The working process of this invention is as follows: When the rotating axle 10 starts to rotate, the double-row double-sided chain 17 mounted on it rotates together. The turbofan rotor power generation module 2, which is fixed on the chain 17, rotates around the center of the rotating axle 10 at the same speed. The blades 20 at its far end are driven by the air fluid to make the rotating shaft 21 of the turbofan rotor power generation module 2 make synchronous circular motion. The coil rotor 22 connected to the blades 20 cuts the magnetic induction lines during the rotation process and generates alternating current. This current is converted from AC to DC by the power rectifier module 5 and provides a stable voltage for the high-efficiency booster module and the Bluetooth communication module 3.

[0022] In addition, the flexible strain sensor module 4 attached to the axle outputs sensing signals to the high-efficiency current booster module and Bluetooth communication module 3 in real time. This module further packages and transmits the input signals, and the upper computer monitors the communication module in real time, and then analyzes and processes the sensing signals, thereby realizing real-time online status monitoring of the axle.

[0023] In this embodiment, as Figure 2 As shown, the rotating axle 10 is provided with a wheelset 1, a right brake disc 12, a left brake disc 14 and a double-row double-sided chain 17; the wheelset 1 includes a left wheel 13 and a right wheel 11 symmetrically arranged on the rotating axle 10.

[0024] The right wheel 11 and left wheel 13 are made of high-carbon steel or micro-alloyed special steel with extremely high strength, wear resistance and heat damage resistance, and can directly bear the static and dynamic loads of the train. The core function of the right brake disc 12 and left brake disc 14 is braking, and they are mainly made of stable powder metallurgy materials or alloy cast iron forging with a high coefficient of friction.

[0025] The rotating axle 10 is made of high-quality medium carbon alloy steel. After forging and strict quenching and tempering, it has high strength, high toughness and high fatigue limit comprehensive mechanical properties, and ultimately bears all the bending and torsional loads from the wheel.

[0026] The right wheel 11, right brake disc 12, left wheel 13 and left brake disc 14 are tightly connected to the rotating axle 10 through an interference fit, together forming a wheelset system.

[0027] In the middle of the rotating axle 10, there is a double-row double-sided chain 17 (such as...) Figure 7 (As shown) The two ends are connected to form a ring chain, which is then connected to the rotating axle 10 through an interference fit to form a continuous body. A heterogeneous double-row curved plate 15 is provided on one side of the double-row double-sided chain 17 (as shown). Figure 8 As shown, the key part of the heterogeneous double-row curved plate 15 is the lateral bending extension platform, which facilitates the installation of accessories or structures. The double-row double-sided chain 17 is made of high-strength alloy steel and is formed by two rows of parallel chains and a common chain pin 16 for locking. This design can distribute the load evenly on the two support points, which not only greatly enhances the overall tensile strength and load-bearing capacity of the chain, but also improves the stability of operation. When the rotating axle 10 is subjected to rotational excitation, the double-row double-sided chain 17 tightly wound on the axle will rotate synchronously at the same speed.

[0028] In this embodiment, as Figure 3 As shown, the turbofan rotor power generation module 2 includes blades 20, a generator shaft 21, a coil rotor 22, a stator housing 23, and a generator guide base 24 mounted on a double-row double-sided chain 17; the stator housing 23 is mounted on the generator guide base 24; the coil rotor 22 is mounted on the left end of the generator shaft 21, the blades 20 are mounted on the right end of the generator shaft 21, the left end of the generator shaft 21 is mounted inside the stator housing 23, and one end of the coil rotor 22 with a permanent magnet assembly is disposed in the stator housing 23.

[0029] The generator guide base 24 is formed in one piece by 3D printing. It is made of acrylonitrile-butadiene-styrene copolymer (ABS) material, which has high strength, high toughness, good heat resistance, strong chemical stability, and can withstand large pressure and impact. Its bottom is fixed to the bent plate of the double-row double-sided chain 17 in the wheel set support module 1 by 4 bolts to ensure that it rotates synchronously with the rotating axle 10 in the wheel set support module 1 and can withstand a large torque.

