Manufacturing system, method and application of casting part embedded with fiber grating sensor

Abstract

The invention discloses a manufacturing system, method and application of a casting part embedded with a fiber grating sensor, and relates to the technical field of nondestructive detection.The system comprises the casting part embedded with the fiber grating sensor, obtained through a pouring process, used for sensing the internal strain, temperature and vibration signals of the casting part through the fiber grating sensor, converting the signal into an optical signal; the laser emitting device is used for emitting laser to the casting part embedded with the fiber grating sensor; the signal processing module is electrically connected with the fiber grating sensor and is used for receiving and processing the optical signal and converting the optical signal into internal strain, temperature and vibration data; and the data analysis module is used for receiving the internal strain, temperature and vibration data transmitted by the signal processing module in real time so as to analyze the structural health state of the casting part embedded with the fiber grating sensor. According to the invention, the fiber grating sensor is directly embedded into the casting part, so that the structure parameters of the casting part can be accurately monitored in real time.

Description

Technical Field

[0001] The invention relates to the technical field of nondestructive testing, and in particular to a manufacturing system, method and application of a casting embedded with a fiber grating sensor. Background Art

[0002] Structural health monitoring technology is an advanced technology that integrates sensor elements into the components to obtain real-time structural health status information. The core idea of ​​the technology is to adopt the new concept of intelligent material structure and embed advanced sensing and driving elements directly into the monitored structure to obtain important information related to the structural health status online and in real time, including stress, strain, temperature, etc. By combining advanced signal processing methods and material structure mechanics modeling technology, characteristic parameters related to structural damage can be extracted, and then the health status and potential damage of the structure can be identified. This technology is of great significance in the self-diagnosis, self-repair and safety assurance of engineering structures, and can effectively monitor the health of structures and extend their service life. Fiber optic sensing technology has been widely used in strain measurement, vibration monitoring and other fields due to its high sensitivity, anti-electromagnetic interference, and high temperature resistance. Fiber optic sensors can work in extreme environments, so they are particularly widely used in complex structures. At present, fiber optic sensing technology is mainly realized by Bragg grating (FBG) sensors, which can sense the stress and strain of structures by monitoring the wavelength changes of light waves in optical fibers.

[0003] However, the traditional installation method of optical fiber sensors is mainly surface pasting or external fixing. Although this method is simple, it is easily disturbed by factors such as mechanical damage and temperature changes in the external environment, resulting in reduced measurement accuracy and stability of the sensor. Especially in dynamic and complex environments, this installation method cannot ensure long-term and reliable monitoring effects.

[0004] In addition, in terms of internal strain measurement of structures, the development of fiber optic sensor embedding technology is relatively lagging. The main reason is that embedding fiber optic sensors inside materials will damage the sensors and affect their performance. Embedding technology using laser remelting technology will cause thermal damage to the optical fiber and interface destruction due to the thermal effect of the laser heat source. In addition, embedding technologies such as ultrasonic additive manufacturing cannot ensure good bonding between the optical fiber and the structural material, resulting in insufficient sensor sensing ability for strain and vibration, affecting the sensitivity and reliability of the measurement.

[0005] Therefore, there is an urgent need for a solution that can perform non-destructive and accurate monitoring of components. Summary of the invention

[0006] The purpose of the present invention is to provide a system, method and application for manufacturing a casting embedded with a fiber grating sensor. By directly embedding the fiber grating sensor into the casting, the influence of the external environment on the sensor measurement is effectively avoided, so that the fiber grating sensor can monitor the strain, vibration and other structural parameters inside the casting in real time and accurately.

