A wireless sensor and train fault monitoring system

Abstract

This application discloses a wireless sensor and a train fault monitoring system, applied in the field of rail transit technology. The system includes: a sensitive unit for signal detection located at a first position; a processing unit for signal output located at a second position, the processing unit including a power supply circuit; a conversion circuit; a control circuit that switches to a sleep state when a switching rule is established, and controls the power supply circuit to disconnect power to the sensitive unit, the conversion circuit, and the wireless communication circuit; a vibration wake-up circuit connected to the control circuit, used to wake up the control circuit when its own vibration amplitude reaches a threshold; and a wireless communication circuit connected to the control circuit. Applying the solution of this application facilitates the installation of the wireless sensor, reduces the number of cables, and, through the wake-up mechanism, enables the wireless sensor to achieve long-term engineering applications.

Description

Technical Field

[0001] This utility model relates to the field of rail transit technology, and in particular to a wireless sensor and train fault monitoring system. Background Technology

[0002] With the increasing demands for intelligent urban rail vehicles, trains need to be equipped with more and more intelligent monitoring equipment, among which the running gear monitoring system has gradually become a necessary configuration. However, the space available for equipment installation on bogies and car bodies is becoming increasingly limited, so sensors with simple structures and easy installation are in high demand.

[0003] Currently, the fault diagnosis system for the running gear of urban rail vehicles such as subways and suburban trains mainly consists of an on-board diagnostic instrument or host (one per car), a pre-processor (2-4 per car), and sensors (8-16 per car). Sensors transmit power and signals via cables, thus their internal circuitry only contains vibration, shock, and temperature-sensitive circuits, resulting in a simple structure and small size. However, because each sensor needs to be connected to the pre-processor via a cable for signal transmission, this current solution requires a large number of cables between the sensors and the pre-processor, leading to a long construction period and high difficulty. While this is barely acceptable when the system can be installed along with the entire new urban rail vehicle, it is difficult to implement when retrofitting existing vehicles (without running gear monitoring systems). This is because the vehicles cannot be disassembled and the retrofit period is short, making it difficult to quickly lay cables and install sensors, thus hindering the implementation of this solution.

[0004] In summary, how to conveniently install sensors and reduce the number of cables is a technical problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0005] The purpose of this invention is to provide a wireless sensor and a train fault monitoring system to facilitate sensor installation and reduce the number of cables.

[0006] To solve the above-mentioned technical problems, this utility model provides the following technical solution:

[0007] In a first aspect, this utility model provides a wireless sensor, comprising:

[0008] A sensitive part is set at a first position for signal detection at the first position;

[0009] A processing unit, disposed at a second position and connected to the sensitive part, for signal output, and the processing unit includes:

[0010] A power supply circuit that connects the control terminal to the control circuit and supplies power to the processing unit and the sensitive unit when the control circuit is in a wake-up state;

[0011] It is connected to the sensitive part and the control circuit respectively, and is used to receive the detection signal of the sensitive part and send it to the conversion circuit of the control circuit after conversion;

[0012] The control circuit is used to switch to a sleep state when the switching rule is met, and to control the power supply circuit to disconnect the power supply to the sensitive part, the switching circuit and the wireless communication circuit.

[0013] Connected to the control circuit, it is used to wake up the vibration wake-up circuit of the control circuit when its own vibration amplitude reaches a threshold.

[0014] A wireless communication circuit connected to the control circuit for outputting the output signal of the control circuit.

[0015] In one embodiment, the sensitive part includes:

[0016] A first detection head for performing vibration and impact detection at the first position;

[0017] A charge amplifier circuit connected to the first detection head, used to convert the charge signal output by the first detection head into a voltage signal and amplify it;

[0018] A differential amplifier circuit connected to the charge amplifier circuit, used to differentially amplify the voltage signal output by the charge amplifier circuit and output it to the conversion circuit.

[0019] In one embodiment, the conversion circuit includes:

[0020] A differential conversion circuit connected to the differential amplifier circuit for converting the voltage level of the signal output by the differential amplifier circuit;

[0021] A first analog-to-digital converter circuit connected to the differential converter circuit is used to perform analog-to-digital conversion on the signal output by the differential converter circuit and output it to the control circuit.

[0022] In one embodiment, the sensitive part further includes:

[0023] A second detection head is used to perform temperature detection at the first position and output the detected temperature signal to the conversion circuit;

[0024] The conversion circuit further includes:

[0025] A second analog-to-digital converter circuit is connected to the second detection head and is used to perform analog-to-digital conversion on the temperature signal output by the second detection head and output it to the control circuit.

[0026] In one embodiment, the wireless sensor further includes: a processing unit housing and a sensing unit housing;

[0027] The processing unit is installed in the processing unit housing, and the sensing unit is installed in the sensing unit housing;

[0028] The processing unit housing is provided with a battery compartment so that the battery pack in the power circuit is fixed inside the battery compartment.

[0029] The processing unit housing also includes a board slot to fix the PCB circuit board inside the board slot, and the conversion circuit, the vibration wake-up circuit, and the control circuit are all arranged on the PCB circuit board.

[0030] In one embodiment, the processing unit further includes:

[0031] A first buffer assembly is filled between the battery pack and the battery compartment to reduce vibration of the battery pack;

[0032] A second buffer assembly used to enclose the individual battery packs in the power circuit to reduce vibration between adjacent battery packs.

[0033] In one embodiment, the wireless communication circuit includes:

[0034] A wireless module connected to the control circuit for receiving the output signal of the control circuit and outputting it externally through an antenna;

[0035] The antenna is connected to the wireless module and is located inside the housing of the processing unit;

[0036] The processing unit housing is a non-metallic processing unit housing, the wireless module is arranged on the PCB circuit board, and the antenna is arranged in the antenna mounting slot in the battery compartment.

[0037] In one embodiment, a waterproof connector is fixed to the outer casing of the processing unit so that the processing unit can be connected to the sensitive part through the waterproof connector and the cable; a corrugated tube is provided on the outside of the cable to protect the cable.

[0038] In one embodiment, the processing unit further includes:

[0039] A waterproof component disposed between the battery compartment and the circuit board compartment for waterproofing.

[0040] In one implementation, it further includes:

[0041] The timing circuit connected to the control circuit is used to clear the timing value and output a trigger signal to the control circuit whenever the timing duration reaches the first duration, so that the control circuit enters the wake-up state after receiving the trigger signal.

