EP4448367B1 - Track system comprising a spindle assembly having an integrated sensor - Google Patents

Description

The present invention is situated in the general field of integrated sensor technology in mechanical assemblies. For example, the invention discloses... DE 10 2005 025 748 B4 an electric linear actuator with limit switches, in which position switches and drivers interact to provide control signals. Similarly, the EP 2 256 032 B1 a sensor unit for a spindle drive which detects relative movement; similarly, the EP 1 832 851 A2 A position encoder is provided, which uses magnets and magnetic sensors to determine a position. General assemblies and measures for torque and control circuits can also be added. DE 20 2006 005 695 U1 or the EP 0 784 174 A2 The aforementioned general principles have in common that they do not take into account specific aspects that would need to be considered in transport-oriented track systems for public passenger transport or freight transport via tracks, such as in the railway sector, in track-guided traffic, in track-guided systems – here in particular concerning the track and/or routes and track sections between two points – as well as generally in the track bed and at a track switch and in devices for leaving one route towards another in track-guided systems.

GENERAL BACKGROUND

The present invention relates to a track system with a spindle assembly for railway applications with an integrated sensor, according to the preamble of the independent claims. Spindle drives are known, for example, as part of actuators, such as... EP 0 784 174 A2 illustrated.

DESCRIPTION OF THE STATE OF THE TECHNOLOGY

Spindles of this type comprise an integral, endocorporeal sensor unit, such as the one described by the applicant, for example, in the DE 20 2020 103 194 U1 suggests.

The endocorporeal arrangement protects sensor assemblies from direct weathering and direct access/impact, enabling them to provide reliable and long-term measurement data for control systems. Surprisingly, the market for spindle drives in the rail/railway sector offers no products that propose or explain sensor technology as described above as an innovative and useful component – especially for rail-guided transport/track systems. The inventors assume that the significantly higher demands in the public transport and rail sector regarding quality and service life explain this: Alloys that exhibit a service life of 25 to 50 years in load-bearing mechanical applications and control assemblies that offer similar performance characteristics when designed in the open are not established as a combination in this sector. Control assemblies for digital process control, in particular, are typically housed in separate enclosures, resulting in complex and costly control circuits. The applicant is familiar with alloys and mechanics of suitable quality, but the arrangement of control and regulation assemblies in such mechanical components has not been the subject of discussion in the railway sector to date. Against this background, the present innovation is, in its basic concept, generally geared towards this area.

From the WO2019/063263 A1 A method for analyzing a long-life switch drive is known, in which at least one sensor is arranged on or in the outer housing of a switch drive. An additional, separate sensor housing is proposed to protect the sensor from environmental influences. Alternative protection options for the sensor are not discussed.

From the KR 10 2019 003 668 2 A Similarly, a torque sensor for track systems is known, which is to be installed as an additional assembly between a spindle and a drive. Here too, the sensor is designed as a separate and additionally installable unit, which could optionally be further protected by its own housing.

From the WO 2004/076257 A1 is a device for monitoring a rotating A known design involves a shaft and attached components such as wheels, brake discs, and other elements, in which sensors are mounted inside the hollow axle of a rail vehicle. The cavity is covered at the ends with lids, which does not completely prevent the ingress of dirt or moisture. A further disadvantage is that the necessary encapsulation of the sensors is not taken into account, meaning that the sensors would again require their own separate housings.

Therefore, the task remains to propose a design in which a spindle assembly in the railway sector can be equipped with additional sensors in a durable and robust manner.

The solution to the problem of equipping a spindle assembly and a track system with a spindle assembly in the railway sector with new, durable sensors for control circuits, which meet the increasing demand for digital process control, is achieved according to the features of independent claims 1 and 10. Advantageous embodiments result from the dependent claims and the following description. The inventors explain the long-standing unmet need for digital measurement and control technology in the railway sector as follows: In principle, the railway sector is exposed not only to direct weathering but also to strong and stressful vibrations and shocks, as well as to tampering attempts by third parties. Known measurement and control technology therefore often failed or was too expensive to be widely used. Advances in industrial quality management have gradually led to significantly more consistent and uniform qualities of alloy components. Furthermore, the further development of control assemblies for actuators has resulted in more consistent and better-controlled drive forces. The interplay of these two factors can explain why an industrial spindle, typically manufactured as a solid body and designed to apply tensile or compressive forces in the kilogram to tonne range, can surprisingly be equipped with an internal cavity and fitted with additional measuring and control technology, including force sensors for compressive and shear forces, without affecting its lifespan or performance. Furthermore, experts in the relevant field are often unaware that the spindle drives The safety margins for track switches are designed for loads in the ton range; the usual switch systems, some of which are manually operated, require significantly less force for normal (regular) operation. Consequently, the designers in this area are unaware that the spindle assemblies installed in housings here are identical to spindle assemblies designed for loads in the ton range. Furthermore, modifying the mechanics does not conform to established approaches in this field. Rather, a track system, such as railway infrastructure, is viewed by its operators as a complex system consisting of substructure and superstructure, tracks, overhead lines, and the signaling, train control, and train protection systems. Only the finely tuned interplay of durable and robust components, including the rolling stock, enables smooth and, above all, safe high-speed rail traffic. Design and operational strategies are traditionally subordinated to this safety, and robust durability is regularly prioritized over potential improvements in order to minimize downtime and associated costs.