[0007] To achieve the above object, the present invention provides the following solutions: A system for manufacturing a casting embedded with a fiber grating sensor, comprising: A mold, wherein the mold is composed of a movable mold and a fixed mold, and a fixing piece for fixing the capillary is arranged above the fixed mold; The fixed mold is provided with a concave flow channel at the same position inside the fixed mold, so as to allow the injected molten metal to flow from the lower part to the upper part of the fiber grating sensor through the concave flow channel until the cavity where the filter is located is filled; The capillary penetrates into one side of the concave flow channel, so as to allow the fiber grating sensor to penetrate and guide the fiber grating sensor to a correct position in the fixed mold; The capillary is divided into two sections, an upper section and a lower section, so that the upper section and the lower section of the fiber grating sensor are both inside the capillary, and the middle section of the fiber grating sensor is exposed; A gate is arranged above the mold, and the gate is communicated with the bottom flow channel of the concave flow channel, and is used to inject molten metal into the cavity of the mold through the gate. After the molten metal is completely solidified, the movable mold is removed, and the cast part embedded with the fiber grating sensor is taken out from the fixed mold.

[0008] Furthermore, the capillary is an aluminum alloy capillary, and the inner diameter of the aluminum alloy capillary is slightly larger than the diameter of the fiber grating sensor.

[0009] Furthermore, the fixed mold includes at least two capillaries, and the casting is a metal component.

[0010] The present invention also provides a method for manufacturing a casting embedded with a fiber grating sensor, which is applied to the manufacturing system of the casting embedded with a fiber grating sensor, and comprises the following steps: S1, installing two capillaries fixed at one end by a fixing member to the upper and lower positions of the fixed mold respectively; S2, assembling the movable mold and the fixed mold together to form a cavity defining the fiber Bragg grating sensor; S3, inserting the fiber grating sensor into the capillary tube so that the upper part and the lower part of the fiber grating sensor are protected in the capillary tube; S4, preheating the fixed mold; S5, pouring molten metal through the gate on the fixed mold, so that the molten metal is injected into the cavity of the fixed mold; the molten metal flows and wraps the middle part of the fiber grating sensor when filling the fixed mold, and the fiber grating sensor is embedded in the casting during the cooling and solidification process of the molten metal; after the metal is completely solidified, the movable mold is removed, and the casting with the embedded fiber grating sensor is taken out from the fixed mold.

[0011] Furthermore, the S4, preheating the fixed mold, specifically includes: making the preheating temperature reach 300-600° C. before pouring.

[0012] The present invention also provides an intelligent monitoring system for a casting embedded with a fiber grating sensor manufactured based on the manufacturing method, comprising: A casting embedded with a fiber Bragg grating sensor is used to sense internal strain, temperature and vibration signals of the casting through the fiber Bragg grating sensor and convert them into optical signals; A laser emitting device, used for sending a pulse signal to the fiber grating sensor embedded in the casting; A signal processing module, electrically connected to the fiber grating sensor, for receiving and processing the optical signal and converting it into internal strain, temperature and vibration data; The data analysis module is used to receive the internal strain, temperature and vibration data transmitted by the signal processing module in real time to analyze the structural health status of the casting embedded with the fiber grating sensor.

[0013] Furthermore, the signal processing module includes a demodulation device, a filter and an amplifier, wherein the filter is used to filter the optical signal transmitted by the optical fiber sensor, the amplifier is used to amplify the filtered signal, and the demodulation device is used to demodulate the amplified signal to extract internal strain, temperature and vibration data.

[0014] Furthermore, the data analysis module includes a data acquisition unit, a data processing unit and an alarm unit. The data acquisition unit is used to collect internal stress, temperature and vibration data from the signal processing module in real time and transmit them to the data processing unit; the data processing unit performs analysis and modeling based on the collected data to obtain the internal stress distribution, vibration characteristics and temperature information of the casting embedded with the fiber grating sensor; the alarm unit is used to issue an alarm when abnormal stress, temperature or vibration signals are monitored.

[0015] Furthermore, the alarm module is used to trigger an alarm when the abnormal stress or vibration signal exceeds a set threshold and mark the abnormal location.