[0042] The switching rule includes: the working time of the control circuit after entering the wake-up state has reached a preset working time threshold.

[0043] In one embodiment, the power supply circuit includes:

[0044] Wireless power receiving coil for receiving wireless power;

[0045] A wireless power processing circuit connected to the wireless power receiving coil for processing electrical energy;

[0046] A charge / discharge management circuit connected to the wireless power processing circuit is used for charge / discharge management and provides circuit protection when overvoltage and / or overcurrent are detected.

[0047] A power management circuit connected to the charge / discharge management circuit for battery pack protection;

[0048] The battery pack connected to the power management circuit;

[0049] A voltage conversion circuit connected to the charge / discharge management circuit for performing voltage level conversion to supply power to external systems.

[0050] In one embodiment, the voltage conversion circuit includes:

[0051] A first conversion sub-circuit connected to the charge / discharge management circuit, used for voltage level conversion to output a first voltage level, and for powering the wireless communication circuit with the first voltage level.

[0052] A second conversion sub-circuit, connected to the charge / discharge management circuit, is used to perform voltage level conversion to output multiple different voltage levels and output a constant current source. When the control circuit is in the wake-up state, it supplies power to the sensitive part through multiple different voltage levels, the conversion circuit, the control circuit, and the vibration wake-up circuit, and provides the constant current source to the conversion circuit.

[0053] The control terminal of the first conversion sub-circuit is connected to the control circuit so that when the control circuit switches to a sleep state, the power supply to the wireless communication circuit is disconnected under the control of the control circuit.

[0054] The control terminal of the second conversion sub-circuit is connected to the control circuit so that when the control circuit switches to a sleep state, the power supply to the sensitive part and the conversion circuit is disconnected under the control of the control circuit.

[0055] In one embodiment, the power supply circuit further includes:

[0056] The power input path management circuit, located between the charge / discharge management circuit and the wireless power processing circuit, is used to receive power from the debugging interface and output it to the charge / discharge management circuit when the debugging interface is connected, and to receive power from the wireless power receiving coil and output it to the charge / discharge management circuit when the debugging interface is not connected.

[0057] In one embodiment, the processing unit further includes a magnetic component to fix the relative position of the processing unit and the charging device when the wireless sensor is charged via the wireless power receiving coil.

[0058] Secondly, this utility model provides a train fault monitoring system, including the wireless sensor described above.

[0059] This application considers that wireless sensors offer advantages in ease of installation and reduced cable complexity. However, compared to wired sensors, which only require vibration, shock, and temperature sensing circuits, wireless sensors need to integrate not only sensing circuits but also energy storage, power supply, and wireless communication. Consequently, traditional wireless sensors are often bulky and difficult to install in confined spaces on trains (such as axle box locations), making direct application impractical. Furthermore, issues such as insufficient power supply also exist.

[0060] This application proposes a separate wireless sensor, where the sensing element and processing element are arranged separately. The sensing element is located at a first position, allowing signal detection there. The processing element is located at a second position and connected to the sensing element, receiving the detected signals and transmitting them wirelessly. It can be seen that the sensing element only needs to perform detection functions, such as vibration, shock, and temperature detection; therefore, its small size allows for easy installation in confined spaces. The processing element needs to have energy storage, power supply, and wireless communication functions, resulting in a larger size, but it can be placed near the sensing element in a relatively spacious location (the second position).

[0061] Furthermore, even though the processing unit can be placed in a relatively large space compared to the sensing unit, space is still limited. This limits the size of the power supply circuit within the processing unit, resulting in limited energy storage. The solution presented in this application addresses this by achieving low power consumption for the wireless sensor. Specifically, this application includes a vibration wake-up circuit connected to the control circuit. This circuit wakes up the control circuit when the sensor's vibration amplitude reaches a threshold. In other words, the wireless sensor only needs to operate when vibration is strong. At this time, the control circuit can control the power supply circuit to power the processing unit and the sensing unit, allowing the wireless sensor to operate and detect the corresponding signal. When a switching rule is met, the control circuit switches to a sleep state. For example, after a certain detection period, it switches to sleep mode. In this state, the control circuit can disconnect the power supply circuit from the sensing unit, the switching circuit, and the wireless communication circuit. This ensures that the power supply circuit consumes almost no energy in the sleep state, eliminating the need for frequent charging and enabling the wireless sensor of this application to achieve long-term engineering applications.

[0062] In summary, this application employs a wireless sensor, which facilitates easy sensor installation, reduces the number of cables, and separates the sensing and processing units, resulting in a smaller sensing unit that can be easily installed in confined spaces. Furthermore, the wake-up mechanism eliminates the need for frequent charging, enabling the wireless sensor to operate for extended periods with minimal power consumption. Attached Figure Description

[0063] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0064] Figure 1 A schematic diagram of the structure of a wireless sensor provided in a specific embodiment of this utility model;

[0065] Figure 2 A schematic diagram of the structure of a wireless sensor provided for another specific embodiment of this utility model;

[0066] Figure 3 A schematic diagram of the power supply circuit in a wireless sensor provided in a specific embodiment of this utility model;

[0067] Figure 4 A schematic diagram of the conversion circuit in a power supply circuit provided in a specific embodiment of this utility model;

[0068] Figure 5 A front view of the processing unit housing provided in a specific embodiment of this utility model;

[0069] Figure 6 This is a schematic diagram of the structure of a wireless sensor provided for another specific embodiment of the present invention. Detailed Implementation

[0070] The core of this invention is to provide a wireless sensor and a train fault monitoring system. The use of a wireless sensor facilitates easy sensor installation, reduces the number of cables, and separates the sensing and processing units, resulting in a smaller sensing unit that can be easily installed in confined spaces. Furthermore, the wake-up mechanism eliminates the need for frequent charging, enabling the wireless sensor to operate for extended periods with minimal power consumption.

[0071] To enable those skilled in the art to better understand the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. 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.

[0072] Please refer to Figure 1 , Figure 1 This is a schematic diagram of the structure of a wireless sensor according to the present invention. The wireless sensor may include:

[0073] A sensing element 10 is disposed at a first position for signal detection at that first position. A processing unit 20 is disposed at a second position and connected to the sensing element 10 for signal output. The processing unit 20 includes:

[0074] A power supply circuit 23 is connected to the control circuit 22 and supplies power to the processing unit 20 and the sensing unit 10 when the control circuit 22 is in the wake-up state.