Furthermore, wireless technologies such as data communication, near-field charging, energy harvesting, and LAN capability of assemblies have developed in technically parallel fields: What works in dry rooms, buildings, and with mobile phones regularly fails under direct outdoor exposure to the elements. Accordingly, data acquisition devices in railway technology always incorporate data cables, encapsulated housings, and heavy-duty, durable mounting mechanisms. Therefore, a specialist in this relevant field is not familiar with any method that relies on wireless, stationary subnetworks or complexly integrated, independent, and field-mountable assemblies as sufficiently reliable and durable.

Therefore, for the first time, a surprisingly simple and advantageous solution is proposed that can address this long-standing need in this specific area, contrary to the established prejudices that such components will not function permanently.

SUMMARY OF THE INVENTION

According to the invention, a track system comprises a spindle assembly with at least one integrated sensor, wherein the at least one sensor is integrated into the spindle assembly via an integral and endocorporeal sensor assembly within the sealed interior of the spindle, which is designed for loads in the ton range. 'Endocorporeal', in analogy to the term 'endoskeleton', refers to the arrangement of the sensor assembly inside a body, and 'integral' indicates the effective connection to the body itself: The sensor assembly is inserted into the body in such a way that the volume states and volume properties of the body, such as elastic deformation, volume conductivity, temperature, temperature gradient, etc., can be detected. Thus, 'integral' denotes a material and data-processing-capable connection between the endocorporeal component and the body itself. In this case, the body is a spindle; conductivities, acting forces, and temperature, for example, can be detected in their magnitudes and gradients by the sensor assembly thus inserted. The sensor assembly is thus specifically integrated into the spindle assembly. Regarding possible additional features, functions, and measures for such a spindle assembly, reference is made to the teaching of... DE 20 2020 103 194 U1 and the documents cited therein; the sensor assembly is integrated, in accordance with the teaching of this document, into the closed internal volume of a mechanical component of a spindle assembly; the component, which tightly encloses the outside, excludes direct weathering and is designed in the alloy for continuous, long-lasting function, preferably for a function of 25 to 50 years, and thus offers an internally arranged sensor assembly the necessary high-quality protection directly and without further housing or additional measures.

DESCRIPTION OF THE INVENTION AND ADVANTAGEOUS FEATURES

In the track system according to the invention, comprising a spindle assembly with at least one integrated sensor, the at least one sensor is integrated into the spindle assembly via an integral and endocorporeal sensor assembly within the sealed interior of the spindle, which is designed for loads in the ton range. This makes it possible, for the first time, to derive statements about various states of an open-air track system with surprising accuracy from measurement data such as conductivities, stresses, forces, torques, or even data groups such as frequency-dependent conductivity, frequency-dependent ultrasonic resonance, frequency-dependent transmittance or resonance for radio waves, or group conductivity of entire mechanical assemblies such as a track switch. Thus, data can be reliably and continuously generated, collected, evaluated, and used for control and/or regulation, preferably for open track systems on open track, in tunnels, in stations, and also in underground track sections. Ideally, when coupled with supplementary data such as humidity, temperature, or temperature gradients, operating conditions can be quantitatively evaluated with improved quality and durability and used for control and regulation tasks, thereby increasing operational reliability and stability. This makes higher-level measurement and control systems of the track system more effective and precise, and the overall operation of the track system becomes more efficient.

Preferably, the spindle assembly is arranged in a track-guided system within the junction area. Junction areas, where a vehicle is scheduled to change lanes onto track paths defined by rails, are regularly critical points: The lane change increases the load on transition areas and, in the event of a malfunction, leads to a shutdown of all intersecting lanes. Improved monitoring of such areas with durable and effectively protected sensors allows such malfunctions to be detected before they even begin and prevented through appropriate measures.

