Stay wire tension intelligent early warning system and method based on double-point monitoring

Abstract

The invention discloses a stay wire tension intelligent early warning system and method based on double-point monitoring. The system comprises a pulling force sensing module, an environment compensation module, a main control module, a power supply module, a structure protection module and a data analysis module, and accurate monitoring of pulling force of a stay wire is achieved through sensors which are symmetrically arranged in a double-point-position mode in combination with a temperature compensation algorithm and a digital filtering algorithm; an intelligent dormancy awakening mechanism is adopted to control power consumption, and an IP67 protection structure is adopted to adapt to an outdoor severe environment. According to the invention, a self-adaptive clamp for clamping force monitoring, a dynamically updated temperature coefficient, space-time correlation joint filtering, predictive early warning logic and a digital twinborn analysis model are innovatively designed, so that the problems of inaccurate single-point monitoring, large environmental interference and high power consumption in the prior art are solved, early warning and long-term operation and maintenance of abnormal pulling force of the stay wire are realized, and the working efficiency is improved. And the device is suitable for power transmission lines with different voltage levels of 35kV-220kV, and has a wide engineering application prospect.

Description

Technical Field

[0001] This invention relates to the field of power facility condition monitoring technology, and in particular to an intelligent early warning system and method for guy wire tension based on dual-point monitoring. Background Technology

[0002] The guy wires of concrete poles in power transmission lines are core components that balance the stress on the towers and ensure structural stability. Their tension state directly affects the safe operation of the transmission lines. Severe winter weather, changes in conductor load, external damage, and guy wire corrosion can easily lead to abnormal tension, causing serious accidents such as tilting and collapse of the concrete poles.

[0003] Currently, existing guy wire tension monitoring technologies have the following main drawbacks: single-point monitoring mode is difficult to fully reflect the overall stress state of the guy wire, and the measurement results are easily inaccurate due to local interference; poor environmental adaptability, with external factors such as temperature changes and mechanical vibrations significantly affecting the monitoring accuracy; high system power consumption and insufficient battery life; and a single early warning method, relying solely on fixed threshold judgments, making it difficult to achieve early warning of faults. Summary of the Invention

[0004] The purpose of this invention is to provide an intelligent early warning system and method for tension in guy wires based on dual-point monitoring, aiming to solve the technical problems of inaccurate single-point monitoring, large environmental interference, high power consumption, and untimely early warning in the prior art.

[0005] To address the aforementioned problems, according to one aspect of this application, an embodiment of the present invention provides an intelligent early warning system for tension in guy wires based on dual-point monitoring, comprising:

[0006] Tension sensing module: includes two S-shaped tension sensors mechanically connected to the cable handle and cable handle respectively. The sensors are fixed by a high-strength aluminum alloy clamp and connected to a 16-bit AD converter.

[0007] Environmental compensation module: includes a temperature sensor connected in parallel with each S-shaped tensile sensor to collect ambient temperature data;

[0008] Main control module: It adopts an STM32 microcontroller. Its input terminal is connected to the AD converter and temperature sensor via a ribbon cable, and its output terminal is connected to the 4G communication module and the sound and light alarm.

[0009] Power supply module: includes a solar panel, a lithium battery and a power management chip. The solar panel is fixed by a rain cover and is connected to the power supply module together with the lithium battery.

[0010] Structural protection module: Includes an IP67-rated housing that accommodates the main control module and power supply module, internally filled with thermally conductive silicone.

[0011] In addition, a data analysis module is used to identify potential loosening or non-uniform deformation of the guy wire structure based on the difference rate of change and covariance analysis of the tension data at two points.

[0012] In some embodiments, the mechanical connection structure between the S-shaped tension sensor and the pull wire includes:

[0013] The fixture body is made of high-strength aluminum alloy and has a surface anti-corrosion treatment.

[0014] The adaptive locking mechanism includes a variable diameter clamping groove and anti-loosening bolts to accommodate pull cables of different diameters.

[0015] The clamping surface of the adaptive locking mechanism is provided with micro-protrusion texture to increase the static friction with the surface of the pull wire, and a piezoelectric thin film sensor is embedded to monitor the long-term stability of the clamping force.

[0016] In some implementations, the temperature compensation algorithm embedded in the main control module is specifically as follows:

[0017] F_comp = F_raw + k × (T - T0);

[0018] Where F_comp is the compensated tensile force value, F_raw is the original measured value, T is the real-time temperature, T0 is the reference temperature, and k is the temperature coefficient;

[0019] Furthermore, the temperature coefficient k is not a fixed value, but a variable that is dynamically updated through linear regression based on historical data, in order to adapt to the long-term aging characteristics of the sensor material.