[0016] According to the specific embodiments provided by the present invention, the present invention discloses the following technical effects: Realize real-time and accurate monitoring: The intelligent monitoring system for castings based on embedded fiber grating sensors provided by the present invention directly embeds the fiber optic sensors inside the castings, so that the fiber optic sensors can monitor the strain, vibration and other structural parameters inside the castings in real time and accurately. Compared with traditional surface mounting technology, the present invention can effectively avoid the influence of the external environment on the sensor measurement, greatly improving the accuracy and reliability of monitoring.

[0017] The present invention uses a casting process to embed the optical fiber sensor into the interior of the casting, which can directly contact the casting material, avoiding interference from the external environment on the measurement results, such as mechanical damage, temperature changes and electromagnetic interference, thereby significantly extending the service life of the sensor. This embedded design ensures the stability and reliability of the sensor under long-term, high-load working conditions, and enables the sensor to more accurately reflect the actual strain and vibration conditions inside the casting, greatly improving the measurement accuracy and reliability. Traditional optical fiber sensor installation requires complex surface pasting or fixing processes, while the present invention completes the embedding of the optical fiber sensor in one step through a casting process, avoiding the use of adhesives or other additional materials, simplifying the production process, shortening the manufacturing cycle, and greatly improving production efficiency.

[0018] Improve the durability and service life of the sensor: The embedded design of the present invention fully utilizes the high temperature and high pressure conditions in the casting process, does not require additional installation materials or energy input, and saves the raw materials and energy required in the production process. At the same time, it reduces the material waste caused by adhesive aging or improper installation in traditional processes.

[0019] The present invention realizes intelligent real-time monitoring of internal strain and vibration of castings by combining with the data analysis platform. When abnormalities are detected, the system can issue early warnings in time, allowing users to take quick measures to prevent structural damage, reduce equipment maintenance costs, and improve the overall safety of the equipment.

[0020] The monitoring system of the present invention can be widely applied to various metal castings. It not only does not change the original casting process and materials, but also has the advantages of environmental protection and energy saving, and meets the requirements of modern manufacturing industry for sustainable development and green manufacturing.

[0021] In summary, the present invention significantly improves the accuracy and reliability of internal strain and vibration monitoring of castings through innovative casting embedding technology, extends the service life of sensors, simplifies the installation process, and realizes intelligent and real-time structural health monitoring. It has broad application prospects and significant economic benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0023] Figure 1 A structural diagram of a manufacturing system for a casting embedded with a fiber grating sensor according to the present invention; Figure 2 A schematic diagram of the structure of an embedded fiber Bragg grating sensor according to an embodiment of the present invention; Figure 3 It is a structural schematic diagram of an intelligent monitoring system for castings based on embedded fiber grating sensors according to an embodiment of the present invention; Explanation of the reference numerals: 1-fiber Bragg grating sensor, 2-aluminum alloy capillary, 3-mold, 4-gate, 5-runner, 6-filter, 7-laser transmitter, 8-metal component embedded with fiber Bragg grating sensor, 9-signal processing module, 10-data analysis platform, 11-coated fiber Bragg grating sensor, 12-fiber Bragg grating sensor with coating removed, 13-fiber Bragg grating. DETAILED DESCRIPTION

[0024] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0025] The purpose of the present invention is to provide a system, method and application for manufacturing a casting embedded with a fiber grating sensor. By directly embedding the fiber grating sensor into the casting, the influence of the external environment on the sensor measurement is effectively avoided, so that the fiber grating sensor can monitor the strain, vibration and other structural parameters inside the casting in real time and accurately.

[0026] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0027] Example 1 like Figure 1 As shown, a system for manufacturing a casting embedded with a fiber grating sensor comprises: A mold, wherein the mold is composed of a movable mold and a fixed mold, and a fixing piece for fixing the capillary is arranged above the fixed mold; The fixed mold is provided with a concave flow channel at the same position inside the fixed mold, so as to allow the injected molten metal to flow from the lower part to the upper part of the fiber grating sensor through the concave flow channel until the cavity where the filter is located is filled; The capillary penetrates into one side of the concave flow channel, so as to allow the fiber grating sensor to penetrate and guide the fiber grating sensor to a correct position in the fixed mold; The capillary is divided into two sections, an upper section and a lower section, so that the upper section and the lower section of the fiber grating sensor are both inside the capillary, and the middle section of the fiber grating sensor is exposed; A gate is arranged above the mold, and the gate is communicated with the bottom flow channel of the concave flow channel, and is used to inject molten metal into the cavity of the mold through the gate. After the molten metal is completely solidified, the movable mold is removed, and the cast part embedded with the fiber grating sensor is taken out from the fixed mold.