The spindle assembly is particularly preferably arranged in the track bed area; the track bed area, as a free, easily accessible area, is directly exposed to the elements and therefore particularly susceptible to malfunctions under rapidly changing weather conditions; recording the necessary and applicable operating forces and accompanying acoustic indicators during operation allows for a similar approach here. Improved analysis of the current state allows for more effective preventative measures to be taken to maintain track-changing areas. A spindle assembly is preferably arranged in at least one encapsulated actuator of a track switch. The already encapsulated motor is doubly shielded externally and offers a particularly robust, time-saving, and safe way (since it is located outside the track) to integrate measurement and control technology into an existing system as a maintenance and replacement element, without requiring any modification or addition to the system itself; only the analog spindle is replaced with the smart spindle. The latter is particularly advantageous when combined with wireless communication via the sensor assembly to directly compare and update data via existing, parallel, or additional radio networks, preferably the WLAN network of passing trains.

Preferably, the spindle assembly is designed to detect the states of a railway technical system and transmit them digitally and/or analogously to measuring and control systems; by using resistant (e.g. against oils) cable sheaths, these are sufficiently protected against liquids prevalent in railway operations.

Preferably, the spindle assembly is integrated into existing and parallel systems via digital and/or analog communication.

Preferably, the spindle assembly can be connected to other spindle assemblies of the same type via digital communication to a peer-to-peer network for emergencies.

Preferably, the spindle assembly includes a tool-free quick-clamping device with anti-theft protection, a power supply and a transmitter, and takes into account an application with limited, given space conditions.

Preferably, an electric spindle drive is designed in the spindle assembly to replicate the motion and force profiles of pneumatically controlled thrust mechanisms.

Preferably, the sensor includes a module for synchronization with a time signal.

Preferably, the sensor includes a multiplex assembly through which data packets are transmitted. The spindle assemblies are interchangeable and synchronized with other spindle assemblies of the same type. In a particularly advantageous combination with a time signal synchronization module, multiple spindle assemblies can be operated synchronously at different force application points. This allows for more efficient and uniform movement, as well as the efficient adjustment of long track segments before initial use, such as those required for high-speed turnouts, with less wear and tear, and enables regular monitoring. Furthermore, the sensor packages allow for data acquisition of the accompanying frictional and deformation forces at each force application point, enabling earlier and more efficient detection of wear, contamination, and accumulating impurities within the turnout system. This improves the identification of the necessity and type of track system maintenance in this section, particularly in the area of high-speed turnouts, thereby increasing operational reliability and dependability.

Preferably, the spindle assembly is arranged in the track bed/superstructure area. The track bed area is regularly exposed to high loads, including direct weathering, vibrations, and released operating fluids and leakage from trains and freight cars. In addition, there are natural loads from vegetation, rodent populations, and settlement movements in the subsoil/substructure and superstructure. A uniform and load-bearing connection between sleepers, rails, and track bed must be monitored. Stresses in the rails, atypical vibrations during use and from traffic, as well as elastic deformations and the associated changes in sound characteristics and conductivity, indicate unacceptable deviations from a target condition. Preferably, the measurement data accessible with the claimed device are transmitted to a condition monitoring system. A condition monitoring system correlates measured values during and outside of operating hours and can correlate initial deviations of actual values from target values with possible causes of errors and advantageously correlate/control and/or confirm or refute these via further measured value acquisitions; thus, operational condition monitoring becomes accessible, which can advantageously encompass the railway superstructure as a whole and can advantageously improve maintenance, repairs and operational safety.

Preferably, the spindle assembly is part of a turnout mechanism. In a turnout mechanism, in addition to the general stresses in the track bed, there are also potential blockages, deformations, or corrosion of the movable, interconnected components necessary for its function; furthermore, the moving components can be impeded or completely impaired by foreign objects, icing, deformation, or corrosion. Unsteady force or torque changes, operating noise, unsteady changes in sliding and/or static friction, unevenly increasing travel forces, significant changes in group conductivity, and atypical operating noises indicate operating conditions that can be advantageously prevented through preventive on-site intervention, thus avoiding system failure, downtime, and the associated costs.

Preferably, the spindle comprises at least one wire inserted at least partially into the thread, which can be used as an antenna, preferably as a data antenna and/or charging antenna; wireless charging and/or communication enables time-saving evaluation and charging via established short-range transmitters and receivers, without the need for expansion or connection to an evaluation unit.

A particularly preferred energy storage device is at least one high-capacity capacitor, also known as an ultracap; compared to established batteries, capacitors offer significantly more charge and discharge cycles and better current handling during rapid charging in a short time.

Particularly preferred are the acquisition of travel forces and distances, which are then used for the digital control of travel speed and/or travel force. Stop and end points during the movement of mechanical components from one position to another can be controlled iteratively or according to a digitally stored control string determined by calculation, Fourier transformation, or approximation. Advantageously, this allows for the digital control and/or regulation of smooth and gentle starting, travel, and braking speeds and/or forces. The digital simulation of established hydraulic or pneumatic components, such as brake, buffer, or damping cylinders, is thus made possible for the first time.

