Railcar Brake Rigging Load Measurement Under Multi-Axis Articulation
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Solution Overview
Problem
The existing brake system inspection processes for railcars are time-consuming and labor-intensive, requiring periodic shutdowns for Class 1A inspections, which can lead to lost revenue and resource expenditure, and are challenging due to the articulating nature of the brake rigging, causing non-axial loading that can result in premature failure of load cells.
Innovation Solution
A load measuring device with an instrumented coupling that includes a strain sensor attached to a bolt, allowing the sensing axis to remain aligned with the applied force, even when the rigging articulates about three orthogonal axes, using a spherical nut and bolt configuration to prevent rotation and ensure accurate force measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional load cell is positioned in the load chain between the articulating rigging and the underframe, then brake force measurement is enabled, but the non-axial loading from rigging articulation causes premature load cell failure
Solution Approach 1:
The patent employs a spherical interface between the load cell and the articulating rigging component. This spherical connection allows the rigging to articulate through multiple axes while maintaining axial alignment of the load cell with the force vector, eliminating non-axial loading and preventing premature failure due to misalignment stresses.
2Reliability
If periodic Class 1A inspections are conducted to ensure brake system proper working order, then brake system reliability is maintained, but railcars must be taken out of service resulting in lost revenue and scheduling delays
Solution Approach 1:
The patent implements continuous monitoring of brake force during normal railcar operation through the load cell integrated into the rigging. This continuous measurement eliminates the need for periodic shutdown inspections, as the system continuously provides data on brake system performance, allowing railcars to remain in service while maintaining reliability through real-time monitoring.
Solution Approach 2:
The load cell provides continuous feedback on brake force application and rigging articulation. This feedback mechanism enables real-time detection of abnormal conditions, allowing for condition-based maintenance rather than fixed-schedule inspections, thereby keeping railcars in service longer while ensuring brake system reliability.
3Reliability
If hundreds of railcars are inspected on a periodic basis to ensure brake system functionality, then safety is maintained, but substantial expenditure of manpower and other resources is required
Solution Approach 1:
The load cell system is self-monitoring and automatically provides data on brake system performance. The system serves itself by continuously measuring and recording brake forces without requiring external inspection resources, thereby eliminating the substantial manpower and resource expenditure previously needed to inspect hundreds of railcars periodically.
4Adaptability or versatility
If the rigging articulates about three orthogonal axes during braking force application and removal, then the brake system functions properly, but positioning a load cell becomes challenging due to non-axial loading
Solution Approach 1:
The spherical interface design enables the load cell to accommodate articulation about three orthogonal axes while maintaining proper force measurement. The spherical connection acts as a universal joint that allows multi-axis movement without transmitting non-axial loads to the load cell, simplifying the positioning challenge while preserving full rigging articulation capability.
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 continuous monitoring of brake force during normal operation, reducing the need for frequent inspections, preventing premature load cell failure, and providing accurate diagnostic data on brake system performance.
Implementation Method 1
a sensor attached to the fastener and configured to generate an output relating to the force transmitted between the first and second members
Data Source
AI summary
Systems for monitoring brake systems on railway assets include a load measuring device. The load measuring device includes an instrumented coupling configured to be connected to the rigging of a brake system of the railway asset; and to an underframe of the railway asset. The load measuring device also includes a data collection unit configured to process an output of a sensor of the instrumented coupling and, based on the sensor output, determine the force being transmitted between the brake rigging and the underframe.