Bridge cable with fiber grating sensor and manufacturing method

Abstract

The invention relates to the technical field of bridge inhaul cables, and discloses a bridge inhaul cable with a fiber grating sensor and a manufacturing method thereof.The bridge inhaul cable comprises a plastic pipe and a steel strand inhaul cable, and the steel strand inhaul cable is arranged in the plastic pipe in a penetrating mode; the polymer fiber grating strain sensors are mounted on the outer wall of the plastic pipe in the circumferential direction, and ultrasonic welding is performed on the polymer fiber grating strain sensors and the plastic pipe through ultrasonic welding equipment; and the protection piece is arranged on the polymer fiber grating strain sensor. The invention provides a three-order packaging system. In the first-order packaging, a modular unit is adopted to realize the protection of a sensor body; in the second-stage packaging, a high-fidelity strain transmission interface is constructed through ultrasonic welding; the three-stage packaging provides environmental protection by means of a plastic pipe, so that the defects that the sensor is easy to damage, poor in environmental adaptability and insufficient in sealing performance are overcome.

Description

Technical Field

[0001] The present invention relates to the technical field of bridge cables, and in particular to a bridge cable with a fiber grating sensor and a manufacturing method thereof. Background Art

[0002] Bridge cables are a vital tool or device widely used during bridge construction, repair, or reinforcement. They are flexible or rigid structures used to transmit force, support weight, or secure bridge components. They play a vital role in modern bridge engineering, particularly in the construction, maintenance, and reinforcement of large bridges.

[0003] Conventional sensors are susceptible to damage, and mechanical fixation can squeeze optical fibers, affecting sensing accuracy. They also suffer from poor environmental adaptability, with adhesives prone to aging and failure in high-temperature and humid environments. Inadequate structural sealing allows for moisture intrusion, corroding the core material or sensor.

[0004] Therefore, there is an urgent need for a bridge cable with a fiber grating sensor and a manufacturing method to solve the above problems. Summary of the Invention

[0005] The purpose of the present invention is to provide a bridge cable with a fiber grating sensor and a manufacturing method thereof, so as to solve the problems existing in the above-mentioned prior art.

[0006] To achieve the above-mentioned object, the present invention provides the following solution: The present invention provides a bridge cable with a fiber Bragg grating sensor, comprising:

[0007] A plastic tube and a steel strand cable, wherein the steel strand cable is inserted into the plastic tube;

[0008] A plurality of polymer fiber Bragg grating strain sensors are circumferentially mounted on the outer wall of the plastic tube, and the polymer fiber Bragg grating strain sensors and the plastic tube are ultrasonically welded by ultrasonic welding equipment;

[0009] The protective component is installed on the polymer fiber Bragg grating strain sensor.

[0010] According to the bridge cable with a fiber Bragg grating sensor provided by the present invention, a plurality of installation grooves are opened on the outer wall of the plastic tube at equal intervals along the circumferential direction, and the polymer fiber Bragg grating strain sensor is adapted to the installation grooves.

[0011] According to a bridge cable with a fiber Bragg grating sensor provided by the present invention, the protective member includes a modular packaging shell, the modular packaging shell is provided with a reserved embedding groove, and the polymer fiber Bragg grating strain sensor is embedded in the reserved embedding groove.

[0012] According to the bridge cable with a fiber grating sensor provided by the present invention, the plastic pipe is a HDPE plastic pipe.

[0013] According to the present invention, a bridge cable with a fiber Bragg grating sensor further comprises an optical fiber, which is ultrasonically welded to the plastic pipe by the ultrasonic welding equipment. The polymer fiber Bragg grating strain sensor is connected to an external moderator via the optical fiber.

[0014] According to the bridge cable with a fiber grating sensor provided by the present invention, the number of the installation grooves is four.