Preferably, the spindle assembly is arranged with electrically measurable contact to at least a portion of the track bed. By using electrically conductive materials and lubricants, a current signal can be selectively injected into the ground via all mechanically coupled components. Preferably, analysis of the residual signal flowing through the ground, comparison with stored data sets, and correlation with known changes in soil moisture, humidity, and temperature allows for the inspection of the entire assembly at once. Advantageously, by successively pre-tensioning the spindle drive in the extension or retraction position with a set torque, the sliding surface required for insertion and retraction can be tested separately, and a more precise inspection of the spindle drive components can be carried out.

Particularly advantageous is the analysis of measured values, which allows for the identification of a deviation. By correlating values during and outside of operation, it is beneficial to determine whether the cause of the deviation lies in the mechanics of the assembly, the structure and condition of the surrounding track bed and superstructure, or both. The necessary maintenance or repair can thus be advantageously directed, for example, to the track bed, track structure, drive, or spindle assembly, individually or in combination. This allows for more efficient, faster, and more cost-effective management of the entire track superstructure, reducing downtime and detecting misuse and inadequate maintenance.

Preferably, the sensor comprises an AC signal emitter assembly. An AC signal with a preset frequency will not detect capacitive resistances, which hardly charge at that frequency. Therefore, an AC signal of constant frequency allows for the selective testing of characteristic AC resistances of assembly components at determined, predefined frequencies.

The sensor preferably comprises an AC signal detector assembly, and more preferably an impedance analysis assembly. Frequency-resolved analysis of an AC conductivity yields volume conductivities and grain boundary conductivities. Surface conductivities, as well as capacitive and inductive components or assemblies, are often separable components; thus, a complete, conductively interconnected assembly can be advantageously tested for uniformity and consistency of grain boundaries, volumes, and surfaces by varying the frequency and subsequent impedance analysis. Corrosion, microcracks, cracks, and foreign material contributions from ice, rust, or trapped foreign bodies can be advantageously detected more effectively, assigned to more specific sections, and taken into account in control and regulation circuits.

Preferably, the sensor includes a module for wireless data communication; a radio connection, particularly preferably a radio connection via the respective WLAN networks of passing trains, allows the direct exchange of measurement data, queries, and control loop commands.

Preferably, the sensor comprises a multiplexing module via which data packets can be output by modulating and superimposing them onto the supply current of other modules, preferably bidirectionally. Advantageously, a power supply line can be used in parallel as a data connection by modulating and parasitically superimposing the available current; this advantageously enables data exchange without additional physical data lines.

Data exchange is preferably encrypted; this makes it more difficult for unauthorized third parties to interfere with or read the data.

Further advantages arise from the exemplary embodiments. The features and advantages described above and the following exemplary embodiments are not to be considered exhaustive combinations of features unless explicitly described as such. Additional advantageous features and combinations of features, as explained in the description and available according to the documents cited herein and their prior art, can be implemented in the claimed subject matter, both individually and in different combinations, within the scope of the independent claims, without departing from the scope of the invention.

DETAILED EXPLANATION OF THE INVENTION BASED ON... EXAMPLES OF EXECUTION

In an advantageous embodiment, a spindle assembly according to the invention in the railway sector has at least one integrated sensor. The at least one sensor is integrated into the spindle of a spindle assembly as an integral and endocorporeal sensor assembly. The spindle assembly is arranged in the track bed area and is part of a turnout mechanism. The spindle assembly is mounted with electrically measurable contact to at least a part of the track bed. The sensor comprises an AC signal emitter assembly with an AC signal detector assembly and an impedance analysis assembly. Via a micromemory controller, preferably a FRAM microcontroller with non-volatile memory with improved reliability, the sensor includes a module for wireless data communication. Furthermore, the sensor includes a multiplexing module via which data packets can be output by modulating a supply current of other modules, preferably bidirectionally.

By integrating sensor modules inside a spindle, the established, durable spindle of at least one spindle drive of a track switch is transformed for the first time into a communication-capable data acquisition unit, which can record and evaluate measured values and assess and communicate operating conditions.

In an advantageous embodiment, sensor data are used to check the condition of assemblies in the railway sector. The sensor data preferably comprise at least one data package from a group of data packages, the group of data packages preferably consisting of: ultrasonic echo, ultrasonic echo with varying frequency, AC resistance, AC resistance with varying frequency, frequency and intensity of a resonant oscillation, electrical resistance, electrical resistance of a track section, electrical resistance of a track bed section, electrical resistance of at least one sleeper, electrical resistance of the track surface, electrical volume resistance of components of the track switch, electrical grain boundary resistance of components of the track switch, track temperature, track bed temperature, temperature of at least one component of a switch, torsional stress, resonant frequency, resonant frequencies, pressure, force, torque, sliding friction, static friction, conductivity, humidity, atmospheric humidity, ground moisture, local temperature, voltage, current. Vibration behavior, operating acoustics.

