Railway Vehicle Bulk Loading Control via Non-Contact Sensing

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Solution Overview

Problem

Existing track construction vehicles face challenges in achieving optimal loading without exceeding the maximum permissible load limit, particularly due to variations in bulk material density and asymmetrical loading conditions.

Innovation Solution

The method involves using a non-contact sensing device to detect the bulk material height and volume, combined with strain gauges on the bogie frame to calculate the payload mass, ensuring the maximum filling level is maintained within safe limits by automatically controlling the movement of the conveyor belt to prevent overloading, and utilizing a telematics module for real-time load monitoring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If bulk material is continuously loaded onto the conveyor belt without control, then the loading capacity is maximized, but the maximum permissible load limit is exceeded

Engineering Contradiction:

Improveloading capacityVSAvoidoverloading

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system continuously monitors the bulk material height using a non-contact sensing device and compares it against the maximum filling level. When the material height approaches the limit, the system automatically activates the conveyor belt to move the material forward, creating a closed-loop feedback control that prevents overloading while maintaining continuous loading operations

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The non-contact sensing device detects the bulk material height in advance before the maximum filling level is reached. This early detection allows the system to proactively activate the conveyor belt to redistribute material, preventing the harmful condition of overloading before it occurs while maintaining optimal loading capacity

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the bulk material height is continuously monitored to prevent overloading, then the load safety is improved, but the device complexity increases

Engineering Contradiction:

Improveload safetyVSAvoidmonitoring system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system replaces complex mechanical level sensing mechanisms with a non-contact sensing device that uses optical or electromagnetic fields to detect bulk material height. This substitution maintains high reliability for load safety while significantly reducing mechanical complexity, maintenance requirements, and potential points of failure

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The non-contact sensing device acts as an intermediary between the bulk material and the control system. It converts physical material height into detectable signals without direct contact, simplifying the overall monitoring system while providing accurate, continuous data for load safety management

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the conveyor belt is activated frequently to maintain maximum filling level, then the load limit compliance is improved, but the energy consumption increases

Engineering Contradiction:

Improveload limit complianceVSAvoidconveyor belt energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The conveyor belt is activated partially - only when and where needed to move material forward based on real-time height detection. This partial action approach maintains load limit compliance by redistributing material only in necessary quantities and locations, rather than continuously operating the conveyor belt, thereby reducing energy consumption while ensuring compliance

Inventive Principle:

Principle #16Partial or excessive action

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

This approach allows for economical and precise loading, ensuring the maximum permissible load is not exceeded, optimizing the use of loading capacity while preventing harmful overloading and ensuring even distribution of bulk material, with visual and acoustic alerts for operators and automatic notifications for excess loads.

Implementation Method 1

a non-contact sensing device 13 is provided in the area of the transfer point 10 and is used for the continuous detection of a bulk material height hs and the volume of a material cone 14 forming in the area of the loading point 11

Methodology Applied

Scientific EffectLight barrier detection: Photoelectric Effect

Implementation Method 2

strain gauges are arranged on the bogie frame for detecting a frame deflection

Methodology Applied

Scientific EffectStrain gauge measurement: Piezoresistive Effect

Data Source

PatentEP3099858B1Method for loading a railway vehicle and railway vehicle

Publication Date: 2019.03.13 PLASSER & THEURER EXPORT VON BAHNBAUMASCHINEN GMBH

Figure 1~3

AI summary

The invention relates to a method for calculating the maximum filling height of a bulk material cone (14) for a railway vehicle (1) in relation to a maximum permissible total load weight mmax, using the bulk density calculated from the volume Vs and the mass ms, a movement of the bulk material away from a loading point (11) being automatically controlled in order to achieve the maximum permissible total load weight mmax for the railway vehicle (1). The method according to the invention allows maximum filling while avoiding the permitted weight per axle to be exceeded.