System, method and application for manufacturing a cast part embedding a fiber bragg grating sensor

Abstract

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

Description

Technical Field

[0001] This invention relates to the field of nondestructive testing technology, and in particular to a system, method, and application for fabricating castings with embedded fiber Bragg grating sensors. Background Technology

[0002] Structural health monitoring technology is an advanced technology that integrates sensing elements within structural components to acquire real-time information on the structural health status. The core idea is to adopt a novel concept of smart material structures, directly embedding advanced sensing and actuation elements into the monitored structure to acquire crucial information related to structural health, including stress, strain, and temperature, online in real time. By combining advanced signal processing methods and material structure mechanics modeling techniques, characteristic parameters related to structural damage can be extracted, thereby identifying the structure's health status and potential damage. This technology is significant for the self-diagnosis, self-repair, and safety assurance of engineering structures, effectively monitoring structural health and extending their service life. Fiber optic sensing technology, due to its high sensitivity, resistance to electromagnetic interference, and high-temperature resistance, has been widely used in strain measurement, vibration monitoring, and other fields. Fiber optic sensors can operate in extreme environments, making their application particularly widespread in complex structures. Currently, fiber optic sensing technology is mainly implemented through Bragg grating (FBG) sensors, which can sense the stress and strain of a structure by monitoring changes in the wavelength of light waves in the optical fiber.

[0003] However, traditional fiber optic sensors are mainly installed by surface bonding or external fixation. While this method is simple, it is susceptible to interference from external environmental factors such as mechanical damage and temperature changes, leading to a decrease in the sensor's measurement accuracy and stability. Especially in dynamic and complex environments, this installation method cannot guarantee long-term reliable monitoring results.

[0004] Furthermore, the development of fiber optic sensor embedding technology in structural strain measurement has lagged behind. This is primarily because embedding fiber optic sensors within materials can damage them, affecting their performance. Laser remelting embedding techniques can cause thermal damage to the fiber and interface failure due to the thermal effect of the laser heat source. Additionally, embedding techniques such as ultrasonic additive manufacturing cannot ensure good adhesion between the fiber and the structural material, resulting in insufficient sensor sensitivity to strain and vibration, thus affecting measurement sensitivity and reliability.

[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 this invention is to provide a system, method and application for manufacturing castings with embedded fiber Bragg grating sensors. By directly embedding the fiber Bragg grating sensor inside the casting, the influence of the external environment on the sensor measurement is effectively avoided, enabling the fiber Bragg grating sensor to monitor the structural parameters such as strain and vibration inside the casting in real time and accurately.

[0007] To achieve the above objectives, the present invention provides the following solution:

[0008] A system for fabricating a casting with an embedded fiber Bragg grating sensor, comprising:

[0009] The mold consists of a movable mold and a fixed mold, with a fixing component for fixing the capillary tube provided above the fixed mold;

[0010] The fixed mold and the corresponding position inside the fixed mold are provided with concave flow channels, which are used to allow the injected molten metal to flow from the bottom to the top of the fiber optic grating sensor through the concave flow channels until the cavity where the filter is located is filled.

[0011] The capillary tube is inserted into one side of the concave flow channel to allow the fiber Bragg grating sensor to pass through and guide the fiber Bragg grating sensor to the correct position in the fixed mold.

[0012] The capillary is divided into upper and lower sections, so that the upper and lower parts of the fiber Bragg grating sensor are both inside the capillary, while the middle part of the fiber Bragg grating sensor is exposed.

[0013] A gate is provided above the mold, and the gate is connected to the bottom channel of the concave flow channel. It is used to inject molten metal into the cavity of the mold through the gate. After the molten metal has completely solidified, the movable mold is removed and the casting of the embedded fiber optic grating sensor is taken out from the fixed mold.

[0014] 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 optic grating sensor.

[0015] Furthermore, the fixed mold includes at least two capillaries, and the casting is a metal component.