[0030] It is worth noting that the generator guide base 24 has a guide cone at the rear end, which is used to optimize the external turbulent airflow with minimal resistance and make it smoothly integrate into the free flow at the rear of the turbofan rotor generator module 2.

[0031] The stator housing 23 is die-cast from high-strength aluminum alloy and internally incorporates stator coils and heat dissipation channels. These channels protect the generator from overheating, preventing damage to the power generation system and extending its lifespan. Furthermore, the stator housing 23 features sealed end caps for waterproofing and dustproofing, while the designed protective layer and lubrication channels provide corrosion resistance and reduce wear, ensuring long-term stable operation of the system in extreme environments such as humidity and dust. One end of the stator housing 23 has a circular through-hole for mounting a circular ball bearing. The end of the coil rotor 22 containing the permanent magnet assembly is located within the stator housing 23 and is mounted within the inner ring of the circular ball bearing to reduce friction and wear on the coil rotor 22, thereby improving energy conversion efficiency.

[0032] The generator shaft 21 is connected to the blades 20 via an interference fit. The blades 20 are made of four lightweight, high-strength, corrosion-resistant, malleable, and machinable glass fiber reinforced plastic blades. Compared to three-bladed blades, four-bladed blades have higher solidity (the ratio of the total blade area to the swept area), enabling them to more effectively capture low-speed airflow. Furthermore, the four-bladed blades have a lower tip speed ratio (the ratio of the blade tip linear velocity to the gas flow velocity), eliminating the need for a high-speed gearbox and further simplifying the structure. The four-bladed layout results in more uniform force distribution on the coil rotor 22, reducing torque pulsation caused by sudden changes in airflow or flow direction disturbances, leading to smoother system operation and relatively lower noise.

[0033] Multiple turbofan rotor power generation modules 2 can be designed and evenly arranged on the rotating axle 10, which helps to disperse the centrifugal force of the system and improve the dynamic balance of the system. In addition, by changing their positions and installation angles, a better wind entry point and power generation efficiency can be obtained. When the rotating axle 10 starts to rotate, the double-row double-sided chains 17 mounted on it rotate together. The turbofan rotor power generation modules 2 fixed on the chains 17 rotate around the center of the rotating axle 10 at the same speed. The blades 20 at their far ends are driven by the airflow to make the rotating shaft 21 of the turbofan rotor power generation module 2 perform synchronous circular motion. The coil rotor 22 connected to the blades 20 cuts the magnetic induction lines during the rotation, thereby generating alternating current.

[0034] In this embodiment, as Figure 4 As shown, the high-efficiency current booster module and Bluetooth communication module 3 include a high-efficiency current booster module 30, a communication module cover plate 31, a Bluetooth communication module 32, and a streamlined housing 33 mounted on a double-row double-sided chain 17; the high-efficiency current booster module 30 and the Bluetooth communication module 32 are disposed inside the streamlined housing 33, and the communication module cover plate 31 covers the streamlined housing 33.

[0035] The streamlined outer shell 33 and the communication module cover 31 are integrally formed by additive manufacturing of acrylonitrile-butadiene-styrene copolymer. This material has excellent mechanical strength, fracture toughness and thermal stability, as well as good sealing performance, which can ensure that the high-efficiency current boosting module 30 and Bluetooth communication module 32 inside are not eroded by wind, sand and rain, effectively improving the service life of the high-efficiency current boosting module and Bluetooth communication module 3.

[0036] The streamlined housing 33 has a through hole at the bottom, which can be tightly connected to the double-row double-sided chain 17 in the wheel support module 1 via bolts. In addition, through holes are provided on both sides of the streamlined housing 33, allowing for better wiring layout. A deep groove is designed inside the streamlined housing 33; after the high-efficiency current booster module 30 and the Bluetooth communication module 32 are installed in the deep groove, they can be connected to the communication module cover plate 31 via bolts.

