Brake Hose Pressure Test for Fast Burst Detection in Trains
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Solution Overview
Problem
Existing methods for detecting brake hose bursts in train pneumatic brake systems are either time-consuming, require specific setups, or have low detection reliability due to high power supply needs and pressure signal dependencies, making them unsuitable for rapid and reliable detection during regular train operation.
Innovation Solution
A detection device and method using an ECU with a brake controller and pressure sensors to monitor actual and demanded brake pressures, applying a predefined test pressure and measuring pressure loss within a short time frame to detect hose breaks, independent of relay valve power supply and dynamic conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If pressure sensors or switches are used to detect hose pressure continuously during regular train operation, then continuous detection capability is improved, but detection reliability deteriorates due to high power supply needs and remaining pressure signals
Solution Approach 1:
The system performs periodic brake tests at predetermined intervals during regular train operation. The brake controller executes a test sequence where the brake hose pressure is monitored over a specific time period (e.g., 5-10 seconds) after applying brake pressure, rather than attempting continuous monitoring. This periodic testing approach maintains acceptable detection reliability while avoiding the problems of continuous high-power consumption and signal ambiguity.
2Power
If relay valves with large choke diameters are used to supply air to brake cylinders, then power supply capability is improved, but detection probability deteriorates due to high remaining pressure signals
Solution Approach 1:
During the brake test sequence, the system applies brake pressure for a sufficient but not excessive duration (e.g., 5-10 seconds) to ensure the brake hose is fully pressurized. This partial action approach allows the relay valve to deliver adequate power while creating a pressure differential that enhances leak detection sensitivity, without the excessive power consumption and remaining pressure issues of continuous operation.
Solution Approach 2:
The brake controller continuously monitors the brake hose pressure during the test sequence and compares it against expected pressure decay rates. This feedback mechanism allows the system to detect leaks even when using relay valves with large choke diameters, as the controller can distinguish between normal pressure maintenance and abnormal pressure decay indicating a hose burst.
3Reliability
If automatic brake tests with minimum performing time of more than 30 sec are conducted, then detection completeness is improved, but time consumption deteriorates
Solution Approach 1:
The system performs preliminary pressurization of the brake hose before the actual leak detection measurement. By pre-charging the brake hose with air pressure and then monitoring pressure decay over a shortened period (e.g., 5-10 seconds), the system achieves complete detection coverage without requiring the full 30+ seconds of traditional brake tests. The preliminary action ensures the system is in the correct state for rapid detection.
4Measurement precision
If brake tests are conducted at standstill of the train, then detection accuracy is improved, but operational flexibility deteriorates
Solution Approach 1:
The brake controller dynamically adapts the brake test sequence based on train operational conditions. The system can execute simplified leak detection routines during service braking operations when the train is in motion, while performing more comprehensive tests when at standstill. This dynamic approach maintains acceptable detection accuracy across varying operational contexts without requiring the train to always be stationary.
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 rapid detection of brake hose breaks in under 3 seconds during train stops, allowing for immediate action without disrupting train operation, and is applicable during service braking under safe conditions.
Implementation Method 1
a brake pressure sensor configured to provide the actual brake pressure lead to the brake cylinder
Data Source
Figure 1
AI summary
A detection device for detecting a hose burst or breakage of a brake hose (1) in a pneumatic brake system, preferably in a brake system of a train, is disclosed comprising an ECU (7) comprising a brake controller, said detection device further comprising a pressure controller, control valves (5, 8, 9), and a brake pressure sensor (4), said pressure controller being configured to control said control valves for providing a brake pressure for operating a brake cylinder (2), said brake pressure sensor (4) being configured to detect the actual brake pressure lead to the brake cylinder (2), said brake controller being configured to receive the actual brake pressure, a demanded brake pressure, and the control valve outputs of the pressure controller, wherein the brake controller comprises an algorithm configured to determine a hose break by initiating a test function in which a predefined pressure is applied in the brake hose (1) while the inlet valve (9) and the exhaust valve (5) are closed for a predefined time and the actual pressure is detected by the brake pressure sensor (4) over the predefined time. Also a detection method is disclosed which can be carried out at any suitable occasion at e.g. any standstill of the train, e.g. at any station where the train stops since only a few seconds are needed to conduct the testing method.