[0028] Specifically, after the movable mold and the fixed mold are combined together, the concave flow channels in the movable mold and the fixed mold will form a channel. At this time, pouring can make the molten metal fill the entire cavity.

[0029] In this embodiment, the capillary is an aluminum alloy capillary, and the inner diameter of the aluminum alloy capillary is slightly larger than the diameter of the fiber grating sensor.

[0030] In this embodiment, the fixed mold includes at least two capillaries, and the casting is a metal component.

[0031] In this embodiment, the fixed mold is further equipped with a heating module to make the preheating temperature reach 300-600° C. before pouring. The heating module is specifically a heating rod.

[0032] In this embodiment, a filter is provided below the pouring gate for filtering slag from the molten metal.

[0033] In this embodiment, the molten metal is aluminum.

[0034] In this embodiment, during the solidification process of the molten metal, the system further includes a feeder for providing sufficient molten aluminum to prevent cavities and gaps from being generated between the optical fiber and the metal due to shrinkage.

[0035] Example 2 The embodiment of the present invention provides a method for manufacturing a casting embedded with a fiber Bragg grating sensor, which is applied to the manufacturing system of the casting embedded with a fiber Bragg grating sensor described in Example 1, and comprises the following steps: S1, installing two capillaries fixed at one end by an external fixing member to the upper and lower positions of the fixed mold respectively; S2, assembling the movable mold and the fixed mold together to form a cavity defining the fiber Bragg grating sensor; S3, inserting the fiber grating sensor into the capillary tube so that the upper part and the lower part of the fiber grating sensor are protected in the capillary tube; S4, preheating the fixed mold; S5, pouring molten metal through the gate on the fixed mold, so that the molten metal is injected into the cavity of the fixed mold; the molten metal flows and wraps the middle part of the fiber grating sensor when filling the fixed mold, and the fiber grating sensor is embedded in the casting during the cooling and solidification process of the molten metal; after the metal is completely solidified, the movable mold is removed, and the casting with the embedded fiber grating sensor is taken out from the fixed mold.

[0036] In this embodiment, the method further includes: during the cooling and solidification of the molten metal, the heat inside the mold can be taken away more quickly through the liquid cooling channels inside the mold and the circulating cooling medium in these liquid cooling channels, thereby more effectively controlling the temperature of the mold. Through intelligent centralized control, the mold temperature is controlled, including temperature, flow, pressure and other setting monitoring and data collection, to achieve digital management, more conveniently increase or decrease oil, water, point and other temperature control equipment, and quickly optimize the adjustment of temperature / flow / pressure data of each mold temperature zone in production to ensure that the fiber Bragg grating sensor can withstand the thermal stress caused by cooling. The cooling rate can also be adjusted according to the thermal expansion characteristics of the material to avoid damage to the fiber Bragg grating sensor.

[0037] In this embodiment, the S4, preheating the fixed mold, specifically includes: making the preheating temperature reach 300-600° C. before pouring.

[0038] In this embodiment, the method further comprises: removing the coating at 10 cm around the fiber Bragg grating sensor to prevent the coating from burning when exposed to molten metal.

[0039] In a further embodiment, the method for manufacturing the casting embedded with the fiber grating sensor specifically comprises the following steps: Step 1, pretreatment and installation of cast aluminum alloy capillary, select aluminum alloy capillary with outer diameter of 0.8mm, inner diameter of 0.6mm and length of 30cm for treatment. One end of the capillary is provided with a cap with holes, through which the capillary is fixed between the upper and lower molds. The main function of the capillary is to guide the fiber grating sensor into the accurate position in the mold and maintain its stability during the casting process.