Preferably, measured and controlled values allow conclusions to be drawn about the condition of assemblies even, and preferably exclusively, in their resting state. This addresses the problem that established control loops often only acquire measured values during operation and then only enable fault detection shortly before the critical function/application. By acquiring measured values in the resting state and/or in a test operation with a short travel distance, defects can be detected and rectified more effectively outside of operation, thereby advantageously increasing the reliability of the overall system. Measurements are also possible and advantageously provided for in the resting state of the spindle drive, i.e., after a switch has been set. The spindle itself can also be used as a data source via its conductivity and its mechanical, often conductive, connection to the track system. A spindle equipped according to the invention thus preferably serves as a permanent measuring point – during the operation/setting of a switch and also afterwards/when trains pass over it. Communication and measurement-based, additional data collection from and with passing trains and digitally enabled road users offers a network of data networks, which, particularly through parallel, redundant transmission of important status data, can increase operational reliability and better prevent failures and accidents; especially advantageous is that with measuring points arranged in a wide area, information on the position of other road users such as motor vehicles or pedestrians with mobile devices can be generated relative to the track system, and the risk of a track being blocked by people or motor vehicles can be better assessed and blockages detected earlier.

The testable condition preferably comprises at least one property from a group of properties, the group of properties comprising, preferably consisting of: freedom from cracks in track sections, strength of track sections, fastening of track sections, freedom from cracks in sleeper bodies, uniformity of the track bed, deformation due to the tractive load of a passing/traversing train, train section, locomotive, wagon, or work unit, vibration due to a passing/traversing train, train section, locomotive, wagon, or work unit, temperature in and out of operation, torsion in the track body, thermal stress in the track body, position of a track switch, mechanical Coupling within the track switch mechanism, play in the track switch mechanism, corrosion of the track switch, altered surface structure of an assembly or component, occurrence of a stick-slip effect in the assembly, material deformations, e.g., due to temperature fluctuations, material deformations due to released stresses in the material, pitch error in the spindle, pitch error in the nut, flowability of the lubricants, freedom from cracks in a spindle, freedom from cracks in a spindle housing, permissible preload of a ball screw, permissible stress within a spindle drive, permissible grain boundary conductivity of an assembly, freedom from microcracks, permissible ratios of the operating forces, target value of a frequency pattern in operation, target value of a frequency pattern when a train is passing, target value of an acoustic frequency pattern, condition of wheel treads, condition of switch components of a track switch, sterility of lubricants, overload due to defective lubricants, crack, fracture, or thermal deformation in/on a spindle drive, contamination on/in sliding surfaces, lubricant deficiency, corrosion, permissible speed and/or feed range, permissible torque range, mobility of a track switch, temperature of a track switch, torsion in a track switch, degree of icing of a track switch, deviations of the current actual values from target operating parameters, discontinuities in changing operating parameters, exceedance of limit values in operating parameters, malfunction, defect warning, necessary maintenance, necessary closure.

In an advantageous embodiment, all sensor modules and wireless interfaces for communication and/or power supply are arranged inside a spindle assembly; such a spindle assembly allows a turnout system to be retrofitted with the internally provided functions simply by replacing the existing spindle drive. Sensor modules can also be used to implement auxiliary control and safety technology, e.g., during construction or for temporary infrastructure. Particularly preferably, modules with low-energy electronics can be equipped with high-performance energy storage devices and, when the energy storage capacity falls below 10% of its original value (or reaches its maximum storage level due to battery capacity loss), can be replaced entirely with a complete module equipped with a new energy storage device; this preferably tool-free replacement enables minimal maintenance times on the track and allows for careful analysis of the modules in use during maintenance. Charging and performance-based billing of component usage; the latter increases the economic efficiency of products that are as durable and long-lasting as possible and effectively contributes to the development of durable assemblies.

A problem with established systems is that they require complex, mechanical, and time-consuming digital integration into the existing analysis landscape and infrastructure for additional or new sensors and sensor assemblies. For the first time, the claimed system, in its advantageous embodiment, overcomes this disadvantage. Due to its mechanical separation, it even allows for parallel and test operation, which can preferably serve as part of a structured analysis procedure for section analysis and data acquisition. Particularly preferably, the spindle assembly with the integrated sensors can be mounted using fasteners with consistently identical dimensions. This reduces the amount of tools required and carried, and simplifies/facilitates replacement/retrofitting, even temporarily. Advantageously, it is combined with an anti-theft device that activates a tracker and/or a lock when the mechanical connection, which preferably includes a digital or current-based measurement connection, is broken.