[0020] In some implementations, the digital filtering algorithm executed by the main control module includes:

[0021] Median filtering based on sliding window to eliminate impulse interference;

[0022] Band-stop filtering based on wire vibration characteristics to suppress mechanical vibration noise;

[0023] It also includes joint filtering based on the spatiotemporal correlation of data at both ends of the string: when a single point of data fluctuates drastically while the data at another point remains stable, it is determined to be interference and filtered out.

[0024] In some implementations, the sleep / wake-up mechanism of the power supply module specifically includes:

[0025] During non-collection periods, power should be turned off to the AD converter and 4G communication module.

[0026] The system is woken up every minute by a timer interrupt to collect data.

[0027] Static power consumption is controlled below 5mA;

[0028] It also includes an event-triggered emergency wake-up mechanism: when the rate of change of the value detected by any tension sensor exceeds a preset emergency threshold, the system immediately exits the sleep state and enters the high-frequency acquisition and transmission mode.

[0029] In some implementations, the warning logic is designed as a multi-level threshold judgment:

[0030] Level 1 warning: When the monitored value exceeds the preset threshold by ±10%, the audible and visual alarm will flash.

[0031] Level 2 warning: When the error exceeds ±20%, an alarm message will be simultaneously pushed to the operation and maintenance platform;

[0032] It also includes predictive warnings based on the deviation of the historical tensile-temperature curve: when the real-time data curve deviates significantly and continuously from the curve shape under historical healthy conditions, an early warning is triggered even if the absolute value threshold is not reached.

[0033] In some implementations, the 4G communication module supports:

[0034] Encrypted data transmission based on the MQTT protocol;

[0035] Automatic reconnection after disconnection and data caching mechanism;

[0036] It also supports remote wireless software upgrades for the communication module, as well as dynamic adjustment of system operating parameters by receiving cloud commands.

[0037] This invention also provides a method for monitoring the tension of a guy wire based on the system described above, comprising the following steps:

[0038] Simultaneous acquisition of tension and temperature data of the guy wire using dual-point sensors;

[0039] Data is processed using temperature compensation and digital filtering algorithms;

[0040] The tension status is determined based on multi-level thresholds, and corresponding warnings are triggered accordingly.

[0041] Data is encrypted and transmitted to the cloud platform via 4G network;

[0042] It also includes: the cloud platform performs fusion analysis on the received dual-point data to establish a digital twin model of the guy wire system, which is used to simulate the stress state under different working conditions and predict the lifespan.

[0043] In some implementations, it also includes:

[0044] The operations and maintenance platform generates a line health curve based on historical data;

[0045] The data collection frequency and early warning threshold can be dynamically adjusted via a remote parameter configuration interface.

[0046] It also includes: the platform automatically sends instructions to the guy wire monitoring system in a specific area based on alarm information from the regional power grid and meteorological disaster warnings, temporarily increasing the collection frequency and warning level.

[0047] This invention also provides an installation structure for a guy wire tension monitoring system, applied to the guy wire tension intelligent early warning system described above, comprising:

[0048] The rain cover is connected to the IP67 housing via a snap-on sealing ring.

[0049] The solar panel is fixed to the side of the tower with an adjustable tilt bracket;

[0050] All cables are introduced into the housing via waterproof connectors;

[0051] It also includes an on-site calibration structure for calibrating the sensor zero point: the structure includes a handheld standard force gauge that can be temporarily connected in parallel with a pull wire, and a calibration button on the housing. When pressed, the system enters calibration mode, reads the current standard value, and corrects the sensor zero point.

[0052] Compared with the prior art, the intelligent early warning system for tension wire based on dual-point monitoring of the present invention has at least the following beneficial effects:

[0053] High monitoring accuracy: It adopts a dual-point symmetrical monitoring structure, combined with dynamic temperature compensation algorithm and multi-level digital filtering algorithm, which effectively eliminates environmental interference and measurement error. The tensile force measurement error is <±1.5%, and the early warning accuracy rate is ≥99.2%.

[0054] High environmental adaptability: The IP67 protection-rated shell, combined with a thermally conductive silicone filling structure, corrosion-resistant clamps, and adjustable tilt solar panels, can adapt to complex and harsh outdoor environments such as areas with frequent lightning strikes, high humidity, and strong winds.