[0016] This invention also provides a method for manufacturing a casting with an embedded fiber Bragg grating sensor, applied to the aforementioned system for manufacturing such a casting, comprising the following steps:

[0017] S1, Install two capillary tubes, one end of which is fixed by a fastener, onto the upper and lower positions of the fixed mold respectively;

[0018] S2, the movable mold and the fixed mold are assembled together to form a cavity that defines the fiber optic grating sensor;

[0019] S3, the fiber Bragg grating sensor is fed into the capillary tube so that both the upper and lower parts of the fiber Bragg grating sensor are protected inside the capillary tube.

[0020] S4, Preheat the fixed mold;

[0021] S5. Molten metal is poured through the gate on the fixed mold, so that the molten metal is injected into the cavity of the fixed mold. When the molten metal fills the fixed mold, it flows and wraps around the middle part of the fiber optic grating sensor. During the cooling and solidification process of the molten metal, the fiber optic grating sensor is embedded in the casting. After the metal is completely solidified, the movable mold is removed and the casting with embedded fiber optic grating sensor is taken out from the fixed mold.

[0022] Furthermore, in step S4, the fixed mold is preheated, specifically by ensuring that the preheating temperature reaches 300~600℃ before casting.

[0023] The present invention also provides an intelligent monitoring system for a casting with an embedded fiber Bragg grating sensor, fabricated based on the aforementioned method, comprising:

[0024] A casting with an embedded fiber optic grating sensor is used to sense the internal strain, temperature, and vibration signals of the casting and convert them into optical signals.

[0025] A laser emitting device is used to send pulse signals to the fiber optic grating sensor embedded inside the casting.

[0026] The signal processing module is electrically connected to the fiber Bragg grating sensor and is used to receive and process the optical signal, and convert it into internal strain, temperature and vibration data.

[0027] The data analysis module is used to receive internal strain, temperature and vibration data transmitted by the signal processing module in real time to analyze the structural health status of the casting with embedded fiber optic grating sensor.

[0028] Furthermore, 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 fiber optic sensor, the amplifier is used to amplify the filtered signal, and the demodulation device is used to demodulate the amplified signal, thereby extracting internal strain, temperature, and vibration data.

[0029] 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 analyzes and models the collected data to obtain the internal stress distribution, vibration characteristics, and temperature information of the casting with the embedded fiber optic grating sensor. The alarm unit is used to issue an alarm when abnormal stress, temperature, or vibration signals are detected.

[0030] Furthermore, the alarm module is used to trigger an alarm and mark the abnormal location when the abnormal stress or vibration signal exceeds a set threshold.

[0031] According to specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0032] Achieving Real-Time and Precise Monitoring: The intelligent monitoring system for castings based on embedded fiber optic grating sensors provided by this invention directly embeds the fiber optic sensors inside the castings, enabling the sensors to monitor structural parameters such as strain and vibration within the castings in real time and accurately. Compared with traditional surface mounting techniques, this invention effectively avoids the influence of the external environment on sensor measurements, greatly improving the accuracy and reliability of monitoring.

[0033] This invention employs a casting process to embed a fiber optic sensor directly into the casting material, avoiding interference from external environmental factors such as mechanical damage, temperature changes, and electromagnetic interference. This significantly extends the sensor's lifespan. This embedded design ensures the sensor's stability and reliability under long-term, high-load operating conditions and allows it to more accurately reflect the true strain and vibration within the casting, greatly improving measurement accuracy and reliability. Traditional fiber optic sensor installation requires complex surface bonding or fixing processes, while this invention achieves embedding in a single step using the casting process, eliminating the need for adhesives or other additional materials. This simplifies the production process, shortens the manufacturing cycle, and significantly improves production efficiency.

[0034] Improving sensor durability and lifespan: The embedded design of this invention fully utilizes the high temperature and high pressure conditions of the casting process, eliminating the need for additional installation materials or energy input, thus saving raw materials and energy required in the production process. At the same time, it reduces material waste caused by adhesive aging or improper installation in traditional processes.

[0035] This invention, through integration with a data analysis platform, enables intelligent real-time monitoring of internal strain and vibration in castings. When an anomaly is detected, the system can issue timely warnings, allowing users to quickly take measures to prevent structural damage, reduce equipment maintenance costs, and improve overall equipment safety.