In an advantageous embodiment, the spindle assembly, preferably coupled via a locking mechanism and particularly preferably with a safety lock featuring a digital and/or mechanical lock, can be inserted and removed with a single release and removal movement. This advantageously allows for direct, rapid replacement with a functional assembly. Maintenance/repair, etc., can thus be carried out off-track in the event of a defective spindle assembly. Intervention times are minimized, and the hazards to railway workers are reduced (unlike with established detectors or those installed in the track, which require personnel to be placed on the sleeper or rail web, resulting in unavoidable time spent on the track). Maintenance is therefore safer, faster, and more efficient.

Preferably, in an advantageous assembly with a spindle drive according to the invention, a first spindle drive allows the assembly to be positively integrated into the track system, while a second spindle drive can provide the necessary positioning function, while furthermore a power supply and a computer-implemented program, Advantageously secured via wireless two-factor authentication, also abbreviated as 2FA, the automatic insertion/removal and tightening/releasing is controlled by the first spindle drive; against this background, the present document also proposes a self-contained sensor assembly as part of a track system, in which a spindle drive according to the invention can advantageously provide the necessary stability of the mechanical connection to the track system and thus provides the track system with a sufficiently stable and particularly easy-to-mount measuring point for multiple data.

Advantageously, the spindle assembly is designed as a spindle drive for a turnout, comprising a power supply and a transmitter. The transmitter, in turn, includes a plug-and-play interface; thus, the assembly can be mounted and automatically integrated into the designated data network, preferably a wireless data network analogous to established IoT cloud applications, during initial operation.

In an advantageous embodiment, the spindle assembly, advantageously designed as a spindle drive for a turnout, comprises supplementary assemblies that address potential additional requirements and loads in the track bed. Depending on the design and structure of the track bed, improper operation or inadequate construction can frequently lead to unusual impact, shock, or shear loads, or to external influences including theft. Such loads can be countered by reinforced composite segments and/or vibration dampers between force-fitted segments; this advantageously avoids both direct weathering/environmental influences and wear due to vibration, thus enabling a significantly increased service life even in adverse environments.

In an advantageous embodiment, the spindle assembly for turnouts is designed for uniform fastening means, preferably comprising a tool-free quick-release device with anti-theft protection. A tool-free quick-release device allows the assembly to be inserted and removed manually; the anti-theft protection is mechanical and/or electronic and only activates after a suitably coded key has been inserted into a lock and/or Upon entering the code, a lock is released, which blocks the quick-release mechanism until then. Preferably, the lock includes a signaling module for sending an alarm in the event of an unauthorized access attempt, most preferably combined with a GPS tracker.

A problem with established systems is that entire tracks must be shut down for replacement and repair, resulting in downtime and financial losses. The advantageously designed mounting system proposed here addresses this problem for the first time. Particularly advantageous is the quick and easy installation with integrated theft protection, which allows for the analysis of entire network sections during operation. This is especially beneficial when using sensor modules that transmit and receive measurement signals bidirectionally over longer track sections. In this context, this description also reveals a potential new application for the proposed module within a quality management system.

Furthermore, by reading the data, personnel tasked with resolving the fault can quickly and efficiently determine from the outside whether a reported fault in the switch section originates from the switch drive, the track superstructure, or the track section itself. This makes accessing track sections more efficient and optimizes fault rectification.

In an advantageous embodiment, the spindle assembly includes devices for analyzing acquired data; typical, relevant information such as train type, number of axles, axle loads, speeds, additional or atypical operating noises, and hazard or failure indicators can be determined, compiled, and made available by comparison with stored data. A problem with established systems is that safety-relevant deviations in passing trains are detected late or not at all; the spindle assembly proposed here addresses this problem for the first time. Uneven loads due to incorrectly loaded wagons, acute and/or permanent deformation of the track bed, compactness and homogeneity of the ballast, voids on or under the sleepers, asymmetric loading of the rails, and the associated high wear are examples of parameters and detectable deviations that can be mitigated by the timely correction of rapidly reinforcing hazards. to effectively counteract subsequent damage/destruction of material.

In an advantageous embodiment, parameters such as rail quality, rail condition, operating noise, sleeper condition, vibrations, movements in the track bed, and small ironwork condition can be individually, preferably correlated, recorded and used for analysis during operation via the spindle assembly in order to support and regulate maintenance and repair more efficiently, both in terms of scope and extent, as well as in identifying and eliminating sources of damage.

In an advantageous embodiment, the spindle assembly comprises devices that can directly or indirectly detect and quantify wear; this is particularly advantageous when combined with a connection to an integrated analysis module or one accessible via data stream. In the particularly preferred combination, the work or performance of the spindle assembly can be quantitatively recorded for the first time, preferably as the basis for a lease-purchase system: With quantifiable wear, such an assembly can, for the first time, be provided for a predefined and payable level of performance/work output. Advantageously, this enables optimal operation in which ecological and economic necessities are reduced to a minimum, service life is maximized, and operational downtime is minimized.