[0040] Step 2, assemble the movable mold with the fixed mold to form a cavity that defines the fiber Bragg grating sensor. The design of the mold ensures that the optical fiber can remain stable and in close contact with the metal component during the casting process. The cavity design takes into account the stress and temperature changes that the optical fiber may be subjected to during the casting process.

[0041] Step 3, pre-treatment and installation of the optical fiber sensor. The optical fiber sensor is made of sapphire optical fiber, which can maintain reliability at temperatures up to 1400°C. The coating of 10 cm near the fiber grating sensor is removed to ensure that the fiber grating can directly contact the metal component. The optical fiber is fed into the capillary so that the upper and lower parts of the fiber grating are protected by the capillary, while the middle part is in direct contact with the metal component. Subsequently, the optical fiber is fixed in the capillary with silicone grease to prevent the optical fiber from shifting during the casting process.

[0042] Step 4 is to preheat the metal capillary and the mold to 400° C. The purpose is to prevent the aluminum alloy melt from solidifying quickly when poured into the mold cavity and to reduce the thermal stress generated during solidification.

[0043] Step 5, AlSi10Mg aluminum alloy is heated to 700℃, and molten aluminum is poured into the mold cavity through the molten metal pouring system. The aluminum liquid enters the cavity from the runner at the bottom of the mold and gradually fills the top of the mold. The casting temperature is controlled at 700℃~750℃, the holding pressure is controlled at 0.45MPa~0.7MPa, and the holding time is 10 minutes. The aluminum liquid covers the fiber Bragg grating sensor during the flow process. Since the optical fiber has been fixed, the fiber Bragg grating sensor will be embedded in the metal component during the cooling and solidification process of the aluminum alloy.

[0044] During the metal cooling and solidification process, an appropriate cooling control system is used to ensure that the fiber Bragg grating sensor can withstand the thermal stress caused by cooling. The temperature control system of the mold adjusts the cooling rate according to the thermal expansion characteristics of the material to avoid damage to the fiber optic sensor. The holding pressure is controlled between 0.45MPa and 0.7MPa to ensure that there is sufficient back pressure after the aluminum liquid is filled, so that the solidification shrinkage defects of the aluminum liquid will not occur.

[0045] Step 6: After the metal is completely solidified, the movable mold is removed and the cast metal component is taken out. At this point, the fiber grating sensor has been embedded in the aluminum alloy component, and the entire process ensures the integrity and measurement accuracy of the sensor.

[0046] The method described in this embodiment ensures the safety and stability of the fiber grating sensor during the casting process; it not only improves the embedding efficiency of the sensor, but also ensures the high reliability of the final product.

[0047] Example 3 like Figure 3As shown, the embodiment of the present invention further provides an application of the casting embedded with the fiber Bragg grating sensor as described in embodiment 1 or embodiment 2, and specifically provides an intelligent monitoring system based on the casting embedded with the fiber Bragg grating sensor, comprising: A casting embedded with a fiber Bragg grating sensor is used to sense internal strain, temperature, vibration and other signals of the casting through the fiber Bragg grating sensor and convert them into optical signals; A laser emitting device, used for sending a pulse signal to the fiber grating sensor embedded in the casting; The signal processing module is electrically connected to the fiber grating sensor, and is used to receive and process the optical signal and convert it into data such as internal strain, temperature and vibration; The data analysis module is used to receive in real time the internal strain, temperature, vibration and other data transmitted by the signal processing module to analyze the structural health status of the casting embedded with the fiber grating sensor.

[0048] In this embodiment, the signal processing module includes a demodulation device, a filter and an amplifier. The filter is used to filter the optical signal transmitted by the optical fiber sensor, the amplifier is used to amplify the filtered signal, and the demodulation device is used to demodulate the amplified signal to extract preliminary internal strain, temperature and vibration data.