[0055] Low power consumption and long-term operation: The static power consumption is controlled below 5mA through the intelligent sleep wake-up mechanism. Combined with the dual power supply mode of solar energy and lithium battery, it can ensure normal operation for more than 7 consecutive rainy days and meet the long-term monitoring needs.

[0056] Intelligent early warning: The innovative combination of multi-level threshold early warning and predictive early warning can achieve ultra-early identification of guy wire faults and effectively avoid pole collapse accidents;

[0057] Convenient and efficient operation and maintenance: It supports remote wireless software upgrades and remote parameter configuration of 4G communication modules. With the linkage function of cloud digital twin model and operation and maintenance platform, it transforms the traditional "periodic inspection" into "condition operation and maintenance", which greatly reduces the cost of manual operation and maintenance.

[0058] High versatility: The adaptive locking mechanism can be adapted to guy wires of different diameters, and the universal communication protocol can be adapted to transmission lines of different voltage levels from 35kV to 220kV, which has broad engineering application prospects.

[0059] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0060] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0061] Figure 1 This is a schematic diagram of the intelligent early warning system for guy wire tension based on dual-point monitoring according to an embodiment of the present invention;

[0062] Figure 2 This is a flowchart of a method for intelligent early warning of tension in guy wires based on dual-point monitoring, according to an embodiment of the present invention.

[0063] Explanation of reference numerals in the attached figures:

[0064] 1. S-shaped tension sensor; 2. 16-bit AD converter; 3. Temperature sensor; 4. STM32 microcontroller; 6. 4G communication module; 7. Audible and visual alarm; 8. Solar panel; 9. Lithium battery; 10. Pull cable; 11. Cement pole; 12. Power module; 101. Pull cable handle; 102. Pull cable handle. Detailed Implementation

[0065] To further illustrate the technical means and effects adopted by the present invention to achieve the intended purpose, the specific embodiments, structures, features, and effects according to the present invention will be described in detail below with reference to the accompanying drawings and preferred embodiments. In the following description, different "an embodiment" or "an embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0066] In the description of this invention, it should be clearly stated that the terms "first," "second," etc., in the specification, claims, and accompanying drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence; the terms "vertical," "lateral," "longitudinal," "front," "rear," "left," "right," "up," "down," "horizontal," etc., indicate orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, and are merely for the convenience of describing this invention, and do not mean that the device or element referred to must have a specific orientation or position, and therefore should not be construed as a limitation of this invention.

[0067] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0068] like Figures 1-2 As shown, this embodiment of the invention provides an intelligent early warning system for guy wire tension based on dual-point monitoring, comprising:

[0069] Tension sensing module: includes two S-shaped tension sensors 1 mechanically connected to the cable handle 101 and the cable handle 102 respectively. The sensors are fixed by a high-strength aluminum alloy clamp and connected to a 16-bit AD converter 2.

[0070] Environmental compensation module: includes temperature sensor 3 connected in parallel with each S-shaped tensile sensor 1, used to collect ambient temperature data;

[0071] Main control module: It adopts STM32 microcontroller 4, whose input terminal is connected to AD converter 2 and temperature sensor 3 via ribbon cable, and whose output terminal is connected to 4G communication module 6 and sound and light alarm 7;

[0072] Power supply module: includes solar panel 8, lithium battery 9 and power management chip. The solar panel 8 is fixed by a rain cover and is connected to the power module 12 together with the lithium battery 9.

[0073] Structural protection module: includes an IP67-rated housing that accommodates the main control module and power supply module, and is filled with thermally conductive silicone.

[0074] In addition, a data analysis module is used to identify potential loosening or non-uniform deformation of the guy wire structure based on the difference rate of change and covariance analysis of the tension data at two points.

[0075] In this embodiment, the system first completes the precise deployment and coordinated debugging of each module in practical application. Two S-shaped tension sensors 1 in the tension sensing module are mechanically fixed to the cable handle 101 and cable lower handle 102 respectively using high-strength aluminum alloy clamps. The clamps fit tightly with the cable to ensure effective transmission of the force signal. The analog tension signal collected by the sensors is transmitted in real time to the 16-bit AD converter 2, completing a high-precision conversion from analog to digital signal, laying the foundation for subsequent data processing. The temperature sensor 3 of the environmental compensation module is installed in parallel with each S-shaped tension sensor 1, synchronously collecting ambient temperature data at the monitoring points, providing key parameters for temperature correction of the tension measurement.