In an advantageous embodiment, a spindle assembly can be connected to a database containing analysis data from a virtual operating model; such data is also referred to as 'Building Information Modeling' and is often abbreviated as 'BIM'. Advantageously, depending on the level of detail of a BIM model, the recorded and transmitted values can be linked to software for controlling and optimizing technical and commercial business processes.

Advantageously, relevant data, such as how and when something was installed, how many movements a switch has already undergone, etc., are used for planned maintenance. This also reveals the use of a data model as a shared data and knowledge platform for all stakeholders, with the data model serving as the basis for decision-making throughout the entire lifespan of a system (from design and construction through to maintenance). The BIM system serves the entire lifecycle (from the operational phase to dismantling). Various stakeholders can use the system in the respective lifecycle phases of the plant/switch to add, retrieve, or edit information. In this way, they support their own work as well as the work of others, since all stakeholders have access to this information.

In an advantageous embodiment, the spindle assembly is designed for data integration into existing and parallel systems. Integration includes data generated directly in the switch drive, as opposed to indirect data from established systems, such as on/off currents within the switch boxes or train data acquired at a third-party level, which only allows indirect conclusions for switch operation.

An independent installation offers the advantage of providing third parties with additional insights. These third parties include manufacturers, suppliers, operators, financiers of track technology, or research institutes operating alongside the infrastructure operator itself.

This approach offers advantages for both manufacturers and authorities (e.g., the European Banking Authority, which monitors the resources used) by enabling them to independently monitor and analyze the product during operation. The resulting transparency also allows for the direct integration of research and development into ongoing operations.

This allows manufacturers to quickly and easily test a new sales approach in the form of guaranteed service lives under given conditions and to price them transparently. Key factors such as axle loads, freight volumes, service frequencies, speeds, train types, track transitions and journeys over switches, as well as temperatures, weather conditions, switch heating operations, maintenance cycles, and the condition of the track superstructure and/or switches can thus be correlated for the first time during operation with minimal to no downtime.

This benefits both manufacturers and service providers/suppliers, enabling them to develop new products including financing, service and maintenance based on reliable data. Compile and offer practice data in a highly transparent manner and, if necessary, adapt it flexibly to actual usage during use.

In an advantageous embodiment, a switching system with the claimed spindle assembly comprises an analysis assembly which detects, stores and subsequently specifies the optimal operating mode of the spindle for different operating conditions, thereby enabling the spindle to be operated with minimal energy consumption.

In an advantageous embodiment, the threaded spindle claimed here is equipped with an endocorporeal sensor cartridge, which enables real-time measurement acquisition and communication for direct data availability and/or evaluation. Condition-based maintenance and monitoring based on delta measurements, trigger detection, identification of damage frequencies, and acceleration sensors become more efficient and cost-effective compared to established standard maintenance, depending on the workload.

Particularly advantageous is the supplementary vibration monitoring during track crossings, which allows conclusions to be drawn about the condition of wheel bearings, wheel discs, and roller bearings of passing vehicles. This information can be conveniently communicated directly to the respective vehicle via wireless interfaces or transmitted as a data packet while passing, thus enabling the fleet owner/operator to arrange for inspection/maintenance at the earliest possible opportunity, and also allowing the infrastructure provider to intervene if necessary.

In an advantageous embodiment, the spindle assembly comprises passive and/or active vandalism and sabotage protection. Passive vandalism protection includes housings and covers that protect sensitive or vulnerable components from unauthorized access, while active vandalism protection includes sensors and alarm systems that detect tampering, preferably evaluate it, and indicate and transmit it via an alarm signal. Advantageously, the active elements are integrated into the assembly in the sensor area and can thus provide increased protection for the system and the network without additional assembly or housing costs.

The integration into a spindle offers the advantage of retrofitting without requiring any modifications to established drives; no additional space needs to be created within or on the drive. Similarly, no safety-related modifications are necessary, as only the mechanically non-relevant internal area of the spindle is adapted.

For track networks with existing control and predictive maintenance mechanisms, the proposed spindle assembly offers the advantageous possibility of an additional, redundant control loop, providing fail-safe protection through a dual system. This is preferably combined with a redundant, additional software system with wireless connectivity, thereby effectively and redundantly implementing the digital component as a parallel system and contributing significantly to superior reliability. Particularly preferably, the spindle assembly includes a communication module which, together with adjacent communication modules of other spindle assemblies, establishes a decentralized peer-to-peer network and provides a parallel emergency communication network for operational data.