[0075] It is connected to the sensing unit 10 and the control circuit 22 respectively, and is used to receive the detection signal of the sensing unit 10 and send it to the conversion circuit 21 of the control circuit 22 after conversion;

[0076] Control circuit 22 is used to switch to sleep mode when the switching rule is established, and to control power circuit 23 to disconnect the power supply to sensitive part 10, switching circuit 21 and wireless communication circuit 24.

[0077] It is connected to the control circuit 22 and is used to wake up the vibration wake-up circuit 25 of the control circuit 22 when its own vibration amplitude reaches a threshold.

[0078] A wireless communication circuit 24 is connected to the control circuit 22 and is used to output the output signal of the control circuit 22.

[0079] Specifically, the sensitive part 10 is used to perform signal detection at a first position. The first position can be set according to actual needs. For example, in one embodiment, the sensitive part 10 is set at the axle box position. In other embodiments, it can be set at other positions where signal detection is required. In practical applications, the space for placing the sensitive part 10 at the first position is usually quite limited.

[0080] In this application, the sensitive part 10 and the processing part 20 are arranged separately. The sensitive part 10 is located in the first position, and the processing part 20 is located in the second position and connected to the sensitive part 10. This allows the sensitive part 10 to only perform the detection function, thus its size can be made smaller, making it easier to install in some confined spaces. The processing part 20 needs to have functions such as energy storage and power supply, and wireless communication, so its size is larger, but it can be placed near the sensitive part in a location with relatively large space (the second position).

[0081] When the sensitive part 10 performs signal detection at the first position, the specific signal content and circuit structure to be detected can be set according to actual needs. In train fault diagnosis, it is usually necessary to detect one or more of the following: impact signal, vibration signal and temperature signal.

[0082] In one specific embodiment of this utility model, please refer to... Figure 2 The sensitive part 10 may include:

[0083] A first detection head for performing vibration and shock detection at a first position;

[0084] A charge amplifier circuit connected to the first detection head, used to convert the charge signal output by the first detection head into a voltage signal and amplify it;

[0085] It is connected to the charge amplifier circuit and is used to differentially amplify the voltage signal output by the charge amplifier circuit and output it to the conversion circuit 21.

[0086] In another specific embodiment, the sensing part 10 may further include a second detection head that performs temperature detection at a first position and outputs the detected temperature signal to the conversion circuit 21.

[0087] In practical applications, the sensing element 10 can detect one or more of the following signals: impact signal, vibration signal, and temperature signal. Specifically, in the above embodiment, the first detection head can perform vibration and impact detection at a first position. For example, a PKGS detection head is used, and vibration and impact detection is achieved through a second-order system. The detection results of the first detection head are then processed by frequency analysis and other methods to extract the vibration signal and impact signal. For example, if the first position is the axle box position, the vibration signal and impact signal are at the axle box position. In other words, in the above embodiment, the first detection head enables the sensing element 10 of this application to detect impact and vibration signals. If the sensing element 10 is equipped with a second detection head that performs temperature detection at the first position and outputs the detected temperature signal to the conversion circuit 21, then the sensing element 10 can also detect the temperature signal.

[0088] During vibration and shock testing, the signal output by the first detection head is a charge signal. That is, the first detection head reflects the vibration and shock situation at the first position through changes in charge. Therefore, a charge amplifier circuit is needed to convert the charge signal output by the first detection head into a voltage signal and amplify it. In practical applications, either a single-ended charge amplifier circuit or a differential charge amplifier circuit can be selected according to actual needs.

[0089] The voltage signal output by the charge amplifier circuit is differentially amplified by the differential amplifier circuit and then differentially transmitted. This is because the differential amplifier circuit and the processing unit 20 need to be connected through a certain length of line, and differential transmission can effectively suppress common-mode interference. Therefore, the differential amplifier circuit is used to differentially amplify the voltage signal output by the charge amplifier circuit and then output it to the conversion circuit 21 of the processing unit 20.

[0090] The second detection head can perform temperature detection at the first position. For example, a platinum resistance thermometer can be used to detect the temperature. The temperature signal detected by the second detection head can be transmitted in various ways. For example, a two-wire method can be used to transmit the signal to the conversion circuit 21 of the processing unit 20, which is relatively convenient.

[0091] The processing unit 20 can receive signals from the sensing unit 10 and output them to the outside. Specifically, the conversion circuit 21 in the processing unit 20 is used to receive the detection signal from the sensing unit 10 and send it to the control circuit 22 after conversion. The specific structure of the conversion circuit 21 can be set according to actual needs. For example, the structure of the conversion circuit 21 can be adapted to the detection signal of the sensing unit 10 so that the conversion circuit 21 can effectively realize its function.

[0092] In one specific embodiment of this utility model, please refer to... Figure 2 The conversion circuit 21 may include:

[0093] A differential converter circuit connected to a differential amplifier circuit to convert the voltage level of the signal output by the differential amplifier circuit;

[0094] It is connected to the differential conversion circuit and is used to perform analog-to-digital conversion on the signal output by the differential conversion circuit and output it to the first analog-to-digital conversion circuit of the control circuit 22.

[0095] In another embodiment, when a second detection head is provided for temperature detection at the first position, the conversion circuit 21 may further include a second analog-to-digital converter circuit connected to the second detection head for performing analog-to-digital conversion on the temperature signal output by the second detection head and outputting it to the control circuit 22.

[0096] See also Figure 2 This implementation takes into account that the voltage level of the signal output by the differential amplifier circuit of the sensitive unit 10 may not be able to meet the requirements of the first analog-to-digital converter circuit. Therefore, a differential converter circuit is provided to convert the voltage level of the signal output by the differential amplifier circuit, and then send it to the first analog-to-digital converter circuit to convert it into the digital signal required by the control circuit 22. In addition, in some embodiments, a filter circuit can be provided on the input or output side of the differential converter circuit to achieve filtering. For example, a low-pass filter circuit can be provided.