[0076] The main control module uses an STM32 microcontroller 4, which receives the tensile digital signal from the AD converter 2 and the temperature data from the temperature sensor 3 via a ribbon cable. As the core control unit of the system, its embedded dedicated algorithm precisely processes the raw data. The processed valid data is transmitted to the audible and visual alarm 7 on one hand, and encrypted and sent to the remote maintenance platform on the other hand via the 4G communication module 6. In the power supply module, the solar panel 8 is fixed to a suitable position on the tower with a rain cover, efficiently collecting solar energy and converting it into electrical energy. Together with the lithium battery 9, it supplies power to the power module 12. The power management chip intelligently regulates the charging and discharging process to ensure that the entire system can obtain a stable power supply under different lighting conditions.

[0077] The IP67-rated protective shell of the structural protection module tightly encloses the main control module and power supply module. The internal thermally conductive silicone not only efficiently dissipates heat generated by the electronic components during operation but also effectively resists the intrusion of external dust and moisture, enabling the system to adapt to complex outdoor temperature and humidity environments. The data analysis module continuously performs in-depth calculations on the tensile force data collected from two points. By calculating the rate of change of the difference between the two tensile force data points, it analyzes the consistency of force transmission between the upper and lower parts of the tension cable. Simultaneously, it uses covariance analysis to determine the correlation between the two data points. When the rate of change of the difference exceeds the normal range or the covariance is abnormal, it can accurately identify potential loosening or non-uniform deformation problems in the tension cable structure.

[0078] This system effectively solves the problem of insufficient accuracy in traditional single-point monitoring through the collaborative work of multiple modules. The symmetrical dual-point monitoring design makes the tension data more valuable. Combined with environmental compensation, efficient power supply, and robust protection design, it ensures stable and long-term operation in harsh outdoor environments. Its standardized fixture design and universal communication protocol can easily adapt to transmission lines of different voltage levels from 35kV to 220kV. It can detect abnormal tension in guy wires in real time, upgrading the traditional "periodic inspection" mode to "condition-based maintenance," significantly reducing the cost of manual inspections, and significantly improving the safe operation level of transmission lines, providing a strong guarantee for the stability and reliability of the power grid.

[0079] In some embodiments, the mechanical connection structure between the S-shaped tension sensor 1 and the pull wire includes:

[0080] The fixture body is made of high-strength aluminum alloy and has a surface anti-corrosion treatment.

[0081] The adaptive locking mechanism includes a variable diameter clamping groove and anti-loosening bolts to accommodate pull cables of different diameters.

[0082] The clamping surface of the adaptive locking mechanism is provided with micro-protrusion texture to increase the static friction with the surface of the pull wire, and a piezoelectric thin film sensor is embedded to monitor the long-term stability of the clamping force.

[0083] In this embodiment, during system installation, the S-shaped tension sensor 1 and the pull wire are precisely fixed via a specialized structure. The clamp body is made of high-strength aluminum alloy and undergoes surface anti-corrosion treatment, providing sufficient structural strength to withstand the long-term tension of the pull wire and effectively resisting the erosion of outdoor elements such as wind, rain, and ultraviolet radiation, thus extending its service life. The adaptive locking mechanism's variable-diameter clamping slot can be flexibly adjusted according to pull wires of different diameters. Combined with the tightening effect of the anti-loosening bolts, it can stably clamp pull wires of various specifications, eliminating the need for custom-made clamps for different diameters and greatly improving the versatility and convenience of installation.

[0084] When the pull cable is in operation, the micro-protrusion texture on the clamping surface of the adaptive locking mechanism significantly increases the static friction with the pull cable surface, effectively preventing relative slippage between the sensor and the pull cable under dynamic loads such as strong wind vibration, ensuring the continuity and accuracy of the tension signal acquisition. Simultaneously, the piezoelectric film sensor embedded in the clamping surface monitors changes in clamping force in real time. When the clamping force decreases due to long-term vibration, thermal expansion and contraction, or other factors, the piezoelectric film sensor transmits relevant signals to the STM32 microcontroller 4. The system can promptly identify potential clamp loosening and issue warning information via the audible and visual alarm 7 or the 4G communication module 6, reminding maintenance personnel to handle the situation promptly.

