Locomotive Brake Chain Tension Sensing With Dual Link Assemblies
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Solution Overview
Problem
Existing systems for monitoring braking systems in locomotives do not account for the status of the chain, which is crucial for operators to prevent damage during operation, as they do not provide real-time tension monitoring of the chain between cars.
Innovation Solution
A chain tension sensor system comprising two link assemblies with U-shaped members, springs, and sensors that transition between configurations to measure the tension in the chain, allowing for real-time monitoring of the chain's engagement status.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a chain tension sensor system is implemented to monitor chain status in real-time, then safety and reliability are improved, but device complexity increases
Solution Approach 1:
The sensor system is divided into two separate link assemblies (first and second link assemblies) that can be independently attached to the chain. Each assembly contains its own U-shaped member, springs, and sensor base, allowing the system to monitor tension through the relative position of these segmented components while maintaining operational independence and reducing overall system complexity.
Solution Approach 2:
The sensor base is nested within the U-shaped member structure, with springs positioned between the sensor base and the U-shaped member walls. This nested arrangement allows multiple functional components (sensor base, springs, U-shaped member) to occupy the same spatial envelope, reducing the overall footprint and complexity of each link assembly while maintaining full monitoring capability.
2Adaptability or versatility
If spring mechanisms are used to enable configuration transitions in the link assemblies, then adaptability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The link assemblies are designed to dynamically transition between a relaxed configuration (when the chain is not under tension) and a pulled configuration (when the chain is under tension). The springs enable this dynamic behavior by automatically adjusting the position of the sensor base relative to the U-shaped member as tension varies, allowing the sensor to adapt to different chain tension states without requiring precise manual adjustment during manufacturing.
Solution Approach 2:
The springs change their physical parameters (compression or extension) in response to chain tension variations. When the chain transitions from a relaxed to a pulled state, the springs compress or extend, which in turn changes the relative position of the sensor base. This parameter change mechanism allows the sensor system to automatically adapt to different tension conditions while using standard, easily manufactured spring components that do not require high precision fabrication.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate monitoring of chain tension, preventing damage to tracks, wheels, and surroundings by determining if the mechanical brake is engaged before locomotive operation, thus enhancing safety and reducing maintenance costs.
Implementation Method 1
a first spring, a second spring
Data Source
AI summary
A chain tension sensor for monitoring a chain between cars in a locomotive. The chain tension sensor comprises a first link assembly and a second link assembly, referred to collectively as the link assemblies. each among the link assemblies comprises a U-link having a first end and a second end, a first spring, a second spring, a first fastener, a second fastener and a sensor base. The U-link of the link assemblies is a “u” shaped member having a curved end pointing outward from one another and an open end of the “u” facing inward toward one another. each among the link assemblies are arranged with the curved end extending out from the sensor base. The chain tension sensor is configured to monitor a signal between one or more sensors of the sensor base of the link assemblies to determine a proximity of the chain tension sensors.