[0097] The first analog-to-digital converter (ADC) can perform analog-to-digital conversion on the signal output from the differential converter circuit. Specifically, the first ADC can be a Σ-Δ type ADC, capable of performing analog-to-digital conversion, digital filtering, and sampling operations, before outputting the signal to the control circuit 22. The second ADC can receive the temperature signal output from the second detection head of the sensing element 10, and also perform analog-to-digital conversion, digital filtering, and sampling operations before outputting the signal to the control circuit 22.

[0098] The output signal of the conversion circuit 21 will be sent to the control circuit 22, for example... Figure 2 In the example, both the first and second analog-to-digital converter circuits can be connected to the control circuit 22 via an SPI interface. The control circuit 22 can be, for example, an MCU with a certain amount of storage space, which can temporarily store the received data and then output it to the outside via the wireless communication circuit 24, which is beneficial to meeting the signal quality requirements of continuous transmission. Figure 2 The control circuit 22 in this embodiment is an MCU. In addition, in some embodiments, the control circuit 22 may also process the received data as needed, and then output it to the outside through the wireless communication circuit 24 after processing. That is to say, the control circuit 22 may process the received data before sending it, or it may only be responsible for data reception, storage and transmission. It can be set according to actual needs and does not affect the implementation of this utility model.

[0099] To enable the wireless sensor of this application to achieve long-term engineering applications, the solution employs a vibration wake-up design. Specifically, the vibration wake-up circuit 25 detects its own vibration amplitude. If the vibration amplitude reaches a threshold, i.e., when the vibration is relatively strong, it will wake up the control circuit 22. Of course, the specific value of this threshold can be set according to actual needs.

[0100] When the control circuit 22 is in the wake-up state, it can control the power supply circuit 23 to supply power to the sensing unit 10 and the processing unit 20. In other words, when the control circuit 22 is in the wake-up state, the wireless sensor can normally perform various parameter detections and can output data through the wireless communication circuit 24. Furthermore, when the switching rule is met, the control circuit 22 can switch from the wake-up state to the sleep state. In the sleep state, the control circuit 22 will disconnect the power supply circuit 23 from the sensing unit 10, the conversion circuit 21, and the wireless communication circuit 24. That is, when the control circuit 22 is in the sleep state, the wireless sensor is simply in standby mode, and its power consumption is very low.

[0101] It can be seen that regardless of whether the control circuit 22 is in a wake-up state or a sleep state, the power supply circuit 23 can supply power to both the control circuit 22 and the vibration wake-up circuit 25, ensuring that the vibration wake-up circuit 25 is always powered, allowing it to detect its own vibration amplitude, regardless of whether the control circuit 22 is in a wake-up state or a sleep state. As for the control circuit 22, it also needs power when in a sleep state; however, it is understandable that in a sleep state, the control circuit 22 is in standby mode, consuming very little power. Figure 2 and Figure 1 In this example, the vibration wake-up circuit 25 is powered by the power supply circuit 23 through the control circuit 22. Therefore, the connection between the power supply circuit 23 and the vibration wake-up circuit 25 is not shown. In other embodiments, the output of the power supply circuit 23 can be directly connected to the vibration wake-up circuit 25 without affecting the implementation of this utility model.

[0102] In one specific embodiment of this utility model, please refer to... Figure 6 It may also include a processing unit housing and a sensing unit housing;

[0103] The processing unit 20 is installed in the processing unit housing, and the sensing unit 10 is installed in the sensing unit housing 103;

[0104] A battery compartment is provided in the outer casing of the processing unit so that the battery pack 35 in the power circuit 23 is fixed inside the battery compartment.

[0105] The processing unit housing also includes a board compartment to fix the PCB circuit board 104 inside the board compartment, and the conversion circuit 21, vibration wake-up circuit 25 and control circuit 22 are all arranged on the PCB circuit board 104.

[0106] In this embodiment, since the present application adopts a separate wireless sensor arrangement, the processing unit 20 and the sensing unit 10 can be protected by corresponding housings, that is, the processing unit 20 can be installed in the processing unit housing, and the sensing unit 10 can be installed in the sensing unit housing 103.

[0107] Furthermore, this embodiment takes into account that the power supply circuit 23 is the component with the highest safety requirements among the sensitive parts 10, especially the battery pack 35 therein. Therefore, in this embodiment, a battery compartment is specially provided in the processing unit housing, so that the battery pack 35 in the power supply circuit 23 can be fixed inside the battery compartment.

[0108] Furthermore, considering that the sensitive part 10 also contains certain circuit components, which typically need to be soldered onto a PCB board for easy fixation, this embodiment also includes a board slot in the processing unit housing. This allows the PCB board 104 to be fixed inside the board slot, and the conversion circuit 21, vibration wake-up circuit 25, and control circuit 22 can all be arranged on the PCB board 104. Of course, in other specific embodiments, other circuit components can be arranged on the PCB board 104 if needed.

[0109] The specific structure and dimensions of the processing unit's outer casing can be set and adjusted according to actual needs, for example, in Figure 6 In this example, the outer casing of the processing unit specifically includes an upper casing 101 and a lower casing 102 that mates with the upper casing 101. The two can be connected as a single unit using bolts or other means. Figure 6 In the example, the upper housing 101 is U-shaped, and the cavity it forms can serve as the board compartment required by the present application. The lower housing 102 is also U-shaped, and the cavity it forms can serve as the battery compartment required by the present application. In practical applications, the volume required for the battery compartment is higher than that required for the board compartment.

[0110] In one specific embodiment of this utility model, the processing unit 20 may further include:

[0111] A first buffer assembly is filled between the battery pack 35 and the battery compartment to reduce vibration of the battery pack 35.

[0112] A second buffer assembly is used to enclose the individual battery packs 35 in the power circuit 23 to reduce vibration between adjacent battery packs 35.

[0113] This implementation takes into account that the power supply circuit 23 includes a battery pack 35, and typically includes two or more battery packs 35 connected in parallel to ensure sufficient power supply. Conventional battery pack solutions have relatively low vibration requirements and cannot meet the vibration level requirements of the wireless sensor installed at the axle box location in this application. Therefore, in this implementation, a first buffer component is filled between the battery pack 35 and the battery compartment to reduce the vibration of the battery pack 35.

