Sensor-Monitored Plug-In Interface for Train Connector Maintenance
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Solution Overview
Problem
Existing plug interfaces in train carriages require frequent maintenance, leading to high maintenance costs and potential operational disruptions.
Innovation Solution
Implementing sensor-monitored feed-through housings with integrated sensors for temperature, distance, vibration, and humidity detection, along with a sensor box for data processing and transmission, and a digital twin system for predictive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plug interfaces are equipped with multiple sensors for monitoring, then reliability and early detection capability improve, but device complexity increases
Solution Approach 1:
The monitoring system is segmented into multiple independent sensor units (temperature sensor 101, distance sensor 102, vibration sensor 103, humidity sensor 104) that can be individually selected and deployed based on specific operational requirements. This allows the system to achieve comprehensive monitoring capability while maintaining modularity and managing complexity through functional decomposition.
Solution Approach 2:
The sensor box 100 is designed as a universal monitoring unit that can accommodate multiple different sensor types and perform various monitoring functions (temperature, distance, vibration, humidity) through a single integrated platform. This multi-functional approach improves reliability across different operational conditions while avoiding the need for separate monitoring systems for each parameter.
2Ease of manufacture
If sensor monitoring and data processing systems are integrated into the feedthrough housing, then maintenance costs reduce through predictive maintenance, but manufacturing complexity increases
Solution Approach 1:
The sensor box 100 combines multiple sensor units, data processing capabilities, and communication interfaces into a single integrated module that is installed within the feedthrough housing 1. This merging of functions into one compact unit reduces the overall number of separate components, simplifies installation and maintenance procedures, and enables predictive maintenance while managing manufacturing complexity through integration.
Solution Approach 2:
The sensor box 100 is equipped with autonomous data processing and evaluation capabilities that allow it to self-monitor its own operational status and predict maintenance needs without requiring external intervention. The system can independently process sensor data, detect anomalies, and trigger maintenance alerts, thereby reducing maintenance costs through predictive maintenance while minimizing the complexity of external monitoring infrastructure.
3Object-affected harmful factors
If physical separation of sensor pairs is implemented, then interference between sensors is reduced, but device complexity increases
Solution Approach 1:
The sensor system is divided into separate physical pairs (first and second sensors in one location, third and fourth sensors in another location) within the sensor box 100. This spatial segmentation reduces electromagnetic interference and cross-sensitivity between different sensor types while maintaining a compact overall design. The segmented layout allows each sensor pair to operate independently with minimal mutual interference.
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
Reduces maintenance frequency and costs by enabling early detection of issues, ensuring reliable operation and preventing disruptions through proactive maintenance.
Implementation Method 1
the first sensor is a temperature sensor and the second sensor is a distance sensor. The temperature sensor can detect potential hazards, such as overheating during the transmission of high currents
Implementation Method 2
The distance sensor can, for example, detect an incorrectly inserted connector into the interface
Implementation Method 3
the third sensor is a vibration and acceleration sensor and the fourth sensor is a humidity sensor. The data provided by the vibration sensor allows for predictions about the service life of the connector interface
Implementation Method 4
The humidity sensor data enables early detection of issues such as deteriorating seals around the connector interface or moisture ingress into the cable conduit between two connector interfaces
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a feedthrough housing, used in the railway sector, wherein the feedthrough housing (1) has at least one plug-in interface (4), which has plug connector modules (5, 5'), wherein the plug-in interface (4) additionally has at least two sensors, a first sensor and a second sensor, wherein the feedthrough housing has a sensor box (7), which has at least two sensors, a third sensor and a fourth sensor. In the method for integrated monitoring of a plurality of plug-in interfaces (4) of the railcars (8, 8', 8'') of a train (9): a) first data from a plurality of sensors are generated by each of the plug-in interfaces (4), b) wherein the first data generated at each plug-in interface (4) are transmitted to a sensor box (7) connected for data transfer to the plug-in interface (4), c) wherein second data are generated by the sensors of the sensor box (7), d) wherein the first and the second data are transmitted together from the sensor box (7) via a switch infrastructure (11, 11', 11'') to a central evaluation unit (12) and/or to a central monitoring point (13), e) wherein a digital twin of the train (9) comprising a plurality of railcars (8, 8', 8'') is calculated from the first and second data by the central evaluation unit and/or by the central monitoring point (13).