[0049] In this embodiment, the data analysis module includes a data acquisition unit, a data processing unit and an alarm unit. The data acquisition unit is used to collect the internal stress, temperature and vibration data from the signal processing module in real time and transmit them to the data processing unit; the data processing unit analyzes and models the collected data to obtain the internal stress distribution, vibration characteristics, and temperature information of the casting embedded with the fiber grating sensor, and identify possible structural abnormalities; the alarm unit is used to issue an alarm when abnormal stress, temperature or vibration signals are monitored, so as to perform preventive maintenance.

[0050] In this embodiment, the alarm module is used to trigger an alarm when the abnormal stress or vibration signal exceeds a set threshold and mark the abnormal position.

[0051] In this embodiment, liquid cooling channels are also provided inside the mold. During the cooling and solidification process of the molten metal, the circulating cooling medium in these liquid cooling channels can remove the heat inside the mold more quickly, thereby more effectively controlling the temperature of the mold.

[0052] In this embodiment, the system also includes an acquisition module and a temperature control module; the acquisition module is used to collect the stress and temperature data of the mold; the temperature control module is used to adjust the temperature of the mold to ensure that the mold temperature remains in the optimal range during the entire production process. The temperature control module includes an oil temperature machine, a water temperature machine, and a point temperature device; wherein the oil temperature machine is used to control the mold temperature through the circulation of hot oil, to increase and control the temperature inside the mold during preheating; the water temperature machine is used to be turned on during pouring / die-casting, using water as a heat transfer medium, to control the mold temperature through water circulation, and to control the temperature during the die-casting process; the point temperature device is used to perform local temperature control of the mold, that is, to adjust the temperature of the designated part of the mold to ensure that the temperature of the designated area remains in an ideal state. In a further embodiment, the die-casting mold includes multiple temperature control areas such as the gate area, the runner area, and the cavity area. Each area sets independent temperature control parameters according to different functions and process requirements, thereby improving molding quality and efficiency. Based on these structures, the present invention realizes intelligent centralized control of mold temperature, and can also conveniently increase or decrease oil, water, point and other temperature control equipment, and quickly optimize the adjustment of temperature / flow / pressure data of each temperature control area in production, ensuring that the fiber Bragg grating sensor can withstand the thermal stress caused by cooling. And the cooling rate can be adjusted according to the thermal expansion characteristics of the material to avoid damage to the fiber Bragg grating sensor.

[0053] In summary, the intelligent monitoring system for castings based on embedded fiber grating sensors provided by the present invention, because the fiber optic sensor is pre-embedded into the casting through the casting process, there is no need for subsequent processes such as strain gauges and fiber laser pasting, so that it can achieve real-time monitoring of internal strain, vibration and other parameters of the component without changing the casting material and process, thereby achieving the purpose of improving the reliability of the sensor and ensuring the accuracy of monitoring, and solving the problems of low measurement accuracy, poor sensor durability and complex installation in the existing component health monitoring technology. The present invention has the following characteristics: 1. The present invention can be applied to a variety of metal component materials and is widely used in aviation, automobiles, construction and other fields. Through an efficient data acquisition and processing system, it is possible to monitor the component status in real time and detect potential problems in a timely manner. Through advanced fiber optic sensing technology, the system can accurately sense the stress, vibration and temperature changes inside the metal component to ensure the accuracy of the monitoring results. Through this method and system, fiber optic sensors can be effectively embedded and real-time monitoring can be performed to ensure the safety and stability of components in high-stress environments.

[0054] 2. Improve the durability and service life of the sensor Resistance to high temperature and high pressure environment: The present invention uses a casting process to embed the optical fiber sensor into the casting, so that it can be protected in a high temperature and high pressure casting environment, avoiding damage that the sensor may suffer in traditional installation methods. The thermal expansion coefficient of the aluminum substrate matches that of the casting material, reducing thermal stress during the cooling stage, helping to extend the service life of the optical fiber sensor and ensuring its stable performance under extreme working conditions.