[0114] For example, in one specific embodiment, the first buffer component filled between the battery pack 35 and the battery compartment can be an epoxy resin filler with suitable hardness. On the one hand, it can fix the battery pack 35, and on the other hand, the epoxy resin filler has a large damping coefficient, which can effectively absorb vibration mechanical energy and reduce the transmission of vibration energy to the battery pack 35.

[0115] Furthermore, in this embodiment, a second buffer assembly is provided to enclose each battery pack 35 in the power circuit to reduce vibration between adjacent battery packs 35, for example... Figure 6 In the example, the second buffer component can be vibration damping cotton 105, which can wrap each battery pack 35 with vibration damping cotton 105, thereby effectively reducing the impact of vibration on adjacent battery packs 35 and reducing cell damage.

[0116] Furthermore, the PCB circuit board 104 can also be designed with vibration resistance. On one hand, when the chips on the board are mounted, filler glue can be added between the chips and the board, and other components can be fixed by dispensing glue. On the other hand, potting can also be performed after the board is installed to ensure that the PCB circuit board 104 and the board compartment become a whole, thus improving vibration resistance.

[0117] The wireless communication circuit 24 of this application serves as a wireless communication device, and its specific form can be configured according to actual needs. In one specific embodiment of this utility model, the wireless communication circuit 24 may include: a wireless module connected to the control circuit 22 for receiving the output signal of the control circuit 22 and outputting it externally through an antenna; and an antenna connected to the wireless module and disposed inside the processing unit housing. The processing unit housing is a non-metallic processing unit housing.

[0118] In this implementation, the output signal of the control circuit 22 is received via a wireless module, specifically a CAT.1 module. Figure 2In this example, the connection to the MCU is via a UART serial port. To adapt to the field application environment and protection requirements, this implementation uses a built-in antenna for communication, meaning the antenna is placed inside the processing unit housing. Because the antenna is inside the processing unit housing, to reduce the shielding of the communication signal by the processing unit housing and ensure communication quality, the processing unit housing is a non-metallic housing; for example, it can be a processing unit housing designed with composite materials.

[0119] Furthermore, during the layout process, the wireless module can typically be mounted on the PCB circuit board 104, while the battery compartment, due to its larger size, provides ample space for the antenna. Therefore, the antenna can usually be placed in the antenna mounting slot within the battery compartment, for example... Figure 6 In one embodiment, an antenna mounting slot is provided on the side of the battery compartment so that the antenna 106 can be arranged in the antenna mounting slot.

[0120] In one specific embodiment of this utility model, a waterproof connector is fixed on the outer shell of the processing unit so that the processing unit 20 is connected to the sensitive unit 10 through the waterproof connector and the cable; a corrugated tube is provided on the outside of the cable to protect the cable.

[0121] This implementation takes into account that the processing unit 20 of this application needs to be connected to the sensitive unit 10. To ensure reliability, please refer to [reference needed]. Figure 6 A waterproof connector 107 is fixed to the outer casing of the processing unit, providing good waterproofing at the interface between the processing unit 20 and the cable, ensuring reliable operation of the wireless sensor in harsh field conditions. A standardized waterproof connector can typically be selected, offering strong versatility and effective cable connection. (See reference...) Figure 5 , Figure 5 This is a front view of the processing unit housing provided in a specific embodiment of the present invention. Figure 5 A waterproof connector is fixed at the lower right corner of the outer casing of the processing unit.

[0122] In addition, the cable is provided with a corrugated tube for protection. The corrugated tube has good impact resistance, pressure resistance and tensile strength, which can effectively protect the cable. Figure 6 In the example, a corrugated pipe 109 is provided on the outside of the cable 108 to protect the cable 108.

[0123] In one specific embodiment of this utility model, the processing unit 20 may further include a waterproof component 110 disposed between the battery compartment and the circuit board compartment for waterproofing. This embodiment takes into account that the outer casing of the processing unit typically adopts the upper and lower shell structure described above to respectively realize the circuit board compartment and the battery compartment. Therefore, the waterproof component 110 can be disposed between the battery compartment and the circuit board compartment to further improve the reliability of the wireless sensor of this application. For example... Figure 6 In the example, an O-type waterproof component 110 is provided for waterproofing, achieving a good sealing effect and a protection level of IP68.

[0124] In this application, the specific structure of the power supply circuit 23 can be set according to actual needs, for example... Figure 2 In this example, the power supply circuit 23 includes a wireless power receiving coil, a wireless power processing circuit, a charge / discharge management circuit, and a DC / DC converter. The wireless power receiving coil and wireless power processing circuit function as wireless power receivers, the charge / discharge management circuit manages charge and discharge, and the DC / DC converter converts the battery pack output voltage to the required voltage levels. Furthermore... Figure 2 The diagram shows the I2C bus between the MCU and the power supply circuit 23, indicating that the MCU can control the power supply circuit 23 through this communication bus, thereby disconnecting the power supply circuit 23 from the sensitive part 10, the conversion circuit 21 and the wireless communication circuit 24 in sleep mode.

[0125] In one specific embodiment of this utility model, the power supply circuit 23 may include:

[0126] Wireless power receiving coil 31 for receiving wireless power;

[0127] A wireless power processing circuit 32 connected to a wireless power receiving coil 31 for processing electrical energy;

[0128] A charge / discharge management circuit 33 connected to the wireless power processing circuit 32 is used for charge / discharge management and provides circuit protection when overvoltage and / or overcurrent are detected.

[0129] A power management circuit 34 connected to the charge / discharge management circuit 33 for protecting the battery pack 35;

[0130] Battery pack 35 is connected to power management circuit 34;

[0131] A conversion circuit 36, connected to the charge / discharge management circuit 33, is used to perform voltage level conversion for external power supply.

[0132] The power supply circuit 23 needs to be able to charge, and considering that charging via wireless power is beneficial to meeting the protection requirements of the train's on-site application environment, in this embodiment, wireless power is received through the wireless power receiving coil 31. The wireless power processing circuit 32 is connected to the wireless power receiving coil 31 and can perform power processing, such as rectification and voltage regulation.