In a further, advantageous embodiment, several spindle assemblies according to the invention are used in synchronized control within a track system in the area of high-speed turnouts. Advantageously, at least three force application points of a turnout control system and/or a heat extraction system are combined, their data is recorded, and they are operated in a coupled manner for the synchronized setting of the turnout and the switching of de-icing measures. Particularly preferably, turnout segments up to 300 meters, more preferably 150 to 200 meters, in length are used via eight motors equipped and integrated according to the invention to set a turnout blade, with three drives equipped according to the invention being assigned to a frog. Advantageously, precisely controlled and set turnouts in the diverging branch can be traversed at speeds of up to 600 km/h, more preferably 200 to 550 km/h, and more preferably around 250 km/h. In extreme weather conditions such as... For example, in winter, the track system is advantageously able to maintain the necessary ice-free conditions by monitoring temperature, humidity, the conductivity of the track segments to each other, as well as travel resistances and force curves during operation. To check the switch more precisely and advantageously ensure it by briefly switching on heaters or hot water spray devices.

In a further, advantageous embodiment, a plurality of the spindle assemblies according to the invention are installed across a track system in various functional areas, including track switch drives, force application points, and measuring points. This enables wireless monitoring, regulation, and control of the area of the track bed thus enclosed, generating a meaningful data set. By simply replacing established track switch drives with identical assemblies featuring the spindle according to the invention and supplementing them with spindle assemblies with quick-release devices and their own power supply at other critical points, an existing track system can be retrofitted in a very short time without additional hardware and subsequently operated more efficiently, effectively, and economically. Against this background, the present document also discloses a retrofit kit with which track bed areas can be upgraded and expanded. Existing systems can thus be upgraded quickly and cost-effectively, even temporarily during construction phases, and outdated systems can be put back into operation with the simplest of measures.

INDUSTRIAL APPLICABILITY

Track systems with sensor assemblies in the railway sector typically involve complex housings, expensive communication lines, and bulky form factors to generate data, especially data in the track bed. These form factors and costs are dictated by the necessary quality standards and application scenarios.

The task is to propose a design that makes data more efficiently and economically accessible.

The solution is achieved with a spindle assembly in the railway sector, which has at least one integral and endocorporeal sensor assembly integrated into the spindle assembly.

By arranging the sensor assembly within the enclosed internal volume of a section of a typically continuous component of a spindle drive, a suitably durable housing is provided cost-effectively. Through wireless communication, communication via the power connection, and also measurement generation via the interacting mechanical components, preferably components of a track switch, several properties can be recorded via measurement data, and states can be determined and communicated.

Retrofitting track bed areas, especially track switches, with supplementary control and regulation circuits to quantitatively assess and communicate conditions such as operational readiness, functionality, icing or corrosion is thus made accessible for the first time with a significantly lower cost factor.

Claims (10)

1. A spindle assembly for a track system, the spindle assembly comprising at least one integrated sensor, characterized in that the at least one sensor is integrated in the spindle assembly in the closed interior of the spindle configured for loads on the ton scale via an integral and endocorporeal sensor assembly.
2. The spindle assembly according to the preceding claim, characterized in that the spindle assembly is arranged in the branch region in a rail-borne system, preferably in the track bed region, particularly preferably in at least one encapsulated servomotor of track points.
3. The spindle assembly according to the preceding claim, characterized in that the spindle assembly is configured to detect states of a railway system and to relay them in a digital and/or analog manner to measurement and regulation systems.
4. The spindle assembly according to any one of the preceding claims, characterized in that the spindle assembly is integrated in existing and parallel systems by means of digital and/or analog communication.
5. The spindle assembly according to any one of the two preceding claims, characterized in that the spindle assembly can be connected to further spindle assemblies of the same type by means of digital communication with a peer-to-peer network for emergencies.
6. The spindle assembly according to any one of the preceding claims, characterized in that the spindle assembly comprises a tool-free quick-release device having theft protection, a power supply, and a transmitter.
7. The spindle assembly according to any one of the preceding claims, characterized in that in the spindle assembly, an electrical spindle drive is configured to emulate movement and force profiles of pneumatically regulated thrust mechanisms.
8. The spindle assembly according to any one of the preceding claims, characterized in that the sensor comprises an assembly for synchronization with a time signal.
9. The spindle assembly according to any one of the preceding claims, characterized in that the sensor comprises a multiplex assembly, by means of which data packets can be exchanged to be synchronized with further spindle assemblies of the same type.
10. A track system comprising a plurality of spindle assemblies according to at least one of the preceding claims, wherein the plurality of spindle assemblies, introduced into a track system in a planar manner in the form of track point drives, force action points, and also measurement points, provide wireless monitoring, regulation, and control of a region of a track bed surrounded in a planar manner.