[0037] The Bluetooth communication module 32 mainly consists of a voltage acquisition unit and a Bluetooth communication unit, and its voltage is provided by the turbofan rotor power generation module 2. The voltage acquisition unit consists of analog circuits, an analog-to-digital converter, a microcontroller, and a communication interface. Based on the interaction principle of analog and digital circuits, the analog circuit first amplifies and filters the sensed signal in the circuit and converts it into an analog-to-digital signal. Then, the analog signal is converted into a digital signal by the analog-to-digital converter, and the microcontroller further processes and analyzes the digital signal.

[0038] The key components of the Bluetooth communication unit include a wireless radio frequency unit, a baseband / link control unit, and a link management unit. After receiving the sensing signal output by the voltage acquisition unit, it transmits it to the host computer through a transmission protocol, an intermediary protocol, and an application protocol.

[0039] The high-efficiency current booster module 30 in the high-efficiency current booster module and Bluetooth communication module 3 consists of a gas discharge tube, inductor, capacitor, and control IC. It can directly power low-power appliances, and the output of this circuit is much higher than that of a direct rectifier circuit. The high-efficiency current booster module 30 is first connected to the diode rectifier via leads, and then connected to the Bluetooth communication module 32. The turbofan rotor generator module 2 and the high-efficiency current booster module and Bluetooth communication module 3 are used together as a pair to form a power generation and transmission unit. Multiple units can be designed and symmetrically installed on the double-row double-sided chain 17 to ensure the dynamic balance of the system.

[0040] In this embodiment, as Figure 5 As shown, the flexible strain sensor module 4 includes an outer layer 40, a middle layer 41, and an inner layer 42 arranged from top to bottom; The outer layer 40, serving as the module's protective structure, is made of polydimethylsiloxane. Its main function is to provide robust physical protection for the intermediate layer 41, shielding it from damage caused by external moisture, oxygen, dust, and mechanical friction, thus ensuring the long-term stability and reliability of the sensor in complex environments. Simultaneously, it isolates the internal sensitive elements from the external environment, guaranteeing the purity of the signal output.

[0041] The intermediate layer 41 is the core sensing unit of the flexible strain sensor module 4. It has the excellent conductivity of metal and is a key component for converting physical signals into electrical signals.

[0042] The main function of the inner layer 42 is to house the channels of the intermediate layer 41, which are in direct contact with the upper intermediate layer 41. By controlling the deformation of the channels, the shape and size of the intermediate layer 41 change, thereby changing its resistance. The flexible strain sensor module 4, attached to the rotating axle 10, monitors its operation in real time and outputs the sensing signal to the high-efficiency current booster module and Bluetooth communication module 3, which further frames and transmits the sensing signal.

[0043] In this embodiment, as Figure 6 As shown, the power rectifier module 5 includes a rectifier diode chip 50, a DC constant voltage source 51, a bypass capacitor 52, and a magnetic field winding output terminal 53.

[0044] The rectifier diode chip 50 is mainly made of single-crystal silicon or silicon carbide. Its core function is to withstand high voltage and high current and achieve unidirectional conduction. The DC constant voltage source 51 can boost or buck the voltage as needed, and at the same time achieve electrical isolation between the input and output terminals. The magnetic field winding output terminal 53 is interconnected with the coil rotor 22 of the turbofan rotor generator module 2 and receives the AC power output from it. The bypass capacitor 52 stores the DC power output by the rectifier diode chip 50 and provides a stable voltage for the high-efficiency booster module and Bluetooth communication module 3.

[0045] The working process and principle of this invention are as follows: The working principle of the double-row double-sided chain self-powered wireless monitoring system based on freight train wheelsets is explained below. When the rotating axle 10 starts to rotate, the double-row double-sided chain 17 on the rotating axle 10 also rotates, further driving the generator guide base 24 to perform circular motion.

