Handheld Laser Wheel Profile Gauge for Railway Maintenance
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Solution Overview
Problem
Current non-contact wheel profile measurement methods for train wheels are limited by inaccuracy, bulkiness, difficulty in use, inability to measure the witness groove, and limited variability in wheel size, leading to measurement errors and complexity in device placement.
Innovation Solution
A hand-held non-contact measurement device with a laser rotatably attached to a rotary encoder, capable of measuring the witness groove and calculating wheel diameter, using a calibration procedure to compensate for rotation and height changes, and equipped with magnets and holder pins for secure attachment and accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors and light emitters are used to measure multiple wheel data points, then measurement coverage is improved, but device complexity and portability are worsened
Solution Approach 1:
The measurement task is segmented into multiple passes with a single sensor-emitter unit. The device measures different sections of the wheel in sequence rather than requiring all measurements simultaneously, reducing the number of components needed at any one time.
Solution Approach 2:
The measurement device is made movable and repositionable rather than static. A single sensor-emitter unit moves to different locations around the wheel to capture all necessary measurement points, replacing the need for multiple fixed sensors.
2Device complexity
If a static measurement device is used, then device simplicity is improved, but adaptability to different wheel sizes is worsened
Solution Approach 1:
The measurement device incorporates adjustable and reconfigurable components that can be modified to match different wheel dimensions. The device can be adapted to various wheel sizes through mechanical adjustment rather than requiring multiple fixed-size devices.
Solution Approach 2:
The device allows changes in its measurement parameters and physical configuration to accommodate different wheel sizes. Measurement ranges, sensor positions, and device dimensions can be adjusted to match the specific wheel being measured.
3Measurement precision
If additional sensors and placement detectors are added to ensure proper device positioning, then measurement accuracy is improved, but device complexity and measurement time are worsened
Solution Approach 1:
The measurement device incorporates self-aligning features and automatic positioning capabilities that reduce or eliminate the need for additional sensors and detectors. The device can determine its own placement and orientation through inherent mechanical features or integrated simple sensors.
Solution Approach 2:
The device uses adjustable positioning mechanisms that allow the operator to set specific geometric parameters (angles, distances) to achieve proper alignment without requiring complex detection systems. Proper positioning is achieved through parameter adjustment rather than sensor-based feedback.
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
The solution provides accurate, portable, and easy-to-use measurements of wheel profiles, including witness grooves and diameters, across various wheel sizes, overcoming the limitations of existing technologies by enabling precise data capture and conversion from polar to Cartesian coordinates.
Implementation Method 1
energizing said laser to emanate a laser beam; rotating said laser to cause said laser beam to reflect off a plurality of points
Implementation Method 2
a laser rotatably attached to a rotary encoder
Implementation Method 3
a laser displacement sensor to measure distance displacement data of a beam of said laser
Implementation Method 4
equipped with magnets and holder pins for secure attachment
Data Source
AI summary
A method, apparatus and system for non-contact measurement of a railway wheel profile are disclosed herein. To measure the wheel profile, a laser having a distance displacement sensor and angular displacement sensor projects a beam of light onto the surface of a railway wheel to measure the wheel profile. In an alternate embodiment, a rail thickness measurement gauge is provided. In another alternate embodiment, a witness groove measurement gauge is provided.