Wearable Trailer Coupling Support with Embedded Wear Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Trailer coupling support members wear out over time, leading to excessive wear and potential damage if not replaced promptly, causing connectivity issues and unnecessary replacement costs.
Innovation Solution
A replaceable support member made of wearable material with integrated electrically conductive elements that form part of an electrical circuit, alerting the driver when wear exceeds a predetermined threshold by changing the circuit's state, ensuring timely replacement and reducing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the support member is used for an extended period to reduce replacement costs, then operating costs are reduced, but excessive wear occurs leading to damage and connectivity issues
Solution Approach 1:
The conductive element is embedded in the support member at a specific depth below the wear surface. As wear progresses, the conductive element gradually approaches the wear surface. When wear reaches the threshold (conductive element exposed), an electrical circuit is completed, triggering a warning signal before the support member fails completely. This preliminary warning allows replacement to be scheduled before damage occurs.
Solution Approach 2:
The wear monitoring system provides continuous feedback about the support member's condition through the electrical circuit. When the conductive element becomes exposed due to wear, the circuit state changes (from open to closed or resistance changes), providing real-time feedback on wear level. This feedback mechanism enables proactive maintenance scheduling based on actual wear conditions rather than fixed time intervals.
2Reliability
If the driver replaces the support member too early to avoid damage, then reliability is maintained, but unnecessary replacement costs occur
Solution Approach 1:
The invention replaces the mechanical/visual inspection method with an electrical monitoring system. Instead of relying on periodic visual checks or preventive replacement schedules, the system uses embedded conductive elements that automatically detect wear through electrical circuit changes. This substitution provides precise, objective wear measurement, eliminating both premature replacement and failure-to-replace scenarios.
Solution Approach 2:
The support member monitors its own wear condition through the embedded conductive element. As the support member wears, the conductive element's position relative to the wear surface automatically indicates the wear state through electrical circuit changes. The system is self-diagnosing, eliminating the need for external inspection or estimation of wear conditions.
3Device complexity
If no wear monitoring system is installed to simplify the device, then device complexity is reduced, but the driver cannot be notified of impending wear
Solution Approach 1:
The wear monitoring function is merged with the existing support member structure by embedding the conductive element directly into the support member material. This integration combines the structural support function with the wear sensing function in a single component, avoiding the need for separate sensors or monitoring systems. The electrical circuit utilizes existing conductive pathways, merging multiple functions into unified components.
Solution Approach 2:
The system monitors wear by detecting changes in electrical parameters (circuit continuity or resistance) rather than physical dimensions. As the support member wears, the position of the conductive element relative to the wear surface changes, altering electrical circuit characteristics. This parameter change provides a simple, binary wear status indication without complex measurement systems.
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 solution provides a simple, reliable, and cost-effective way to notify drivers of impending support member wear, preventing damage and optimizing maintenance schedules, thereby reducing unnecessary costs and ensuring continuous vehicle operation.
Implementation Method 1
the support member comprises an electrically conductive element integrated with the wearable material, the conductive element being arranged so as to form a part of an electrical circuit, and so that, when an amount of wear of the support member exceeds a predetermined threshold, an electrical state of the electrical circuit changes
Data Source
Figure 1
Figure 2
Figure 3
AI summary
There is disclosed a replaceable support member for a trailer coupling (1) mounted on a towing vehicle, the support member being intended to support a connection portion (100) of a drawbar (101) mounted to a trailer, the support member thereby being susceptible to wear by the connection portion (100), wherein the support member is formed by a wearable material, and comprises an electrically conductive element integrated with the wearable material, the conductive element being arranged so as to form a part of an electrical circuit, and so that, when an amount of wear of the support member exceeds a predetermined threshold, an electrical state of the electrical circuit changes. A trailer coupling (1) is also disclosed.