[0036] The monitoring system of this 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 being environmentally friendly and energy-saving, which meets the requirements of modern manufacturing industry for sustainable development and green manufacturing.

[0037] In summary, this invention, through innovative casting embedding technology, significantly improves the accuracy and reliability of internal strain and vibration monitoring of castings, extends the service life of sensors, simplifies the installation process, and realizes intelligent, real-time structural health monitoring, which has broad application prospects and significant economic benefits. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 This is a structural diagram of the fabrication system for the embedded fiber optic grating sensor of the present invention.

[0040] Figure 2 This is a schematic diagram of the embedded fiber Bragg grating sensor according to an embodiment of the present invention;

[0041] Figure 3 This is a schematic diagram of the structure of an intelligent monitoring system for a casting based on an embedded fiber optic grating sensor, according to an embodiment of the present invention.

[0042] Explanation of reference numerals in the attached drawings: 1-Fiber Bragg grating sensor, 2-Aluminum alloy capillary tube, 3-Mold, 4-Gate, 5-Runner, 6-Filter, 7-Laser emitter, 8-Metal component embedded with fiber Bragg grating sensor, 9-Signal processing module, 10-Data analysis platform, 11-Fiber Bragg grating sensor with coating, 12-Fiber Bragg grating sensor without coating, 13-Fiber Bragg grating. Detailed Implementation

[0043] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0044] The purpose of this invention is to provide a system, method and application for manufacturing castings with embedded fiber Bragg grating sensors. By directly embedding the fiber Bragg grating sensor inside the casting, the influence of the external environment on the sensor measurement is effectively avoided, enabling the fiber Bragg grating sensor to monitor the structural parameters such as strain and vibration inside the casting in real time and accurately.

[0045] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0046] Example 1

[0047] like Figure 1 As shown, a fabrication system for a casting embedded with a fiber Bragg grating sensor includes:

[0048] The mold consists of a movable mold and a fixed mold, with a fixing component for fixing the capillary tube provided above the fixed mold;

[0049] The fixed mold and the corresponding position inside the fixed mold are provided with concave flow channels, which are used to allow the injected molten metal to flow from the bottom to the top of the fiber optic grating sensor through the concave flow channels until the cavity where the filter is located is filled.

[0050] The capillary tube is inserted into one side of the concave flow channel to allow the fiber Bragg grating sensor to pass through and guide the fiber Bragg grating sensor to the correct position in the fixed mold.

[0051] The capillary is divided into upper and lower sections, so that the upper and lower parts of the fiber Bragg grating sensor are both inside the capillary, while the middle part of the fiber Bragg grating sensor is exposed.

[0052] A gate is provided above the mold, and the gate is connected to the bottom channel of the concave flow channel. It is used to inject molten metal into the cavity of the mold through the gate. After the molten metal has completely solidified, the movable mold is removed and the casting of the embedded fiber optic grating sensor is taken out from the fixed mold.

[0053] Specifically, after merging the movable mold and the fixed mold together, the concave flow channels in the movable mold and the fixed mold will form a channel. At this time, casting can be carried out to allow the molten metal to fill the entire cavity.

[0054] 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 optic grating sensor.

[0055] In this embodiment, the fixed mold includes at least two capillaries, and the casting is a metal component.

[0056] In this embodiment, the fixed mold is also equipped with a heating module to preheat the temperature to 300~600℃ before casting. The heating module is specifically a heating rod.

[0057] In this embodiment, a filter is provided below the gate to filter slag from the molten metal.

[0058] In this embodiment, the molten metal is aluminum.

[0059] In this embodiment, during the solidification process of the molten metal, the system also includes a feeder to provide sufficient molten aluminum to prevent cavities and voids from forming between the optical fiber and the metal due to shrinkage.