[0133] This application includes a charge / discharge management circuit 33 for charge / discharge management, specifically including functions such as power monitoring and charge / discharge rate control. Furthermore, for effective circuit protection, the charge / discharge management circuit 33 also implements circuit protection when overvoltage and / or overcurrent are detected. That is, the charge / discharge management circuit 33 can detect the voltage and current flowing through it to determine whether overvoltage and / or overcurrent have occurred. In practical applications, overvoltage and / or overcurrent mostly occur during charging. The charge / discharge management circuit 33 can effectively detect abnormalities during the charge / discharge process, preventing damage to circuit components. For example, when overvoltage and / or overcurrent are detected, the main charge / discharge switch of the battery pack 35 can be cut off to avoid damaging components in the wireless sensor.

[0134] In addition to the charge / discharge management circuit 33, this embodiment also includes a power management circuit 34, or BMS, for protecting the battery pack 35. The BMS effectively protects the battery pack 35, for example, by detecting abnormal conditions such as overvoltage during charging, undervoltage during discharging, overcurrent during charging, or overheating. Furthermore, the simultaneous inclusion of both the BMS and the charge / discharge management circuit 33 provides redundant protection, further ensuring the reliability of the power supply circuit 23 of the wireless sensor.

[0135] The battery pack 35 can be a single battery pack 35 or multiple battery packs 35. When multiple battery packs 35 are used, they can be connected in series or in parallel, depending on the actual needs. For example, in a specific implementation, the battery pack 35 uses two parallel lithium iron phosphate battery packs.

[0136] The conversion circuit 36 ​​is used to perform voltage level conversion, thereby providing different voltage levels to power the corresponding components.

[0137] For example, in one specific embodiment of this utility model, the conversion circuit 36 ​​may include:

[0138] A first conversion sub-circuit connected to the charge / discharge management circuit 33, used to perform voltage level conversion to output a first voltage level voltage, and to power the wireless communication circuit 24 with the first voltage level voltage;

[0139] A second conversion sub-circuit connected to the charge / discharge management circuit 33 is used to perform voltage level conversion to output multiple different voltage levels and output a constant current source. When the control circuit 22 is in the wake-up state, it supplies power to the sensitive part 10, the conversion circuit 21, the control circuit 22 and the vibration wake-up circuit 25 through multiple different voltage levels, and provides a constant current source for the conversion circuit 21.

[0140] The control terminal of the first switching sub-circuit is connected to the control circuit 22 so that when the control circuit 22 switches to a sleep state, the power supply to the wireless communication circuit 24 is disconnected under the control of the control circuit 22.

[0141] The control terminal of the second conversion sub-circuit is connected to the control circuit 22 so that when the control circuit 22 switches to a sleep state, the power supply to the sensitive part 10 and the conversion circuit 21 is disconnected under the control of the control circuit 22.

[0142] This implementation takes into account the large power consumption and startup current of the wireless communication circuit 24. Therefore, to ensure sufficient load capacity, a separate power supply is designed for it, that is, a voltage level conversion is specifically performed through the first conversion sub-circuit to output a first voltage level voltage to the wireless communication circuit 24. For example Figure 4 In the example, the first conversion sub-circuit can be a DC / DC circuit, and the output voltage of the wireless communication circuit 24 is 3.8V.

[0143] The second conversion sub-circuit can perform voltage level conversion, and to improve integration and reduce the size of the wireless sensor, it can output multiple voltage levels and a constant current source, for example... Figure 4 In this example, the second conversion sub-circuit is specifically implemented using a PMIC chip, which can provide 5V, 3.3V, and 1.8V voltages. The MCU and vibration wake-up circuit 25 require 1.8V, and this voltage is kept in an on-state. The 5V and 3.3V voltages can be switched on and off under the control of the control circuit 22. The 3.8V output from the first conversion sub-circuit can also be switched on and off under the control of the control circuit 22. This allows the circuit supplying power to the wireless communication circuit 24 from the first conversion sub-circuit, and the circuit supplying power to the conversion circuit 21 and the sensitive part 10 from the second conversion sub-circuit, to be turned on or off under the control of the control circuit 22, thus achieving the switching between the sleep state and the wake-up state described above.

[0144] Both the first and second conversion sub-circuits can use switching power supplies, i.e., digital power supplies, which helps to reduce power loss.

[0145] exist Figure 4The ADC shown in the example can be the first analog-to-digital converter circuit and the second analog-to-digital converter circuit described in the above embodiment. In this example, it needs to be supplied with voltages of 5V and 1.8V, and the second conversion sub-circuit also generates a 2.5V reference source and provides it to the first analog-to-digital converter circuit and the second analog-to-digital converter circuit as the reference voltage Vref required by both.

[0146] Figure 4 The temperature detection shown in the example refers to the temperature detection-related device in the sensitive part 10, which in this example needs to be supplied with voltages of 3.3V and 1.8V. Figure 4 The vibration and shock detection shown in the example refers to the vibration and shock detection-related devices in the sensing element 10 and the conversion circuit 21, which require a 5V voltage in this example. The second conversion sub-circuit can also provide a constant current source for the conversion circuit 21, typically specifically providing a constant current source for the probe end of the vibration and shock detection in the sensing element 10.

[0147] Figure 4 In the example, the 1.8V voltage is marked as ON to indicate that the second conversion sub-circuit will always provide a 1.8V voltage, ensuring that the control circuit 22 and the vibration wake-up circuit 25 are always powered. The 5V and 3.3V voltages are marked as ON / OFF to indicate that the on / off state can be determined by the state of the control circuit 22.

[0148] In one specific embodiment of this utility model, the power supply circuit 23 may further include:

[0149] The power input path management circuit 37, which is located between the charge / discharge management circuit 33 and the wireless power processing circuit 32, is used to receive power from the debugging interface and output it to the charge / discharge management circuit 33 when the debugging interface is connected, and to receive power from the wireless power receiving coil 31 and output it to the charge / discharge management circuit 33 when the debugging interface is not connected.

[0150] See also Figure 3 This implementation provides a debugging interface, allowing the wireless sensor to be debugged during production testing. Specifically, when the debugging interface is not connected, the power input path management circuit 37 receives electrical energy from the wireless power receiving coil 31 and outputs it to the charge / discharge management circuit 33. It is understood that after the wireless sensor leaves the factory, it is typically charged via the wireless power receiving coil 31.

