Flexible Substrate Sensor Interface for Railcar Bearings
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Solution Overview
Problem
Existing technologies lack a deformable, load-bearing substrate with embedded sensors that can effectively monitor and communicate conditions between relatively rigid objects, such as stress, temperature, and vibrations, while maintaining a compliant interface and providing data processing and communication functions.
Innovation Solution
A flexible substrate with embedded sensors and data processing units, powered by an internal source, capable of measuring and transmitting various physical parameters like stress, temperature, and vibrations, using communication devices such as radio transmitters and receivers, integrated within the substrate to provide a compliant interface between rigid objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are attached to rigid objects or built into smart materials, then measurement capability is provided, but the compliant interface function is lost
Solution Approach 1:
The patent combines multiple functions into a single integrated substrate: the flexible substrate serves both as a compliant mechanical interface between rigid objects and as the embedding medium for sensors. This merging allows the system to simultaneously provide compliance (through the flexible substrate's mechanical properties) and sensing capability (through embedded sensors), resolving the contradiction between measurement precision and adaptability.
Solution Approach 2:
The invention uses a composite structure where a flexible substrate (providing compliance) is combined with embedded sensors (providing measurement). The substrate itself acts as a composite material system that integrates the mechanical compliance function with the sensing function, allowing both the compliant interface and measurement capabilities to coexist in a single component.
2Device complexity
If multiple functions (sensing, processing, communication) are integrated into the substrate, then system complexity is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent segments the system into distinct functional modules that are embedded within the flexible substrate: sensors for measurement, data processing units for signal processing, communication devices for data transmission, and power sources for energy supply. This segmentation allows each component to be optimized and manufactured separately using appropriate techniques, then integrated into the substrate, thereby managing manufacturing complexity while achieving high system integration.
Solution Approach 2:
The flexible substrate serves as a universal platform that hosts multiple different functions (sensing, processing, communication, power). By designing the substrate with universal embedding capabilities, the invention allows diverse components to be integrated into a single system, reducing overall device complexity while maintaining manufacturability through standardized embedding processes.
3Duration of action of stationary object
If sensors are embedded within the flexible substrate, then sustained interface between rigid objects is provided, but sensor protection from environmental factors is reduced
Solution Approach 1:
The patent embeds sensors and other electronic components within the flexible substrate, creating a nested structure where the substrate acts as a protective enclosure. The sensors are nested inside the substrate material, which physically protects them from environmental factors such as moisture, dust, and mechanical damage, while still allowing the substrate to maintain its compliant interface function between rigid objects.
Solution Approach 2:
The flexible substrate itself acts as a protective shell or film that encloses and protects the embedded sensors. This flexible protective layer provides environmental protection while maintaining the compliance and flexibility needed for the interface function, allowing the sensors to operate sustainably in protected conditions while the substrate continues to provide mechanical compliance.
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 and evaluation of interactions between rigid objects, providing accurate data on stress, temperature, and vibrations, while maintaining the mechanical properties of the substrate and ensuring autonomous operation without external electrical connections.
Implementation Method 1
elastomeric substrates positioned between relatively rigid objects to attenuate shock or vibration
Implementation Method 2
at least one sensor is embedded within the flexible substrate. The sensor is adapted to measure a parameter such as voltage differential, luminous intensity, sound intensity, heat flux, electrical current, moisture diffusion, chemical species diffusion, magnetic flux, neutron flux, ionizing radiation, temperature, displacement, velocity, acceleration, stress, strain, pressure, and force
Data Source
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AI summary
A sensor interface (10) is disclosed including a flexible substrate (12) within which are embedded sensors (22, 24, 26) for measuring physical parameters such as temperature, displacement, velocity, acceleration, stress, strain, pressure and force present between objects (18, 20) such as a railcar bearing (44) and a truck side frame (48) The substrate (12) is positioned between the objects ( 18, 20) of interest Electronic components such as a data processing unit (28), a data storage device (32), a communication device (34), and a power source (38) may also be embedded within the substrate The electronic devices (28, 32, 34, 38) communicate with one another and the sensors (22, 24, 26) to process signals generated by the sensors (22, 24, 26) indicative of the parameters being measured.