[0046] At this time, since the stator housing 23 and the generator guide base 24 are fixedly connected, the stator housing 23 will rotate around the rotating axle 10. While rotating around the rotating axle 10, the blades 20 are subjected to the action of air fluid, causing them to rotate, which further drives the coil rotor 22 to rotate. During the rotation, the coil rotor 22 generates relative motion with the magnetic pole stator in the stator housing 23, thereby generating an AC voltage. The magnetic field winding output terminal 53 is interconnected with the coil rotor 22 of the turbofan rotor generator module 2 to receive the AC voltage. This voltage is processed by the rectifier diode chip 50 made of single crystal silicon or silicon carbide and achieves unidirectional conduction. The DC constant voltage source 51 boosts or bucks the voltage as needed, while achieving electrical isolation between the input and output terminals. The output DC power is stored in the bypass capacitor 52. The DC power output from the bypass capacitor 52 is transmitted to the high-efficiency booster module 30 of the high-efficiency booster module and the Bluetooth communication module 3 for buck boosting, thereby providing a stable voltage for the Bluetooth communication module 32.

[0047] The flexible sensor module 4 is always attached to the rotating axle 10. When the inner layer 42 detects the vibration of the rotating axle 10, it deforms and affects the middle layer 41 that is in close contact with it. This effect is manifested as a change in shape caused by channel pressure, which is reflected in a precise change in the electrical characteristics (resistance) of the middle layer 41. The sensing signal of this change is protected and isolated by the outer layer 40 and then led out by the electrodes integrated on the flexible sensor module 4 to the high-efficiency current booster module and the Bluetooth communication module 3. After receiving the sensing signal, the wireless radio frequency unit, baseband / link control unit and link management unit of the Bluetooth communication module 32 transmit it to the host computer through the transmission protocol, the intermediary protocol and the application protocol, respectively.

[0048] The present invention provides a double-row, double-sided chain-type self-powered wireless monitoring method for freight train wheelsets, characterized by comprising the following steps: Step S1: Install the above-described embodiment of a double-row double-sided chain self-powered wireless monitoring system device based on freight train wheelsets on the rotating axle 10; Step S2: When the rotating axle 10 starts to rotate, the double-row double-sided chain 17 on the rotating axle 10 also rotates, further driving the turbofan rotor power generation module 2 to perform circular motion, thereby providing a stable voltage for the high-efficiency booster module and Bluetooth communication module 3. Step S3, Front-end Signal Collection Stage: When the rotating axle 10 rotates at a certain speed, the flexible sensor module 4, which is attached to the rotating axle 10 by pressure-sensitive adhesive tape, also rotates synchronously. Since the rotating axle 10 maintains close contact with the flexible sensor module 4 under dynamic rotation and forced vibration, the flexible sensor module 4 can collect strain signals from the surface area of ​​the rotating axle 10 in real time. Based on the piezoresistive sensing principle, the flexible sensor module 4 converts the deformation of the outer surface of the rotating axle 10 into a change in resistivity, thereby outputting a sensing signal that is linearly proportional to the magnitude of the strain. This sensing signal is routed to the high-efficiency current booster module 30 for front-end conditioning and gain amplification to improve the signal-to-noise ratio and ensure compatibility with subsequent communication link requirements.

[0049] Step S4, Signal Transmission and Packaging Stage: The analog sensing signal output from the front end is converted into a discrete signal by the analog-to-digital converter circuit inside the Bluetooth communication module 32, and then framed into data packets. This includes writing protocol header information such as timestamps and sensor identifiers, constructing data packets adapted to the link layer protocol. The data packets are then transmitted to the host data analysis platform using Bluetooth data link technology, completing stable, reliable, and real-time wireless data transmission between the rotating component and the static monitoring terminal.

[0050] Step S5, Signal Analysis and Algorithm Processing Stage: After receiving the data packet, the host data analysis platform first decodes the frame structure to obtain valid strain waveform time-series data. Then, it executes digital signal processing algorithms, mainly including signal smoothing and denoising (using an anti-aliasing low-pass filter to remove high-frequency electromagnetic noise and mechanical environmental noise), feature parameter extraction (calculating time-domain feature statistics such as arithmetic mean, variance, and peak value), spectral feature analysis (using discrete Fourier transform to obtain the spectrum and identify characteristic harmonic components), and data regularization (compensating for the modulation effect of speed fluctuations on strain sensing data, making the feature vectors comparable).