[0055] 3. Process simplification and improved production efficiency Adhesive-free design: Traditional embedding technology usually requires the use of adhesives to fix the optical fiber sensor on the surface or inside the casting, which not only increases the production process, but may also lead to problems such as insufficient bonding strength or adhesive aging. The present invention directly embeds the sensor into the casting through the casting process, eliminating the step of using adhesives, simplifying the manufacturing process, shortening the production cycle, and thus improving production efficiency.

[0056] 4. Save materials and energy Reduced material waste: Traditional sensor installation methods may require additional installation structures or protective layers, which increases material consumption. The embedded design of the present invention not only reduces the use of these additional materials, but also makes full use of the high temperature and high pressure environment generated during the casting process, so that the sensor and the casting are integrated, further saving raw materials and energy consumption.

[0057] Optimized energy utilization: By embedding the sensor directly into the casting, the present invention utilizes the heat and pressure inherent in the casting process, allowing the sensor to be embedded without increasing additional energy consumption, effectively improving energy utilization efficiency.

[0058] 5. Improve the real-time and intelligent nature of structural health monitoring Real-time online monitoring: The fiber optic sensor embedded in the present invention can obtain real-time data such as strain, vibration and temperature inside the casting, and analyze it through the signal processing system. This real-time monitoring capability provides timely and accurate data support for structural health diagnosis, which helps to warn in advance and prevent potential structural damage.

[0059] Intelligent diagnosis and control: By combining with advanced signal processing technology and structural health monitoring system, the fiber optic sensing system created by the present invention can automatically identify the state changes of castings and perform intelligent diagnosis and control based on the monitoring results, thereby reducing maintenance costs and improving the safety and reliability of castings.

[0060] 6. Since the present invention reduces the use of adhesives and other chemical materials, the risk of environmental pollution in the production process is reduced. In addition, the saving of energy and materials also indirectly reduces carbon emissions, which helps to achieve a more environmentally friendly production process. The present invention simplifies the production process and material use, reduces the generation of waste in the production process, and further promotes sustainable production and green manufacturing.

[0061] In summary, the present invention not only improves the accuracy and reliability of strain and vibration monitoring inside castings by optimizing the embedding method of optical fiber sensors, but also significantly improves production efficiency and the service life of sensors, reduces material and energy consumption, and realizes smarter and more environmentally friendly structural health monitoring. The application of this technical solution provides strong technical support for high-precision and real-time monitoring, and has broad application prospects and significant economic benefits.

[0062] The remaining technical features in this embodiment can be flexibly selected by those skilled in the art according to actual conditions to meet different specific practical needs. However, it is obvious to those skilled in the art that it is not necessary to adopt these specific details to implement the present invention. In other examples, in order to avoid confusing the present invention, the well-known components, structures or parts are not specifically described, which are all within the technical protection scope defined by the technical solution claimed for protection in the claims of the present invention.

[0063] Modifications and changes made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the scope of protection of the claims attached to the present invention. In the above description, a large number of specific details are set forth in order to provide a thorough understanding of the present invention. However, it is obvious to those of ordinary skill in the art that these specific details are not necessary to practice the present invention. In other examples, in order to avoid confusing the present invention, well-known technologies, such as specific construction details, operating conditions and other technical conditions, are not specifically described.

[0064] The principles and implementation methods of the present invention are described in this article using specific examples. The description of the above embodiments is only used to help understand the method and core idea of ​​the present invention. At the same time, for those skilled in the art, according to the idea of ​​the present invention, there will be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as limiting the present invention.

