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The unilateral axle counting sensor is an important railway signal device that detects a train. For efficient and stable detection, the amplitude of induced electromotive force and its changes must be big enough. Therefore, the purpose of this study is to find a way to design and optimize the sensor structure quickly and accurately.

With the help of extensive electromagnetic field calculations, the study puts forward a modified model based on the finite element method, establishes an independent air domain around the sensor, wheel and the railway and adopts a unique grid division method. It offers a design optimization method of the induction coil angles and its spatial location with respect to the excitation coil by using the combination weighting algorithm.

The modified modeling method can greatly reduce the number of finite element mesh and the operation time, and the method can also be applied to other areas. The combination weighting algorithm can optimize the structure of the sensor quickly and accurately.

This study provides a way to design and optimize the structure of the sensor and a theoretical basis for the development. The results can improve and expand the technology of the axle counting sensor.