[0015] A method for manufacturing a bridge cable with a fiber grating sensor comprises the following steps:

[0016] embedding the polymer fiber Bragg grating strain sensor into the protective member;

[0017] placing the polymer fiber Bragg grating strain sensor embedded in the protective member on the outer wall of the plastic tube along the circumferential direction;

[0018] Ultrasonic welding the polymer fiber Bragg grating strain sensor to the outer wall of the plastic pipe by the ultrasonic welding equipment;

[0019] The steel strand cable is passed through the plastic tube.

[0020] According to the method for manufacturing a bridge cable with a fiber Bragg grating sensor provided by the present invention, the optical fiber wire on the polymer fiber Bragg grating strain sensor is welded to the plastic pipe by the ultrasonic welding equipment.

[0021] Compared with the prior art, the present invention has the following advantages and technical effects:

[0022] The present invention provides a bridge cable with a fiber grating sensor and a manufacturing method. A protective piece is installed on a polymer fiber grating strain sensor. The polymer fiber grating strain sensor with the protective piece installed is distributed circumferentially on a plastic tube. The polymer fiber grating strain sensor and the plastic tube are ultrasonically welded using ultrasonic welding equipment. The ultrasonic welding of this application uses high-frequency vibration friction to locally melt and fuse the contact surface, forming a molecular-level bond without the introduction of additional materials. The mechanical strength of the weld zone is close to that of the parent material, which can withstand the dynamic load transmitted by the cable and ensure the stability of the sensor in long-term stress environments such as bridges and buildings. There is no adhesive aging problem, and the connection is not prone to cracking after long-term use, making it suitable for long-term monitoring scenarios. Ultrasonic energy is concentrated on the welding surface, resulting in a short heating time and a very small heat-affected zone. The single-point welding cycle is short, suitable for automated production lines, and significantly improves the sensor packaging efficiency. The local temperature rise is controllable to avoid overall thermal deformation of the plastic tube or cable polymer material, maintain the fiber preload and grating wavelength stability. It meets the needs of sensor miniaturization. In intelligent cable bridge monitoring, ultrasonic welding ensures long-term, reliable packaging of fiber optic sensors under complex vibration, temperature, and humidity fluctuations, while also avoiding the signal drift associated with traditional adhesive bonding, thereby improving the accuracy of structural health monitoring systems. A three-stage packaging system has been proposed: the first stage utilizes modular units to protect the sensor body; the second stage utilizes ultrasonic welding to create a high-fidelity strain transmission interface; and the third stage relies on plastic tubing for environmental protection, addressing the sensor's fragility, poor environmental adaptability, and insufficient sealing. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. Those skilled in the art can also derive other drawings based on these drawings without inventive work.

[0024] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0025] Figure 2 This is a schematic diagram of the assembly state of the polymer fiber Bragg grating strain sensor of the present invention;

[0026] Figure 3 Schematic diagram of the distribution of the polymer fiber Bragg grating strain sensor on the plastic pipe of the present invention;

[0027] Figure 4 Schematic diagram of welding the polymer fiber Bragg grating strain sensor and the plastic pipe of the present invention;

[0028] Among them, 1. Polymer fiber Bragg grating strain sensor; 2. Modular packaging shell; 3. Ultrasonic welding equipment; 4. Plastic tube; 5. Steel stranded wire rope; 6. Reserved embedding groove; 7. Installation groove. DETAILED DESCRIPTION

[0029] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. 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 making creative efforts are within the scope of protection of the present invention.

[0030] 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.

[0031] Reference Figure 1-Figure 4 The present invention provides a bridge cable with a fiber Bragg grating sensor, comprising:

[0032] A plastic tube 4 and a steel strand cable 5, wherein the steel strand cable 5 is passed through the plastic tube 4;

[0033] Several polymer fiber Bragg grating strain sensors 1 are circumferentially mounted on the outer wall of the plastic tube 4, and the polymer fiber Bragg grating strain sensors 1 and the plastic tube 4 are ultrasonically welded by an ultrasonic welding device 3;

[0034] The protective part is installed on the polymer fiber Bragg grating strain sensor 1.