Claims

1. A system for manufacturing a casting embedded with a fiber grating sensor, characterized in that: include: A mold, wherein the mold is composed of a movable mold and a fixed mold, and a fixing piece for fixing the capillary is arranged above the fixed mold; The fixed mold is provided with a concave flow channel at the same position inside the fixed mold, so as to allow the injected molten metal to flow from the lower part to the upper part of the fiber grating sensor through the concave flow channel until the cavity where the filter is located is filled; The capillary penetrates into one side of the concave flow channel, so as to allow the fiber grating sensor to penetrate therein and guide the fiber grating sensor to a correct position in the fixed mold; The capillary is divided into two sections, an upper section and a lower section, so that the upper section and the lower section of the fiber grating sensor are both inside the capillary, and the middle section of the fiber grating sensor is exposed; A gate is arranged above the mold, and the gate is communicated with the bottom flow channel of the concave flow channel, and is used to inject molten metal into the cavity of the mold through the gate. After the molten metal is completely solidified, the movable mold is removed, and the cast part embedded with the fiber grating sensor is taken out from the fixed mold.

2. The system for manufacturing a casting with an embedded fiber Bragg grating sensor according to claim 1, characterized in that: The capillary is an aluminum alloy capillary, and the inner diameter of the aluminum alloy capillary is slightly larger than the diameter of the fiber grating sensor.

3. The system for manufacturing a casting with an embedded fiber Bragg grating sensor according to claim 1, characterized in that: The fixed mold includes at least two capillaries, and the casting is a metal component.

4. A method for manufacturing a casting embedded with a fiber Bragg grating sensor, applied to the manufacturing system of a casting embedded with a fiber Bragg grating sensor according to any one of claims 1 to 3, characterized in that: The following steps are involved: S1, installing two capillaries fixed at one end by a fixing member to the upper and lower positions of the fixed mold respectively; S2, assembling the movable mold and the fixed mold together to form a cavity defining the fiber Bragg grating sensor; S3, inserting the fiber grating sensor into the capillary tube so that the upper part and the lower part of the fiber grating sensor are protected in the capillary tube; S4, preheating the fixed mold; S5, pouring molten metal through the gate on the fixed mold, so that the molten metal is injected into the cavity of the fixed mold; the molten metal flows and wraps the middle part of the fiber grating sensor when filling the fixed mold, and the fiber grating sensor is embedded in the casting during the cooling and solidification process of the molten metal; after the metal is completely solidified, the movable mold is removed, and the casting with the embedded fiber grating sensor is taken out from the fixed mold.

5. The method for manufacturing a casting embedded with a fiber grating sensor according to claim 4, characterized in that: The S4, preheating the fixed mold, specifically includes: making the preheating temperature reach 300-600° C. before pouring.

6. An intelligent monitoring system for a casting with an embedded fiber grating sensor manufactured by the manufacturing method according to any one of claims 4 to 5, characterized in that: include: A casting embedded with a fiber Bragg grating sensor is used to sense internal strain, temperature and vibration signals of the casting through the fiber Bragg grating sensor and convert them into optical signals; A laser emitting device, used for sending a pulse signal to the fiber grating sensor embedded in the casting; A signal processing module, electrically connected to the fiber grating sensor, for receiving and processing the optical signal and converting it into internal strain, temperature and vibration data; The data analysis module is used to receive the internal strain, temperature and vibration data transmitted by the signal processing module in real time to analyze the structural health status of the casting embedded with the fiber grating sensor.

7. The intelligent monitoring system according to claim 6, characterized in that: The signal processing module includes a demodulation device, a filter and an amplifier. The filter is used to filter the optical signal transmitted by the optical fiber sensor, the amplifier is used to amplify the filtered signal, and the demodulation device is used to demodulate the amplified signal to extract internal strain, temperature and vibration data.

8. The intelligent monitoring system according to claim 6, characterized in that: The data analysis module includes a data acquisition unit, a data processing unit and an alarm unit. The data acquisition unit is used to collect the internal stress, temperature and vibration data from the signal processing module in real time and transmit them to the data processing unit; the data processing unit analyzes and models the collected data to obtain the internal stress distribution, vibration characteristics and temperature information of the casting embedded with the fiber grating sensor; the alarm unit is used to issue an alarm when abnormal stress, temperature or vibration signals are monitored.

9. The intelligent monitoring system according to claim 8, characterized in that: The alarm module is used to trigger an alarm when the abnormal stress or vibration signal exceeds a set threshold and mark the abnormal position.

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