Indirect Operating Stress Estimation via Weighted Effect Operands
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Solution Overview
Problem
Directly recording operating stresses of components, such as brake discs and pads in rail vehicles, is challenging due to complex nonlinear influencing factors, making indirect estimation difficult, especially during operation.
Innovation Solution
A method involving the recording of measured values for predefined measurement variables during different operating modes, determining effect operands, setting up and solving a system of equations to obtain weighting factors, and using these to calculate operating stress without direct measurement, allowing for indirect estimation during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct measurement of operating stress is attempted, then measurement precision would be improved, but device complexity and difficulty of detecting and measuring worsen due to complex nonlinear influencing factors
Solution Approach 1:
The patent introduces effect operands as intermediary variables that mediate between measurable quantities (like temperature, pressure, velocity) and the target operating stress. These effect operands serve as intermediate representations that simplify the complex nonlinear relationship, allowing stress to be calculated through a system of equations rather than direct measurement, thus reducing device complexity while maintaining measurement precision.
Solution Approach 2:
The patent replaces direct mechanical stress measurement systems with a computational approach. Instead of using complex mechanical sensors and transducers to directly measure stress, the system substitutes a mathematical model that calculates stress from easily measurable parameters (temperature, pressure, velocity) through predefined relationships and system of equations, significantly reducing device complexity.
2Reliability
If operating stress is recorded during scheduled inspections, then measurement reliability is improved, but loss of time increases due to regular maintenance intervals and downtime
Solution Approach 1:
The patent enables continuous monitoring of operating stress during normal operation by calculating it from continuously available measurement data (temperature, pressure, velocity). This eliminates the need to stop operations for scheduled inspections, maintaining continuous useful action while ensuring reliable stress recording, thus reducing time loss without compromising reliability.
Solution Approach 2:
The system allows the component to monitor its own operating stress during normal operation through the calculation model. The component essentially performs self-diagnosis and self-monitoring using its own operational parameters, eliminating the need for external inspection interventions and reducing maintenance downtime while maintaining reliable stress data.
3Difficulty of detecting and measuring
If visual inspection is performed to check for cracks or deformations, then detection capability is improved, but loss of time increases due to inspection requirements
Solution Approach 1:
The patent implements continuous feedback through real-time calculation of operating stress during operation. By constantly monitoring stress levels and comparing them against threshold values or historical data, the system can detect abnormal conditions (indicative of cracks or deformations) immediately during operation, providing timely feedback without requiring separate inspection interventions, thus reducing time loss while maintaining detection capability.
Data Source
AI summary
A method for determining operating stress on a component during operation includes recording measured values for predefined measurement variables not equal to the operating stress on the component to be determined, during operation of the component for at least n≥2 predefined different operating modes, determining m≥2 and m≤n effect operands W1 to Wm, in dependence on the measured values for each operating mode, recording a measured value of operating stress after operating the component for n operating modes, and setting up and solving an equation system having n equations to obtain m weighting factors a1 to am weighting the m effect operands. A sum of weighted effect operands for each operating mode is equal to the measured value of the operating stress recorded for the operating mode. A calculation rule determining the operating stress during operation of the component uses the weighting factors.