Vehicle Coupling Wear Detection Using a Pressurized Wear Element
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Solution Overview
Problem
Existing methods for detecting wear in fifth-wheel kingpins and coupling bolts of tractor-trailers and road trains are unreliable, labor-intensive, and prone to human error, leading to potential safety risks due to incomplete or inaccurate assessments of wear, which can result in premature replacement or continued use of worn components.
Innovation Solution
A coupling device with a wear detection system that includes a wear element arranged circumferentially around the component, sealed by a cavity with fluid under pressure, where wear causes the fluid to escape when a limit is reached, detected by a pressure sensor, allowing continuous and seamless monitoring of wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual wear inspection methods are used, then labor cost and time consumption are high, but detection reliability is low due to human error
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated sensor-based detection system. Pressure sensors continuously monitor wear by detecting changes in contact force between the kingpin and coupling, eliminating human involvement and associated errors while improving both reliability and efficiency simultaneously
Solution Approach 2:
The wear detection system is self-monitoring and automatically reports wear status without requiring external inspection. The system uses the existing operational forces during normal tractor-trailer operation to continuously assess wear, making the component self-diagnostic and eliminating the need for separate inspection activities
2Reliability
If frequent manual inspections are conducted, then wear detection reliability improves, but loss of time and operational downtime increase
Solution Approach 1:
The patent implements continuous wear monitoring that operates without interruption during the entire service life of the kingpin. Pressure sensors continuously measure contact forces and detect wear progression in real-time, eliminating the discontinuous nature of manual inspections and preventing operational downtime
Solution Approach 2:
The system detects wear trends and predicts remaining service life before critical wear occurs. By continuously monitoring and analyzing wear progression, the system enables proactive maintenance planning and prevents sudden failures without requiring frequent stoppages for inspection
3Reliability
If wear detection systems are added to the coupling device, then wear monitoring reliability improves, but device complexity increases
Solution Approach 1:
The patent makes the existing pressure sensors serve dual functions: monitoring both operational forces during normal operation and detecting wear simultaneously. This multi-functionality approach adds wear detection capability without requiring completely separate dedicated sensors, thereby limiting the increase in device complexity
Solution Approach 2:
The wear detection functionality is merged with the existing structural components and force transmission paths of the coupling device. The pressure sensors utilize the same mechanical contact interfaces already present in the kingpin-coupling system, integrating wear monitoring into the existing device architecture rather than adding separate monitoring subsystems
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 reliable, continuous, and seamless wear detection, reducing the risk of human error and premature replacement, enhancing road safety by ensuring timely identification of impermissible wear.
Implementation Method 1
at least one pressure sensor, which is designed to detect the pressure of the fluid in the cavity
Data Source
AI summary
A coupling device for a vehicle combination which extends along a longitudinal axis (X), with a wear detection means which comprises:one wear element, which is arranged, aligned perpendicularly to the longitudinal axis (X), in and/or on the coupling device in such a manner that wear of the coupling device perpendicular to the longitudinal axis (X) equally or exclusively wears the wear element,wherein the wear element is arranged in the circumferential direction (U) around the coupling deviceone cavity, which extends in the circumferential direction (U) in a manner corresponding to the wear element,wherein the cavity is sealed in a fluid-tight manner by the wear element, anda pressure sensor for detecting the pressure of the fluid in the cavity,wherein the wear element is dimensioned perpendicularly to the longitudinal axis (X) in such a manner that the fluid can escape through a through-opening of the wear element caused by wear, when a wear limit of the coupling device is reached at this point of the coupling device.