[0051] Step S6, Fault Diagnosis and Decision Output Stage: The feature attribute vector processed by the algorithm is loaded into the pre-calibrated fault identification model. The diagnostic model can perform consistency checks based on the threshold method, pattern recognition classification algorithm and benchmark state database to evaluate the service status of the rotating axle 10 in real time.

[0052] The service status classification mainly includes: standard health status, fatigue crack initiation stage, overload status, and potential structural damage. The assessment results are dynamically displayed on the data monitoring panel through a visualization interface. If there is a difference between the sensed signal and the standard signal, a hierarchical alarm can be triggered according to the preset conditions. In addition, all the collected front-end raw data and fault diagnosis conclusions are stored in the data management system to support subsequent trend analysis and operation and maintenance decision support.

[0053] The theoretical model of the rotor generator is briefly derived below. V 1,2,3 Defined as the induced electromotive force per phase of a three-phase generator. R i and R e These represent the internal resistance of each phase coil winding of the generator and the resistance of the external load, respectively.

[0054] According to the definition of a three-phase generator, we can obtain: (1) in E m Indicates the amplitude of the induced electromotive force. ω e This represents the angular frequency of the induced electromotive force of the generator.

[0055] (2) The output power of a generator can be expressed as follows: (3) The amplitude of the induced electromotive force of a generator can be defined as the generator main shaft speed. ω c With back electromotive force constant K e The product of: (4 Substituting equation (4) into equation (3) yields: (5) According to the law of conservation of energy, the instantaneous total power of the generator can also be expressed as: (6) in, T e This represents the electromagnetic torque of the generator's main shaft. The electromagnetic torque of the generator main shaft is directly proportional to its rotational speed. (7) Substituting equation (7) into equation (6) also yields the relationship between the instantaneous total power and the generator's rotating electromagnetic damping: (8) The above description is not intended to limit the present invention in any way. Although the present invention has been disclosed through the above embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some changes or modifications to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall fall within the scope of the present invention.

Claims

1. A double-row, double-sided chain-type self-powered wireless monitoring system device based on freight train wheelsets, characterized in that, It includes a flexible strain sensor module (4) and a double-row double-sided chain (17) mounted on a rotating axle (10); the double-row double-sided chain (17) is equipped with a turbofan rotor power generation module (2), a high-efficiency current boosting module and a Bluetooth communication module (3), and the high-efficiency current boosting module and Bluetooth communication module (3) are equipped with a power rectification module (5); the AC power generated by the turbofan rotor power generation module (2) is converted from AC to DC by the power rectification module (5) to provide a stable voltage for the high-efficiency current boosting module and Bluetooth communication module (3).

2. The double-row, double-sided chain self-powered wireless monitoring system device based on freight train wheelsets according to claim 1, characterized in that, The rotating axle (10) is made of high-quality medium carbon alloy steel.

3. The double-row, double-sided chain self-powered wireless monitoring system device based on freight train wheelsets according to claim 1, characterized in that, The double-row double-sided chain (17) is provided with a heterogeneous double-row curved plate (15).

4. The double-row, double-sided chain self-powered wireless monitoring system device based on freight train wheelsets according to claim 1, characterized in that, The turbofan rotor power generation module (2) includes blades (20), a generator shaft (21), a coil rotor (22), a stator housing (23), and a generator guide base (24) mounted on a double-row double-sided chain (17). The stator housing (23) is mounted on the generator guide base (24). The coil rotor (22) is mounted on the left end of the generator shaft (21), and the blades (20) are mounted on the right end of the generator shaft (21). The left end of the generator shaft (21) is mounted inside the stator housing (23), and one end of the coil rotor (22) with a permanent magnet assembly is located in the stator housing (23).

