Strain Gage Brake Force Sensor for Railway Inspection
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Solution Overview
Problem
Manual inspection of railway vehicle brake systems is time-consuming and unreliable, especially for in-board brake units, as it is difficult to verify brake pad-to-disc or shoe-to-tread contact, and existing methods like air pressure or piston travel monitoring are not always accurate.
Innovation Solution
A brake force sensor arrangement using a strain gage on the brake force application member, such as a lever, to measure stress and strain, which is proportional to the applied brake force, with a notification device to relay this information, eliminating the need for manual inspections and providing real-time brake performance data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used to verify brake pad-to-disc or shoe-to-tread contact, then operators can visually check brake application, but it is difficult to see and properly identify brake application especially on in-board brake units, requiring pit or maintenance facility access
Solution Approach 1:
The patent replaces the manual visual inspection method with a strain gage-based sensing system that directly measures brake force on the application member. This substitution eliminates the need for operators to physically access and visually verify brake contact, as the strain gage automatically detects and quantifies brake force application through electrical signals.
Solution Approach 2:
The strain gage acts as an intermediary element between the brake force application member and the inspection system. Instead of directly observing brake contact, the strain gage measures the mechanical strain on the application member caused by brake force, converting mechanical deformation into measurable electrical signals that indicate brake application status.
2Reliability
If operators manually inspect brake units using a pit or maintenance facility to access in-board brake units, then they can verify brake function, but the inspection process becomes very time consuming
Solution Approach 1:
The brake inspection system performs self-verification through the strain gage that continuously monitors brake force application automatically. The strain gage measures brake force without requiring external manual intervention, enabling the brake system to self-report its functional status through electrical signals that indicate proper brake application, eliminating the time-consuming manual inspection process.
Solution Approach 2:
The strain gage provides real-time feedback on brake force application by measuring strain on the application member and converting it into electrical signals. This feedback mechanism allows continuous monitoring of brake function, enabling operators to immediately identify malfunctioning brake units without time-consuming manual inspection procedures.
3Productivity
If air pressure or piston travel monitoring methods are used to check brake unit function, then brake operation can be monitored, but these methods are not always reliable as air pressure or piston travel may be present but no force is being applied to the brakes
Solution Approach 1:
The patent replaces indirect monitoring methods (air pressure or piston travel sensors) with direct mechanical force measurement using a strain gage on the brake application member. This substitution ensures reliable brake force verification by directly measuring the actual force applied to the brake, eliminating false positives where pressure or piston movement exists without corresponding brake force.
Solution Approach 2:
The strain gage serves as a direct intermediary between the brake application member and the measurement system, providing accurate feedback on actual brake force. Unlike air pressure or piston travel monitoring that indirectly infer brake application, the strain gage directly measures the mechanical strain caused by brake force, ensuring reliable verification of actual braking 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
Enables remote and accurate measurement of brake force, reducing the need for periodic manual inspections, improving inspection efficiency, and ensuring proper brake function without the need for maintenance facilities, thus saving time and resources.
Implementation Method 1
a strain gage positioned on the brake force application member. The strain gage may be configured to measure the stress, strain, or stress and strain of the brake force application member. The stress, strain, or stress and strain of the brake force application member may be proportional to the brake force applied by the brake unit.
Data Source
AI summary
A brake force sensor arrangement for a brake unit includes a brake unit including a brake force application member; and a strain gage positioned on the brake force application member. The strain gage may be configured to measure the stress, strain, or stress and strain of the brake force application member. The stress, strain, or stress and strain of the brake force application member may be proportional to the brake force applied by the brake unit.