[0060] Example 2

[0061] This invention provides a method for manufacturing a casting with an embedded fiber Bragg grating sensor, applied to the manufacturing system for the casting with an embedded fiber Bragg grating sensor described in Embodiment 1, comprising the following steps:

[0062] S1, Install two capillary tubes, one end of which is fixed by an external fastener, onto the upper and lower positions of the fixed mold respectively;

[0063] S2, the movable mold and the fixed mold are assembled together to form a cavity that defines the fiber optic grating sensor;

[0064] S3, the fiber Bragg grating sensor is fed into the capillary tube so that both the upper and lower parts of the fiber Bragg grating sensor are protected inside the capillary tube.

[0065] S4, Preheat the fixed mold;

[0066] S5. Molten metal is poured through the gate on the fixed mold, so that the molten metal is injected into the cavity of the fixed mold. When the molten metal fills the fixed mold, it flows and wraps around the middle part of the fiber optic grating sensor. During the cooling and solidification process of the molten metal, the fiber optic grating sensor is embedded in the casting. After the metal is completely solidified, the movable mold is removed and the casting with embedded fiber optic grating sensor is taken out from the fixed mold.

[0067] In this embodiment, the method further includes: during the cooling and solidification process of the molten metal, the heat inside the mold can be removed more quickly through the circulating cooling medium in the liquid cooling channels inside the mold, thereby more effectively controlling the temperature of the mold. Intelligent centralized control allows for mold temperature control, including setting and monitoring of temperature, flow rate, and pressure, as well as data collection, achieving digital management. This facilitates the addition or removal of temperature control equipment such as oil, water, and hot water, and allows for rapid optimization of temperature / flow / pressure data adjustments in each mold temperature zone during production, ensuring that the fiber Bragg grating sensor can withstand the thermal stress caused by cooling. Furthermore, the cooling rate can be adjusted according to the thermal expansion characteristics of the material to avoid damage to the fiber Bragg grating sensor.

[0068] In this embodiment, step S4, which involves preheating the fixed mold, specifically includes ensuring that the preheating temperature reaches 300~600℃ before pouring.

[0069] In this embodiment, the method further includes removing the coating within 10 centimeters around the fiber optic grating sensor to prevent the coating from burning when exposed to molten metal.

[0070] In a further embodiment, the method for manufacturing the casting of the embedded fiber Bragg grating sensor specifically includes the following steps:

[0071] Step 1: Pre-treatment and installation of the embedded aluminum alloy capillary. Select an aluminum alloy capillary with an outer diameter of 0.8 mm, an inner diameter of 0.6 mm, and a length of 30 cm for processing. One end of the capillary has a perforated cap, which is used to fix the capillary between the upper and lower molds. The main function of the capillary is to guide the fiber optic grating sensor into the accurate position within the mold and maintain its stability during the casting process.

[0072] Step 2 involves assembling the movable mold and the fixed mold together to form a cavity that defines the fiber Bragg grating sensor. The mold design ensures that the optical fiber remains stable and in close contact with the metal components during the casting process. The cavity design takes into account the stress and temperature changes that the optical fiber may experience during casting.

[0073] Step 3: Pre-processing and installation of the fiber optic sensor. The fiber optic sensor is made of sapphire fiber, which can maintain reliability at temperatures up to 1400℃. The coating within 10cm of the fiber Bragg grating sensor is removed to ensure direct contact between the fiber Bragg grating and the metal component. The fiber is then inserted into a capillary tube, protecting the upper and lower parts of the fiber Bragg grating while the middle part directly contacts the metal component. Subsequently, silicone grease is used to fix the fiber inside the capillary tube to prevent displacement during the casting process.

[0074] Step 4: Preheat the metal capillary tube and mold to 400°C. The purpose of this is to prevent the aluminum alloy melt from solidifying rapidly when it is poured into the mold cavity, and to reduce the thermal stress generated during solidification.

[0075] Step 5: The AlSi10Mg aluminum alloy is heated to 700℃, and the molten aluminum is injected into the mold cavity through a molten metal casting system. The molten aluminum enters the cavity from the bottom channel 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. During the flow of the molten aluminum, a fiber Bragg grating sensor is enveloped. Since the optical fiber is fixed, the fiber Bragg grating sensor will be embedded in the metal component during the cooling and solidification process of the aluminum alloy.