5. The double-row, double-sided chain self-powered wireless monitoring system device based on freight train wheelsets according to claim 1, characterized in that, The high-efficiency current boosting module and Bluetooth communication module (3) include a high-efficiency current boosting module (30), a communication module cover plate (31), a Bluetooth communication module (32), and a streamlined housing (33) mounted on a double-row double-sided chain (17); the high-efficiency current boosting module (30) and the Bluetooth communication module (32) are disposed inside the streamlined housing (33), and the communication module cover plate (31) covers the streamlined housing (33).

6. The double-row, double-sided chain-type self-powered wireless monitoring system device based on freight train wheelsets according to claim 5, characterized in that, The high-efficiency current boosting module (30) consists of a gas discharge tube, an inductor, a capacitor and a control IC. It is first connected to the diode rectifier through a lead wire, and then connected to the Bluetooth communication module (32).

7. A double-row, double-sided chain-type self-powered wireless monitoring system device based on freight train wheelsets according to claim 5, characterized in that, The Bluetooth communication module (32) consists of a voltage acquisition unit and a Bluetooth communication unit. The voltage acquisition unit consists of an analog circuit, an analog-to-digital converter, a microcontroller, and a communication interface. The important components of the Bluetooth communication unit include a wireless radio frequency unit, a baseband / link control unit, and a link management unit.

8. The double-row, double-sided chain self-powered wireless monitoring system device based on freight train wheelsets according to claim 1, characterized in that, The flexible strain sensor module (4) includes an outer layer (40), a middle layer (41), and an inner layer (42) arranged from top to bottom. The outer layer (40) serves as the protective structure of the module. The middle layer (41) is a key component that converts physical signals into electrical signals. The inner layer (42) is a channel for placing the middle layer (41). The channel is in direct contact with the upper middle layer (41). By controlling the deformation of the channel, the shape and size of the middle layer (41) change, thereby changing the resistance.

9. A double-row, double-sided chain-type self-powered wireless monitoring system device based on freight train wheelsets according to claim 1, characterized in that, The power rectifier module (5) includes a rectifier diode chip (50), a DC constant voltage source (51), a bypass capacitor (52), and a magnetic field winding output terminal (53).

10. A method for monitoring double-row, double-sided chain-type self-powered wireless systems based on freight train wheelsets, characterized in that, Includes the following steps: Step S1: Install the double-row double-sided chain self-powered wireless monitoring system device based on freight train wheelsets as described in any of claims 1-9 on the rotating axle (10); Step S2: When the rotating axle (10) starts to rotate, the double-row double-sided chain (17) on the rotating axle (10) also rotates, further driving the turbofan rotor power generation module (2) to perform circular motion, thereby providing a stable voltage for the high-efficiency booster module and Bluetooth communication module (3). Step S3: Front-end signal collection stage; The flexible sensor module (4) converts the deformation of the outer surface of the rotating axle (10) into a change in resistivity based on the piezoresistive sensing principle, thereby outputting a sensing signal that is linearly proportional to the magnitude of the strain. This sensing signal is routed to the high-efficiency current boosting module (30) for front-end conditioning and gain amplification to improve the signal-to-noise ratio and meet the requirements of subsequent communication links. Step S3, Signal Transmission and Packaging Stage; The analog sensing signal output from the front end is converted into a discrete signal by the analog-to-digital converter circuit inside the Bluetooth communication module (32) and then framed into a data packet adapted to the link layer protocol. Data packets are transmitted to the host data analysis platform by applying Bluetooth data link technology; Step S4: Signal analysis and algorithm processing stage; After receiving the data packet, the host data analysis platform first decodes the frame structure to obtain valid strain waveform timing data; then it executes digital signal processing algorithms. Step S5: Fault diagnosis and decision output stage; After processing by the algorithm, the feature attribute vector is loaded into the pre-calibrated fault identification model. The diagnostic model performs consistency checks based on the threshold method, pattern recognition classification algorithm and benchmark state database, and evaluates the service status of the rotating axle (10) in real time. The service status classification mainly includes: standard health status, fatigue crack initiation stage, overload status and potential structural damage. The evaluation results are dynamically displayed on the data monitoring panel through the visualization interface. If there is a difference between the perceived signal and the standard signal, a hierarchical alarm is triggered according to the preset situation.

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