[0035] In one embodiment of the present application, a protective piece is installed on the polymer fiber Bragg grating strain sensor 1, and the polymer fiber Bragg grating strain sensor 1 after the protective piece is installed is distributed circumferentially on the plastic tube 4, and the polymer fiber Bragg grating strain sensor 1 and the plastic tube 4 are ultrasonically welded by ultrasonic welding equipment 3.

[0036] As an optional embodiment, a plurality of mounting grooves 7 are formed on the outer wall of the plastic tube 4 at equal intervals along the circumferential direction, and the polymer fiber Bragg grating strain sensor 1 is adapted to the mounting grooves 7 .

[0037] In one embodiment of the present application, the installation groove 7 is adapted to the polymer fiber Bragg grating strain sensor 1 , and the polymer fiber Bragg grating strain sensor 1 is placed in the installation groove 7 before welding.

[0038] As an optional embodiment, the protective member includes a modular packaging shell 2 , a reserved embedding groove 6 is opened on the modular packaging shell 2 , and the polymer fiber Bragg grating strain sensor 1 is embedded in the reserved embedding groove 6 .

[0039] In one embodiment of the present application, the polymer fiber Bragg grating strain sensor 1 is embedded in the reserved embedding groove 6 to ensure the overall sealing.

[0040] As an optional embodiment, the plastic pipe 4 is a HDPE plastic pipe.

[0041] In one embodiment of the present application, the material of the plastic tube 4 is preferably HDPE.

[0042] As an optional embodiment, it also includes an optical fiber, which is ultrasonically welded to the plastic tube 4 through an ultrasonic welding device 3, and the polymer fiber Bragg grating strain sensor 1 is connected to an external moderator through the optical fiber.

[0043] In one embodiment of the present application, the optical fiber is welded to the plastic tube 4 by ultrasonic welding equipment 3 for connection to an external modem.

[0044] As an optional implementation, the number of the mounting slots 7 is four.

[0045] In one embodiment of the present application, the number of the mounting slots 7 is preferably four.

[0046] A method for manufacturing a bridge cable with a fiber grating sensor comprises the following steps:

[0047] Embedding the polymer fiber Bragg grating strain sensor 1 in the protective component;

[0048] The polymer fiber Bragg grating strain sensor 1 embedded in the protective member is placed on the outer wall of the plastic tube 4 along the circumferential direction;

[0049] Ultrasonic welding of the polymer fiber Bragg grating strain sensor 1 to the outer wall of the plastic tube 4 is performed using an ultrasonic welding device 3;

[0050] The steel strand cable 5 is passed through the plastic tube 4 .

[0051] In one embodiment of the present application, when in use, the polymer fiber Bragg grating strain sensor 1 is embedded in the reserved embedding groove 6 on the modular packaging shell 2, the polymer fiber Bragg grating strain sensor 1 is placed in the installation groove 7, the polymer fiber Bragg grating strain sensor 1 and the plastic tube 4 are ultrasonically welded by ultrasonic welding equipment 3, and the steel strand cable 5 is passed through the plastic tube 4.

[0052] As an optional implementation, the optical fiber line on the polymer fiber Bragg grating strain sensor 1 is welded to the plastic tube 4 by ultrasonic welding equipment 3 .

[0053] In one embodiment of the present application, the optical fiber is ultrasonically welded to the plastic tube 4 by ultrasonic welding equipment 3 to ensure stable data transmission.