[0076] During the metal cooling and solidification process, an appropriate cooling control system is employed to ensure that the fiber Bragg grating sensor can withstand the thermal stress caused by cooling. The mold temperature control system adjusts the cooling rate according to the thermal expansion characteristics of the material to avoid damage to the fiber Bragg sensor. The holding pressure is controlled between 0.45 MPa and 0.7 MPa to ensure sufficient back pressure after the aluminum liquid is filled, preventing solidification shrinkage defects in the aluminum liquid.

[0077] Step 6: After the metal has completely solidified, remove the movable mold and take out the cast metal component. At this point, the fiber optic grating sensor is embedded in the aluminum alloy component. The entire process ensures the integrity of the sensor and the measurement accuracy.

[0078] The method described in this embodiment ensures the safety and stability of the fiber Bragg grating sensor during the casting process; it not only improves the embedding efficiency of the sensor but also guarantees the high reliability of the final product.

[0079] Example 3

[0080] like Figure 3 As shown, this embodiment of the invention also provides an application of the casting with the embedded fiber grating sensor described in Embodiment 1 or Embodiment 2, specifically providing an intelligent monitoring system based on the casting with the embedded fiber grating sensor, including:

[0081] The casting with embedded fiber optic grating sensors is used to sense signals such as internal strain, temperature and vibration of the casting through the fiber optic grating sensors and convert them into optical signals.

[0082] A laser emitting device is used to send pulse signals to the fiber optic grating sensor embedded inside the casting.

[0083] The signal processing module is electrically connected to the fiber Bragg grating sensor to receive and process the optical signal and convert it into data such as internal strain, temperature and vibration.

[0084] The data analysis module is used to receive data such as internal strain, temperature, and vibration transmitted by the signal processing module in real time to analyze the structural health status of the casting with embedded fiber optic grating sensor.

[0085] 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 fiber optic sensor, the amplifier is used to amplify the filtered signal, and the demodulation device is used to demodulate the amplified signal, thereby extracting preliminary internal strain, temperature, and vibration data.

[0086] 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 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 with the embedded fiber grating sensor, and identifies possible structural anomalies. The alarm unit is used to issue an alarm when abnormal stress, temperature, or vibration signals are detected, so as to carry out preventive maintenance.

[0087] In this embodiment, the alarm module is used to trigger an alarm and mark the abnormal location when the abnormal stress or vibration signal exceeds a set threshold.

[0088] In this embodiment, the mold is also provided with liquid cooling channels. During the cooling and solidification process of molten metal, the circulating cooling medium in these liquid cooling channels can remove the heat from the inside of the mold more quickly, thereby controlling the temperature of the mold more effectively.

[0089] In this embodiment, the system further includes a data acquisition module and a temperature control module. The data acquisition module is used to acquire 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 within the optimal range throughout the production process. The temperature control module includes an oil temperature controller, a water temperature controller, and a spot temperature device. The oil temperature controller is used to control the mold temperature through the circulation of hot oil, thereby increasing and controlling the temperature inside the mold during preheating. The water temperature controller is used to turn on during casting / die casting, using water as the heat transfer medium to control the mold temperature through water circulation, thus controlling the temperature during the die casting process. The spot temperature device is used for local temperature control of the mold, that is, to adjust the temperature of a 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, runner area, and cavity area. Each area is set with independent temperature control parameters according to different functions and process requirements, thereby improving molding quality and efficiency. Based on these structures, this invention achieves intelligent centralized control of mold temperature, and allows for convenient addition or removal of temperature control equipment such as oil, water, and hot water. It also enables rapid optimization of temperature / flow / pressure data adjustments in various temperature control zones during production, ensuring that the fiber Bragg grating sensor can withstand the thermal stress caused by cooling. Furthermore, the cooling rate can be adjusted according to the thermal expansion characteristics of the material to prevent damage to the fiber Bragg grating sensor.