[0151] When the debugging interface is connected, to avoid safety risks caused by simultaneous connection of wired and wireless power, the power input path management circuit 37 employs a two-way selection design. That is, as long as the debugging interface is connected, regardless of whether the wireless power receiving coil 31 is energized, the power input path management circuit 37 will receive power from the debugging interface and output it to the charge / discharge management circuit 33. In practical applications, this can be achieved through circuit settings. For example, when the debugging interface is connected, an enable pin of the power input path management circuit 37 can be pulled high, causing the power input path management circuit 37 to disconnect from the wireless power receiving coil 31.

[0152] Furthermore, it is understandable that the debugging interface is required before leaving the factory. Therefore, the debugging interface does not need to be exposed outside the housing of the wireless sensor, thus meeting the protection requirements of the field application environment. In other words, in the application field, charging is always done wirelessly, and the wired power provided by the debugging interface is only for debugging purposes.

[0153] In one specific embodiment of this utility model, it may further include:

[0154] The timing circuit connected to the control circuit 22 is used to clear the timing value and output a trigger signal to the control circuit 22 whenever the timing duration reaches the first duration, so that the control circuit 22 enters the wake-up state after receiving the trigger signal.

[0155] The switching rules include: the working time of the control circuit 22 after entering the wake-up state has reached the preset working time threshold.

[0156] It is understood that the control circuit 22 of this application will not always be in a wake-up state. The specific switching rules for switching from the wake-up state to the sleep state can be set according to actual needs. For example, it is usually set that after working for a period of time after being woken up, it will automatically enter the sleep state. That is, in this embodiment, the switching rule is that the working time of the control circuit 22 after entering the wake-up state reaches a preset working time threshold. The value of the working time threshold can be set according to actual needs, such as 30 seconds, 1 group, etc.

[0157] In addition, to avoid the control circuit 22 being unable to be woken up by vibration for an extended period of time in this embodiment, another wake-up method is provided. Specifically, whenever the timing circuit reaches a first duration, the timing value can be reset to zero and a trigger signal can be output to the control circuit 22, so that the control circuit 22 enters the wake-up state upon receiving the trigger signal. In other words, in this embodiment, the control circuit 22 can be woken up periodically. In some embodiments, the timing circuit can be integrated inside the control circuit 22.

[0158] In some embodiments, if the control circuit 22 is woken up in this way, since the current vibration intensity is low, it can be set to only perform temperature detection at this time. That is, when the control circuit 22 is woken up by the timing circuit, the relevant components for impact vibration detection in the sensitive part 10 will not be powered. Only the relevant components for temperature detection need to be powered to transmit the temperature back, which is beneficial to save energy consumption.

[0159] Furthermore, in practical applications, low-power devices and small packages can be selected for the components in wireless sensors, which helps to reduce the size and power consumption of wireless sensors. Wireless sensor circuits are primarily powered by 1.8V, using a low voltage level to reduce power consumption. This reduces the use of capacitors, and resistors are set with high resistance values ​​depending on the circuit requirements, which also helps to reduce circuit operating power consumption.

[0160] In one specific embodiment of this utility model, the processing unit 20 further includes a magnetic component, so that when the wireless sensor is charged through the wireless power receiving coil 31, the relative position of the processing unit and the charging device is fixed by the magnetic component.

[0161] As described above, charging via wireless power is beneficial for meeting the protection requirements of the train's on-site application environment. Therefore, wireless power is typically received via a wireless power receiving coil 31. This embodiment further considers that when charging the wireless sensor using an external charging device, a magnetic component can be provided in the processing unit 20 to effectively fix it in place. During charging, the magnetic component can attract the charging device, thereby fixing the relative positions of the processing unit 20 and the charging device. The magnetic component is typically a magnet, for example... Figure 6 In the example, a mounting slot for magnet 111 is provided on PCB circuit board 104 to realize the placement of magnet 111.

[0162] This application considers that wireless sensors offer advantages in ease of installation and reduced cable complexity. However, compared to wired sensors, which only require vibration, shock, and temperature sensing circuits, wireless sensors need to integrate not only sensing circuits but also energy storage, power supply, and wireless communication. Consequently, traditional wireless sensors are often bulky and difficult to install in confined spaces on trains (such as axle box locations), making direct application impractical. Furthermore, issues such as insufficient power supply also exist.

[0163] This application proposes a separate wireless sensor, where the sensing element and processing element are arranged separately. The sensing element is located at a first position, allowing signal detection there. The processing element is located at a second position and connected to the sensing element, receiving the detected signals and transmitting them wirelessly. It can be seen that the sensing element only needs to perform detection functions, such as vibration, shock, and temperature detection; therefore, its small size allows for easy installation in confined spaces. The processing element needs to have energy storage, power supply, and wireless communication functions, resulting in a larger size, but it can be placed near the sensing element in a relatively spacious location (the second position).

[0164] Furthermore, even though the processing unit can be placed in a relatively large space compared to the sensing unit, space is still limited. This limits the size of the power supply circuit within the processing unit, resulting in limited energy storage. The solution presented in this application addresses this by achieving low power consumption for the wireless sensor. Specifically, this application includes a vibration wake-up circuit connected to the control circuit. This circuit wakes up the control circuit when the sensor's vibration amplitude reaches a threshold. In other words, the wireless sensor only needs to operate when vibration is strong. At this time, the control circuit can control the power supply circuit to power the processing unit and the sensing unit, allowing the wireless sensor to operate and detect the corresponding signal. When a switching rule is met, the control circuit switches to a sleep state. For example, after a certain detection period, it switches to sleep mode. In this state, the control circuit can disconnect the power supply circuit from the sensing unit, the switching circuit, and the wireless communication circuit. This ensures that the power supply circuit consumes almost no energy in the sleep state, eliminating the need for frequent charging and enabling the wireless sensor of this application to achieve long-term engineering applications.

[0165] In summary, this application employs a wireless sensor, which facilitates easy sensor installation, reduces the number of cables, and separates the sensing and processing units, resulting in a smaller sensing unit that can be easily installed in confined spaces. Furthermore, the wake-up mechanism eliminates the need for frequent charging, enabling the wireless sensor to operate for extended periods with minimal power consumption.

[0166] Corresponding to the above embodiments of wireless sensors, this utility model also provides a train fault monitoring system, which may include the wireless sensors in any of the above embodiments. It can be referred to in correspondence with the above description, and will not be repeated here.

[0167] This application uses specific examples to illustrate the principles and implementation methods of this utility model. The descriptions of the above embodiments are only for the purpose of helping to understand the technical solution and core ideas of this utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made to this utility model without departing from the principles of this utility model, and these improvements and modifications also fall within the protection scope of this utility model.

