The paper is dedicated to the development of a specialized tensometric force sensor which will be implemented in railway wayside monitoring systems. The developed sensor will be a basis to implement number of facilities for control on wheel load of railway vehicles in motion. The global goal is the improvement of the main engineering and economic indicators: reducing wear of wheel and track; reducing failures and damages in the wheeled part of rail vehicles, increasing the inter-repair runs; improving the comfort of riding, etc. The innovation aspect in the paper is optimization in the sensor structure by mathematical modelling and numerical examination on its behavior by varying geometric parameters and under different model of loading. The optimization of the sensor structure is achieved by: creating of a 3D model of the sensor; determining deformation and stress states of the sensor under load; optimizing the sensor geometric dimensions in order to increase its sensitivity; extending the measuring range of the sensor and accuracy of measurement. Simulation of the sensor model is performed with characteristics modes of loading. Also a new technology for management and control on the process of polymerization of strain-gauge rosettes is developed. The technology includes low temperature curing process with precise computer control system, developed specially for this purpose. The results obtained from the advanced sensor have confirmed the possibility to measure the loads of railway vehicles in motion at an operating speed. The force sensor has been tested under laboratory conditions and is fir for implementation in practice.

force measurement; railways; modelling; numerical analysis; monitoring systems