Rubber Spring Load Sensing With Integrated Dielectric Elastomer Film
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rail vehicle suspension systems face challenges in accurately measuring mechanical loads on rubber leathers without increasing installation space, weight, or altering the spring properties, especially when separate sensors are used, which are susceptible to wear and require additional components that can affect the elasticity of the rubber leather.
Innovation Solution
Integration of a foil-like dielectric elastomer sensor within the rubber leather as a load sensor, which is extremely flexible, lightweight, and adaptable, functioning as a thin electrostatic plate capacitor that measures mechanical loads by changing capacitance in response to deformation, allowing for accurate load measurement without altering the spring system's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate sensors (strength sensors or ultrasonic sensors) are used to measure load on the air spring, then load measurement capability is achieved, but additional installation space is required and the sensors are susceptible to wear
Solution Approach 1:
The sensor is integrated directly into the rubber leather structure, merging the sensing function with the spring component itself. The sensor elements (first sensor part and second sensor part) are embedded within the rubber leather, eliminating the need for separate external sensors and reducing installation space requirements.
Solution Approach 2:
The rubber leather serves dual functions: it acts as both the spring element and the sensor housing/structure. The sensor parts are incorporated into the rubber leather, allowing the same component to perform both mechanical suspension and load measurement functions simultaneously.
2Measurement precision
If field sensors with metallic components (coil around inner cone or metallic plate with inner cone) are integrated into the rubber leather, then load measurement is achieved without additional installation space, but the elasticity properties of the rubber leather change unfavorably and weight increases noticeably
Solution Approach 1:
The sensor is positioned in a specific local region of the rubber leather where it can measure load without significantly affecting the overall elasticity properties. By placing the sensor parts at specific locations (with the first sensor part and second sensor part arranged to move relative to each other during compression), the measurement function is achieved while minimizing impact on the rubber leather's bulk elastic properties.
3Measurement precision
If conventional sensors are used to measure air spring deflection, then deflection measurement is achieved, but the enclosure of the rubber leather is not determined itself and is therefore not being taken into account
Solution Approach 1:
The sensor provides direct feedback about the rubber leather's compression state and enclosure condition. By measuring the relative movement between the first and second sensor parts that are integrated into the rubber leather, the system can determine both the deflection and the enclosure state of the rubber leather, ensuring that the rubber leather's condition is properly monitored and taken into account.
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 dielectric elastomer sensor provides a sensitive, lightweight, and cost-effective means to measure mechanical loads on the rubber leather, enhancing the accuracy of load determination without affecting the spring properties or increasing the system's size, and can be used as both an additional and emergency spring in vehicle suspension systems.
Implementation Method 1
functioning as a thin electrostatic plate capacitor that measures mechanical loads by changing capacitance in response to deformation
Implementation Method 2
The foil-like dielectric elastomer sensor integrated in the rubber body is loaded by the pollution of the rubber leather according to the loading force, which reduces the folia thickness of the sensor and enlarges the electrode surface
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a rubber spring (13) with an integrated load-bearing capacity sensor (16), which is designed and arranged as an auxiliary spring on a spring system (4) of a vehicle (1). To enable the measurement of the mechanical load on the rubber spring (13) without making structural changes to the spring system (4) itself, without a noticeable increase in weight due to the load-bearing capacity sensor (16), and without influencing the spring characteristics of the spring system (4) through the load-bearing capacity sensor (16), and with low manufacturing costs, the invention provides that the load-bearing capacity sensor (16) is designed as a film-like dielectric elastomer sensor.