Claims

1. A wireless sensor, characterized in that, include: A sensitive part is set at a first position for signal detection at the first position; A processing unit, disposed at a second position and connected to the sensitive part, for signal output, and the processing unit includes: A power supply circuit that connects the control terminal to the control circuit and supplies power to the processing unit and the sensitive unit when the control circuit is in a wake-up state; It is connected to the sensitive part and the control circuit respectively, and is used to receive the detection signal of the sensitive part and send it to the conversion circuit of the control circuit after conversion; The control circuit is used to switch to a sleep state when the switching rule is established, and to control the power supply circuit to disconnect the power supply to the sensitive part, the switching circuit and the wireless communication circuit. Connected to the control circuit, it is used to wake up the vibration wake-up circuit of the control circuit when its own vibration amplitude reaches a threshold. A wireless communication circuit connected to the control circuit for outputting the output signal of the control circuit.

2. The wireless sensor of claim 1, wherein, The sensitive part includes: A first detection head for performing vibration and impact detection at the first position; A charge amplifier circuit connected to the first detection head, used to convert the charge signal output by the first detection head into a voltage signal and amplify it; A differential amplifier circuit connected to the charge amplifier circuit, used to differentially amplify the voltage signal output by the charge amplifier circuit and output it to the conversion circuit.

3. The wireless sensor of claim 2, wherein, The conversion circuit includes: A differential conversion circuit connected to the differential amplifier circuit for converting the voltage level of the signal output by the differential amplifier circuit; A first analog-to-digital converter circuit connected to the differential converter circuit is used to perform analog-to-digital conversion on the signal output by the differential converter circuit and output it to the control circuit.

4. The wireless sensor of claim 2, wherein, The sensitive part also includes: A second detection head is used to perform temperature detection at the first position and output the detected temperature signal to the conversion circuit; The conversion circuit further includes: A second analog-to-digital converter circuit is connected to the second detection head and is used to perform analog-to-digital conversion on the temperature signal output by the second detection head and output it to the control circuit.

5. The wireless sensor of claim 1, wherein, The wireless sensor further includes: a processing unit housing and a sensing unit housing; The processing unit is installed in the processing unit housing, and the sensing unit is installed in the sensing unit housing; The processing unit housing is provided with a battery compartment so that the battery pack in the power circuit is fixed inside the battery compartment. The processing unit housing also includes a board slot to fix the PCB circuit board inside the board slot, and the conversion circuit, the vibration wake-up circuit, and the control circuit are all arranged on the PCB circuit board.

6. The wireless sensor of claim 5, wherein, The processing unit further includes: A first buffer assembly is filled between the battery pack and the battery compartment to reduce vibration of the battery pack; A second buffer assembly used to enclose the individual battery packs in the power circuit to reduce vibration between adjacent battery packs.

7. The wireless sensor of claim 5, wherein, The wireless communication circuit includes: A wireless module connected to the control circuit, used to receive the output signal of the control circuit and output it externally through an antenna; The antenna is connected to the wireless module and is located inside the housing of the processing unit; The processing unit housing is a non-metallic processing unit housing, the wireless module is arranged on the PCB circuit board, and the antenna is arranged in the antenna mounting slot in the battery compartment.

8. The wireless sensor of claim 5, wherein, A waterproof connector is fixed to the outer casing of the processing unit so that the processing unit can be connected to the sensitive part through the waterproof connector and the cable; a corrugated tube is provided on the outside of the cable to protect the cable.

9. The wireless sensor of claim 5, wherein, The processing unit further includes: A waterproof component disposed between the battery compartment and the circuit board compartment for waterproofing.

10. The wireless sensor of claim 1, wherein, Also includes: The timing circuit connected to the control circuit is used to clear the timing value and output a trigger signal to the control circuit whenever the timing duration reaches the first duration, so that the control circuit enters the wake-up state after receiving the trigger signal. The switching rule includes: the working time of the control circuit after entering the wake-up state reaches a preset working time threshold.

11. The wireless sensor of any one of claims 1 to 10, wherein, The power supply circuit includes: Wireless power receiving coil for receiving wireless power; A wireless power processing circuit connected to the wireless power receiving coil for processing electrical energy; A charge / discharge management circuit connected to the wireless power processing circuit is used for charge / discharge management and provides circuit protection when overvoltage and / or overcurrent are detected. A power management circuit connected to the charge / discharge management circuit for battery pack protection; The battery pack connected to the power management circuit; A voltage conversion circuit connected to the charge / discharge management circuit for performing voltage level conversion to supply power to external systems.

12. The wireless sensor of claim 11, wherein, The voltage conversion circuit includes: A first conversion sub-circuit connected to the charge / discharge management circuit, used for voltage level conversion to output a first voltage level, and for powering the wireless communication circuit with the first voltage level. A second conversion sub-circuit, connected to the charge / discharge management circuit, is used to perform voltage level conversion to output multiple different voltage levels and output a constant current source. When the control circuit is in the wake-up state, it supplies power to the sensitive part through multiple different voltage levels, the conversion circuit, the control circuit, and the vibration wake-up circuit, and provides the constant current source to the conversion circuit. The control terminal of the first conversion sub-circuit is connected to the control circuit so that when the control circuit switches to a sleep state, the power supply to the wireless communication circuit is disconnected under the control of the control circuit. The control terminal of the second conversion sub-circuit is connected to the control circuit so that when the control circuit switches to a sleep state, the power supply to the sensitive part and the conversion circuit is disconnected under the control of the control circuit.

13. The wireless sensor of claim 11, wherein, The power supply circuit also includes: The power input path management circuit, located between the charge / discharge management circuit and the wireless power processing circuit, is used to receive power from the debugging interface and output it to the charge / discharge management circuit when the debugging interface is connected, and to receive power from the wireless power receiving coil and output it to the charge / discharge management circuit when the debugging interface is not connected.

14. The wireless sensor of claim 11, wherein, The processing portion further includes a magnetic member to fix the relative position of the processing portion and the charging device by the magnetic member when the wireless sensor is charged by the wireless power receiving coil.

15. A train fault monitoring system characterised by, The wireless sensor according to any one of claims 1 to 14.

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