Electric Rail Brake Wear Detection Using Pulse Count and Pressure
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Solution Overview
Problem
Existing solutions for monitoring brake lining wear in rail vehicles are either unreliable due to lack of thickness measurement or increase the complexity and cost of the brake system, affecting braking efficiency.
Innovation Solution
An electrically operated brake assembly with a controller that generates control signals to monitor the wear of friction members by tracking pulse counts and pressure signals, allowing for precise wear detection and timely replacement without impairing braking capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electrical loops are integrated into the brake lining to detect lining thickness, then the measurement capability is improved, but the device complexity and cost increase
Solution Approach 1:
The patent introduces an intermediary measurement system consisting of a sensor, evaluation device, and reference surface. Instead of embedding complex electrical loops directly in the brake lining, the system uses a separate sensor that measures the distance to a reference surface on the rotating member. This intermediary approach provides thickness measurement capability while keeping the brake lining structure simple and maintaining braking efficiency.
2Measurement precision
If electrical loops are integrated into the brake lining to detect wear, then the wear detection capability is improved, but the braking efficiency deteriorates
Solution Approach 1:
The patent segments the measurement function from the braking function. The wear detection is achieved through a separate sensor system that measures the distance between a reference surface and the brake lining, rather than integrating measurement components into the friction material itself. This segmentation ensures that the braking surfaces remain clean and effective while providing accurate wear detection capability.
3Productivity
If parameterization process with test drives is used to forecast wear, then the wear forecasting capability is improved, but the reliability deteriorates due to lack of direct thickness measurement
Solution Approach 1:
The patent implements a feedback mechanism where the sensor continuously measures the actual distance between the reference surface and brake lining during operation. This real-time feedback provides direct thickness measurement data that can be used to verify and adjust wear forecasts, significantly improving the reliability of wear predictions compared to purely parameter-based forecasting methods.
Data Source
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Figure 3c
AI summary
An electrically operated brake assembly for a rail vehicle contains: a rotating member mechanically linked to a wheel axle of the rail vehicle, at least one friction member movable between an engaged position in which the friction member(s) contact/s the rotating member and a disengaged position in which the rotating member is freely rotatable, a gear assembly operating mechanically on the friction member(s), an electric motor controlled via a control signal to cause the gear assembly to operate on the friction member(s) to move between the engaged and disengaged positions, and a controller generating the control signal. When generating the control signal (710), the controller obtains a pulse-count signal (720) and a pressure signal (730). The pulse-count signal reflects an angular movement of an output shaft of the electric motor, and the pressure signal indicates a magnitude of a force experienced in the gear assembly when the friction member(s) is/are located in the engaged position and/or the disengaged position. Based on the pressure and pulse count signals, the controller checks if an alarm criterion is fulfilled (740) with respect to a wear of the friction member(s), and if so, triggers an alarm (750).