[0090] In summary, the intelligent monitoring system for castings based on embedded fiber optic grating sensors provided by this invention eliminates the need for subsequent processes such as strain gauge or fiber laser bonding because the fiber optic sensors are pre-embedded inside the casting. This allows for real-time monitoring of internal parameters such as strain and vibration without altering the casting material or process, thereby improving sensor reliability and monitoring accuracy. It also solves the problems of low measurement accuracy, poor sensor durability, and complex installation in existing component health monitoring technologies. This invention has the following characteristics:

[0091] 1. This invention can be applied to various metal component materials and is widely applicable in multiple fields such as aerospace, automotive, and construction. Through a highly efficient data acquisition and processing system, real-time monitoring of component status can be achieved, enabling timely detection of potential problems. Utilizing advanced fiber optic sensing technology, the system can accurately sense stress, vibration, and temperature changes within the metal component, ensuring the accuracy of monitoring results. This method and system effectively embed fiber optic sensors for real-time monitoring, ensuring the safety and stability of components under high-stress environments.

[0092] 2. Improve the durability and lifespan of the sensor.

[0093] High Temperature and High Pressure Resistance: This invention utilizes a casting process to embed the fiber optic sensor within the casting, protecting it from the high temperature and high pressure of the casting environment and avoiding potential damage to the sensor under traditional installation methods. The thermal expansion coefficients of the aluminum substrate and the casting material are matched, reducing thermal stress during the cooling phase, which helps extend the lifespan of the fiber optic sensor and ensures its stable performance under extreme conditions.

[0094] 3. Simplified processes and increased production efficiency

[0095] Adhesive-free design: Traditional embedding technologies typically require adhesives to fix fiber optic sensors to the surface or interior of castings. This not only increases production steps but can also lead to insufficient bond strength or adhesive aging. This invention embeds the sensor directly into the casting through a casting process, eliminating the need for adhesives, simplifying the manufacturing process, shortening the production cycle, and thus improving production efficiency.

[0096] 4. Saves materials and energy

[0097] Reduced material waste: Traditional sensor mounting methods may require additional mounting structures or protective layers, thus increasing material consumption. The embedded design of this invention not only reduces the use of these additional materials but also fully utilizes the high temperature and high pressure environment generated during the casting process, making the sensor an integral part of the casting, further saving raw materials and energy.

[0098] Energy utilization optimization: By directly embedding the sensor inside the casting, this invention utilizes the inherent heat and pressure during the casting process, enabling the sensor to be embedded without increasing additional energy consumption, thus effectively improving energy utilization efficiency.

[0099] 5. Improve the real-time nature and intelligence of structural health monitoring.

[0100] Real-time online monitoring: The fiber optic sensor embedded in this invention can acquire data such as strain, vibration, and temperature inside the casting in real time, and analyze them through a signal processing system. This real-time monitoring capability provides timely and accurate data support for structural health diagnosis, helping to provide early warning and prevent potential structural damage.

[0101] Intelligent Diagnosis and Control: By combining with advanced signal processing technology and structural health monitoring systems, the fiber optic sensing system created in this invention can automatically identify changes in the state 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.

[0102] 6. Because this invention reduces the use of adhesives and other chemical materials, it lowers the risk of environmental pollution during the production process. Furthermore, the savings in energy and materials indirectly reduce carbon emissions, contributing to a more environmentally friendly production process. This invention simplifies the production process and material usage, reduces waste generation during production, and further promotes sustainable production and green manufacturing.

[0103] In summary, this invention, by optimizing the embedding method of the fiber optic sensor, not only improves the accuracy and reliability of internal strain and vibration monitoring in castings, but also significantly enhances production efficiency and sensor lifespan, reduces material and energy consumption, and achieves smarter and more environmentally friendly structural health monitoring. The application of this technical solution provides strong technical support for high-precision, real-time monitoring, and has broad application prospects and significant economic benefits.

[0104] The remaining technical features in this embodiment can be flexibly selected by those skilled in the art to meet different specific practical needs. However, it is obvious to those skilled in the art that these specific details are not necessary to implement the present invention. In other instances, to avoid obscuring the present invention, well-known components, structures, or parts are not specifically described, and all are within the scope of technical protection defined by the claims of the present invention.