[0054] The ultrasonic welding of this application uses high-frequency vibration friction to locally melt and fuse the contact surface, forming a bond at the molecular level without the introduction of additional materials. The mechanical strength of the welding area is close to that of the parent material, and can withstand the dynamic load transmitted by the cable, ensuring the stability of the sensor in long-term stress environments such as bridges and buildings. There is no adhesive aging problem, and the connection is not easy to crack after long-term use, which is suitable for long-term monitoring scenarios. Ultrasonic energy is concentrated on the welding surface, the heating time is short, and the heat-affected zone is extremely small. The single-point welding cycle is short, suitable for automated assembly lines, and significantly improves the sensor packaging efficiency. The local temperature rise can be controlled to avoid overall thermal deformation of plastic pipes or cable polymer materials, maintain the optical fiber preload and grating wavelength stability. Adapt to the needs of sensor miniaturization. In intelligent cable bridge monitoring, ultrasonic welding can ensure the long-term and reliable packaging of optical fiber sensors under complex vibrations, temperature and humidity changes, while avoiding the signal drift problem caused by traditional bonding, and improving the accuracy of the structural health monitoring system. It proposes a three-stage packaging system: the first-level packaging adopts modular units to protect the sensor body; the second-level packaging constructs a high-fidelity strain transfer interface through ultrasonic welding; the third-level packaging relies on plastic tubes to provide environmental protection to solve the shortcomings of easy damage to the sensor, poor environmental adaptability and insufficient sealing.

[0055] In the description of the present invention, it should be understood that the terms "longitudinal", "transverse", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0056] The embodiments described above are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Without departing from the spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by persons skilled in the art should fall within the scope of protection defined by the claims of the present invention.

Claims

1. A bridge cable with a fiber Bragg grating sensor, characterized in that: include: A plastic tube (4) and a steel strand cable (5), wherein the steel strand cable (5) is inserted into the plastic tube (4); A plurality of polymer fiber Bragg grating strain sensors (1) are circumferentially mounted on the outer wall of the plastic tube (4), and the polymer fiber Bragg grating strain sensors (1) and the plastic tube (4) are ultrasonically welded using ultrasonic welding equipment (3); A protective element is mounted on the polymer fiber grating strain sensor (1).

2. The bridge cable with a fiber Bragg grating sensor according to claim 1, characterized in that: A plurality of mounting grooves (7) are provided on the outer side wall of the plastic tube (4) at equal intervals along the circumferential direction, and the polymer fiber grating strain sensor (1) is adapted to the mounting grooves (7).

3. The bridge cable with a fiber Bragg grating sensor according to claim 1, characterized in that: The protective component comprises a modular packaging shell (2), a reserved embedding groove (6) is provided on the modular packaging shell (2), and the polymer fiber grating strain sensor (1) is embedded in the reserved embedding groove (6).

4. The bridge cable with a fiber Bragg grating sensor according to claim 1, characterized in that: The plastic pipe (4) is a HDPE plastic pipe.

5. The bridge cable with a fiber Bragg grating sensor according to claim 1, characterized in that: It also includes an optical fiber, which is ultrasonically welded to the plastic tube (4) through the ultrasonic welding device (3), and the polymer fiber grating strain sensor (1) is connected to an external regulator through the optical fiber.

6. The bridge cable with a fiber Bragg grating sensor according to claim 2, characterized in that: The number of the mounting slots (7) is four.

7. A method for manufacturing a bridge cable with a fiber Bragg grating sensor, applicable to the bridge cable with a fiber Bragg grating sensor according to claim 1, characterized in that: The following steps are involved: embedding the polymer fiber Bragg grating strain sensor (1) in the protective component; placing the polymer fiber Bragg grating strain sensor (1) embedded in the protective member on the outer wall of the plastic tube (4) along the circumferential direction; Ultrasonic welding the polymer fiber grating strain sensor (1) to the outer wall of the plastic pipe (4) using the ultrasonic welding equipment (3); The steel strand cable (5) is passed through the plastic tube (4).

8. The method for manufacturing a bridge cable with a fiber Bragg grating sensor according to claim 7, characterized in that: The optical fiber line on the polymer fiber grating strain sensor (1) is welded to the plastic pipe (4) through the ultrasonic welding equipment (3).

Images