Wheelset Bearing Sensor Layout Using a Claw-Pole Generator
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Solution Overview
Problem
Existing axlebox bearing systems for rail vehicles lack efficient and space-saving solutions for integrating and operating sensor systems, particularly in terms of power supply and configuration.
Innovation Solution
A claw-pole generator with a non-rotating claw ring is used to power a sensor system, where sensor modules are attached to a carrier on the claw ring or another non-rotating part, with a common data line serving as both a power and data transmission line, enabling a versatile and space-efficient arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensor modules are integrated into the wheelset bearing, then monitoring capability is improved, but device complexity increases
Solution Approach 1:
The sensor carrier integrates multiple sensor modules (acceleration, speed, position sensors) onto a single carrier structure that is mounted on the claw ring of the claw-pole generator. This merging approach consolidates multiple monitoring functions into one integrated unit, improving reliability while managing complexity through modular design.
Solution Approach 2:
The claw ring of the claw-pole generator serves multiple functions: it is part of the power generation system and simultaneously serves as a mounting structure for the sensor carrier. This multi-functionality reduces the need for additional separate mounting structures, thereby improving monitoring capability without proportionally increasing device complexity.
2Reliability
If a separate power supply is provided for sensors, then reliability is improved, but device complexity increases
Solution Approach 1:
The sensor system is powered by the same claw-pole generator that serves the wheelset bearing, merging the power generation function with the sensor power supply. The generator's electrical output is used to supply power to the sensor modules, eliminating the need for a separate power supply system and reducing overall device complexity while maintaining reliable power delivery.
Solution Approach 2:
The wheelset bearing system generates its own electrical power through the claw-pole generator, which then supplies power to the integrated sensor modules. This self-service approach allows the system to power its own monitoring components without external power sources or additional generators, reducing complexity while ensuring reliable power supply during operation.
3Volume of moving object
If sensor modules are arranged on a carrier on the claw ring, then space utilization is improved, but manufacturing complexity increases
Solution Approach 1:
The sensor system is divided into modular sensor modules that can be independently manufactured and then mounted on the sensor carrier. This segmentation allows each sensor module to be produced using standard manufacturing processes, and the carrier provides a standardized mounting interface, reducing overall manufacturing complexity while achieving efficient space utilization on the claw ring.
Solution Approach 2:
The sensor carrier is arranged in the circumferential direction of the claw ring, utilizing the radial and circumferential dimensions of the generator structure. By mounting sensors along the circumferential arc rather than radially outward, the design efficiently uses the available space within the generator's magnetic field region without requiring additional radial clearance, thus optimizing space utilization while maintaining manufacturability.
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 configuration provides an uninterruptible power supply to sensors during movement and allows for wireless data transmission, maintaining energy for sensors when stationary, and enables easy configuration and exchange of sensor modules for various applications.
Implementation Method 1
a generator (12) designed as a claw pole generator, which has a non-rotating claw ring (14, 15) and interacts with a rotating magnetic field from the wheelset axle
Data Source
Figure 1
Figure 2
AI summary
A wheelset bearing (1) for a rail vehicle comprises: - a generator, which is designed as a claw-pole generator (12) and comprises at least one non-rotating claw ring (14, 15); and - a sensor system (17), which is supplied with electrical energy by the generator (12) and comprises a plurality of sensor system modules (19, 20, 21, 22), at least some of which are fastened on a sensor carrier (18) placed onto the claw ring (14, 15) and which are connected to a common data line (23).