[0105] Modifications and variations made by those skilled in the art that do not depart from the spirit and scope of this invention should be within the protection scope of the appended claims. In the above description, numerous specific details have been set forth to provide a thorough understanding of the invention. However, it will be apparent to those skilled in the art that these specific details are not necessary to practice the invention. In other instances, to avoid obscuring the invention, well-known techniques, such as specific construction details, operating conditions, and other technical conditions, have not been specifically described.

[0106] This document uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. Furthermore, those skilled in the art will recognize that, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A system for fabricating a casting with an embedded fiber Bragg grating sensor, characterized in that, include: The mold consists of a movable mold and a fixed mold, with a fixing component for fixing the capillary tube provided above the fixed mold; The fixed mold and the movable mold are provided with concave flow channels at the same positions inside, which are used to allow the injected molten metal to flow from the bottom to the top of the fiber optic grating sensor through the concave flow channels until the cavity where the filter is located is filled. The capillary tube is inserted into one side of the concave flow channel to allow the fiber Bragg grating sensor to pass through and guide the fiber Bragg grating sensor to the correct position in the fixed mold. The capillary is divided into upper and lower sections, so that the upper and lower parts of the fiber Bragg grating sensor are both inside the capillary, while the middle part of the fiber Bragg grating sensor is exposed. A gate is provided above the mold, and a filter is provided below the gate. The gate is connected to the bottom channel of the concave flow channel. It is used to inject molten metal into the cavity of the mold through the gate. After the molten metal has completely solidified, the movable mold is removed and the casting of the embedded fiber optic sensor is taken out from the fixed mold.

2. The fabrication system for the casting of 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 optic grating sensor.

3. The fabrication system for the casting of 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 of an embedded fiber Bragg grating sensor, applied to the manufacturing system for the casting of an embedded fiber Bragg grating sensor as described in any one of claims 1-3, characterized in that, Includes the following steps: S1, Install two capillary tubes, one end of which is fixed by a fastener, onto the upper and lower positions of the fixed mold respectively; S2, the movable mold and the fixed mold are assembled together to form a cavity that defines the fiber optic grating sensor; S3, the fiber Bragg grating sensor is fed into the capillary tube so that both the upper and lower parts of the fiber Bragg grating sensor are protected inside the capillary tube. S4, Preheat the fixed mold; S5. Molten metal is poured through the gate on the fixed mold, so that the molten metal is injected into the cavity of the fixed mold. When the molten metal fills the fixed mold, it flows and wraps around the middle part of the fiber optic grating sensor. During the cooling and solidification process of the molten metal, the fiber optic grating sensor is embedded in the casting. After the metal is completely solidified, the movable mold is removed and the casting with embedded fiber optic grating sensor is taken out from the fixed mold.

5. The method for manufacturing a casting of an embedded fiber Bragg grating sensor according to claim 4, characterized in that, S4 involves preheating the fixed mold, specifically by ensuring that the preheating temperature reaches 300~600℃ before casting.

6. An intelligent monitoring system for a casting of an embedded fiber optic grating sensor, manufactured using the method described in any one of claims 4-5, characterized in that, include: A casting with an embedded fiber optic grating sensor is used to sense the internal strain, temperature, and vibration signals of the casting and convert them into optical signals. A laser emitting device for sending pulse signals to a fiber optic grating sensor embedded inside a casting. The signal processing module is electrically connected to the fiber Bragg grating sensor and is used to receive and process the optical signal, and convert it into internal strain, temperature and vibration data. The data analysis module is used to receive internal strain, temperature and vibration data transmitted by the signal processing module in real time to analyze the structural health status of the casting with embedded fiber optic 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 fiber Bragg grating sensor, the amplifier is used to amplify the filtered signal, and the demodulation device is used to demodulate the amplified signal, thereby extracting 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 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 with the embedded fiber optic grating sensor. The alarm unit is used to issue an alarm when abnormal stress, temperature, or vibration signals are detected.

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

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