Railway Clamping Force Sensor with Radial Strain Gauge Strip
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Solution Overview
Problem
Existing clamping force sensors in the railway field face high manufacturing costs and electrical consumption due to the need for flexible supports and strain gauges to measure the distance of the force application from the main axis, which is not always aligned.
Innovation Solution
A sensor design featuring a ring with two opposite faces and a flat surface, equipped with an electronic device comprising three circuits: a full-bridge strain gauge circuit for measuring clamping force in the main axis, and two half-bridge strain gauge circuits for measuring the distance of the force from the center in two perpendicular directions, installed on a rigid longitudinal support strip, optimizing measurement accuracy and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gauges are mounted on flexible supports that conform to the curvature of the ring to detect the distance of the clamping force application point from the main clamping axis, then measurement accuracy is improved, but manufacturing cost and power consumption increase
Solution Approach 1:
The support structure is segmented into multiple rigid strips arranged radially around the ring, each strip carrying strain gauges for specific measurement functions. This segmentation allows each strip to be independently manufactured and positioned, simplifying production while maintaining measurement capability across the entire ring circumference.
Solution Approach 2:
The solution transitions from a two-dimensional flexible membrane conforming to the ring curvature to a three-dimensional radial arrangement of rigid strips. The strips extend radially from the ring center outward, creating a spatial structure that maintains measurement accuracy while enabling simpler manufacturing through standardized rigid components.
2Measurement precision
If strain gauges are mounted on flexible supports that conform to the curvature of the ring to detect the distance of the clamping force application point from the main clamping axis, then measurement accuracy is improved, but power consumption increases
Solution Approach 1:
The support structure is segmented into multiple rigid strips arranged radially around the ring, each strip carrying strain gauges for specific measurement functions. This segmentation allows each strip to be independently manufactured and positioned, simplifying production while maintaining measurement capability across the entire ring circumference.
Solution Approach 2:
The solution transitions from a two-dimensional flexible membrane conforming to the ring curvature to a three-dimensional radial arrangement of rigid strips. The strips extend radially from the ring center outward, creating a spatial structure that maintains measurement accuracy while enabling simpler manufacturing through standardized rigid components.
3Ease of manufacture
If a flat rigid support is used instead of flexible supports conforming to the ring curvature, then manufacturing cost and power consumption are reduced, but the ability to detect force application point distance from the main axis may be compromised
Solution Approach 1:
The solution transitions from a two-dimensional flexible membrane conforming to the ring curvature to a three-dimensional radial arrangement of rigid strips. The strips extend radially from the ring center outward, creating a spatial structure that maintains measurement accuracy while enabling simpler manufacturing through standardized rigid components.
Solution Approach 2:
The rigid radial strip structure serves multiple functions simultaneously: it provides a stable mounting platform for strain gauges, maintains geometric relationship with the ring center for accurate offset measurement, and transmits clamping forces to the strain gauges. This multi-functionality eliminates the need for separate flexible support structures.
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 design allows for precise measurement of clamping force and its offset from the main axis, reducing manufacturing costs and energy consumption while improving measurement accuracy, enabling efficient and cost-effective monitoring of clamping forces in railway applications.
Implementation Method 1
Force sensors include strain gauges that detect sensor deformation and measure the intensity of an electrical signal produced by the gauge deformation
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a sensor (1) for measuring a tightening force applied on a screw-assembly member (2), the measurement sensor comprising a ring and an electronic device comprising a longitudinal support strip having two opposite ends, said support strip being installed on a flat surface of the ring, the electronic device (26) comprising: - a first circuit, capable of generating a signal representative of a tightening force applied in a tightening direction on one of the two opposing faces; - a second circuit, capable of generating a signal representative of the distance of said applied force from the centre of the ring in a first direction perpendicular to said tightening direction; and - a third circuit, capable of generating another signal representative of the distance of said applied force from the centre of the ring in a second direction perpendicular to said tightening direction.