Rail Brake Actuator Position Locking for Power-Loss Braking
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Solution Overview
Problem
Current rail vehicle braking systems, particularly pneumatically regulated brakes, suffer from slow and imprecise regulation, risk of malfunctions due to leakages, and inability to ensure consistent braking force, especially when the electric power supply is interrupted.
Innovation Solution
A brake system incorporating a brake actuator, gear assembly, self-locking mechanism, stepper motor, and position sensor that allows precise positioning and locking of brake components, ensuring consistent braking force even without power supply, using a backup power unit for continued operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pneumatically regulated brakes are used, then braking force can be applied, but regulation is slow and imprecise
Solution Approach 1:
The patent replaces the pneumatic regulation system with an electrically controlled system. The brake actuator receives electric control signals and converts them to mechanical braking force through a drive mechanism, eliminating the slow and imprecise pneumatic regulation in favor of fast and accurate electric control.
2Device complexity
If the same brake units are used for service braking and emergency braking, then device complexity is reduced, but reliability decreases due to inability to verify braking position
Solution Approach 1:
The patent introduces a position sensor that detects the position of the pressing member and provides feedback signals to the control unit. This feedback mechanism allows the system to verify whether the braking force has been correctly applied, significantly improving reliability while maintaining reasonable device complexity.
3Use of energy by moving object
If electric power supply is interrupted, then energy consumption is reduced, but braking force cannot be maintained
Solution Approach 1:
The patent implements a self-locking mechanism that automatically engages when electric power is interrupted or reduced. This mechanism uses a spring-loaded locking structure with a release element that normally holds the pressing member in the engaged position. When power fails, the spring force automatically overcomes the holding force and maintains the braking action, providing beforehand cushioning against power failure.
4Reliability
If a self-locking mechanism is added to maintain braking force without power, then reliability improves, but device complexity increases
Solution Approach 1:
The patent merges the self-locking mechanism with the existing brake actuator structure. The release element is integrated into the drive mechanism, and the locking function is combined with the pressing member assembly. This integration approach maintains reliability improvement while minimizing the increase in device complexity by sharing components and structural elements.
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 system provides highly accurate and reliable braking, with immediate malfunction detection and secure locking of brake components, ensuring safety and efficiency in various braking conditions.
Implementation Method 1
The self-locking mechanism is configured to automatically lock the first and second pressing members if a supply of electric power to the brake unit fails
Implementation Method 2
The position sensor is configured to produce a position signal indicating an angular position of a power transmission shaft of the stepper motor
Implementation Method 3
the stepper motor is configured to act on the gear assembly so as to cause the first and second pressing members to move towards or away from the rotatable member and attain a specified position interrelationship
Implementation Method 4
The gear assembly is arranged to operate mechanically on the first and second pressing members
Implementation Method 5
the brake unit is configured to receive the electric brake-force signal, and in response thereto cause the first and second pressing members to apply a braking force to the rotatable member
Data Source
Figure 1~2
Figure 3~8
Figure 4a~4b
AI summary
A rail vehicle (100) has a brake system containing a brake actuator (120) and a brake unit (200). The brake actuator (120) receives a brake command (cmdp) and produces a resulting electric brake-force signal (BF). The brake unit (200) contains first and second pressing members (211) and a rotatable member (110) being mechanically linked to at least one wheel (105) of the rail vehicle (100). When receiving the electric brake-force signal (BF), the brake unit (200) causes the first and second pressing members (211) to apply a braking force to the rotatable member (110). A gear assembly (220) in the brake unit (200) operates mechanically on the first and second pressing members (211). A stepper motor (230), in turn, acts on the gear assembly (120) in response to the electric brake-force signal (BF), thus causing the first and second pressing members (211) to move towards or away from the rotatable member (110) and attain a specified position interrelationship. Based on a position signal (P) indicating an angular position of the stepper motor's (230) power transmission shaft, the brake unit (200) determines if the specified position interrelationship has been attained; and if so, it stops producing the electric brake-force signal (BF) to allow a self-locking mechanism to lock the first and second pressing members (211).