[0085] This mechanical connection structure is designed to fully consider various needs in practical applications. It solves the compatibility problem of different diameter guy wires and ensures the stability and reliability of the connection through multiple safeguards. Its corrosion-resistant and durable characteristics are suitable for complex outdoor working environments, while the real-time monitoring function of clamping force enables closed-loop management of the installation status of the monitoring system itself, avoiding data distortion caused by loose clamps. This further improves the accuracy and reliability of the entire guy wire tension monitoring system, providing a solid hardware foundation for subsequent data analysis and early warning decisions.

[0086] In some implementations, the temperature compensation algorithm embedded in the main control module is specifically as follows:

[0087] F_comp = F_raw + k × (T - T0);

[0088] Where F_comp is the compensated tensile force value, F_raw is the original measured value, T is the real-time temperature, T0 is the reference temperature, and k is the temperature coefficient;

[0089] Furthermore, the temperature coefficient k is not a fixed value, but a variable that is dynamically updated through linear regression based on historical data, in order to adapt to the long-term aging characteristics of the sensor material.

[0090] In this embodiment, during the tension monitoring of the tension cable, temperature changes significantly affect the measurement accuracy of the S-shaped tension sensor 1. The embedded temperature compensation algorithm effectively counteracts this interference. During system operation, the temperature sensor 3 collects the real-time temperature T of the monitoring environment, while the S-shaped tension sensor 1 collects the original tension value F_raw of the tension cable. These data are synchronously transmitted to the STM32 microcontroller 4. The main control module corrects the original tension data according to the preset temperature compensation formula F_comp = F_raw + k × (T - T0), where F_comp is the accurate tension value after compensation, T0 is the preset reference temperature, and k is the temperature coefficient.

[0091] Unlike traditional fixed-temperature-coefficient compensation methods, the temperature coefficient k in this system is not a constant value, but is dynamically updated through the system's self-learning mechanism. The STM32 microcontroller periodically stores raw tensile force data, corresponding temperature data, and verified accurate tensile force values ​​for a period of time. A linear regression algorithm is used to analyze and process this historical data, continuously optimizing and adjusting the value of the temperature coefficient k to accurately adapt to changes in the aging characteristics of the sensor material caused by long-term stress and temperature cycling. For example, in the initial stage of sensor use, the k value is within the initial set range. As usage time increases, the system automatically corrects the k value through continuous analysis of historical data, ensuring that the accuracy of temperature compensation remains at a high level.

[0092] This dynamic adaptive temperature compensation algorithm effectively solves the problem of traditional static compensation methods struggling to cope with sensor aging, significantly improving the long-term accuracy of tensile force measurement. Under extreme environmental conditions such as low temperatures in winter and high temperatures in summer, the algorithm can quickly respond to temperature changes and promptly correct tensile force measurements, avoiding false alarms caused by temperature interference. Through precise temperature compensation, the system's tensile force measurement error can be controlled within ±1%, providing reliable data support for subsequent multi-level early warning and data analysis. This ensures that maintenance personnel can accurately grasp the actual stress state of the guy wire and promptly identify potential risks.

[0093] In some implementations, the digital filtering algorithm executed by the main control module includes:

[0094] Median filtering based on sliding window to eliminate impulse interference;

[0095] Band-stop filtering based on wire vibration characteristics to suppress mechanical vibration noise;

[0096] It also includes joint filtering based on the spatiotemporal correlation of data at both ends of the string: when a single point of data fluctuates drastically while the data at another point remains stable, it is determined to be interference and filtered out.

[0097] In this embodiment, the tension monitoring process is inevitably affected by various interference factors. The multi-dimensional design of the digital filtering algorithm provides a strong guarantee for data accuracy. After the S-shaped tension sensor 1 and temperature sensor 3 collect the raw data, the STM32 microcontroller 4 first starts the median filtering algorithm based on the sliding window to process the data sequence one by one. By selecting the median value within the sliding window as the valid data, it can quickly eliminate pulse interference caused by sudden situations such as bird strikes and leaf impacts, and avoid the influence of a single abnormal data point on the overall measurement result.

[0098] To address the mechanical vibration noise generated by the guy wire under wind force, the system employs a band-stop filtering algorithm based on the guy wire's vibration characteristics. By analyzing the guy wire's natural vibration frequency, a specific filtering frequency band is set to precisely suppress vibration noise within that band, ensuring that the tension data accurately reflects the actual stress state of the guy wire. More importantly, leveraging the advantage of dual-point monitoring, the system uses a joint filtering algorithm based on the spatiotemporal correlation of data from both ends of the guy wire. When the sensor data at one point fluctuates drastically while the data at the other point remains stable, the system determines that the fluctuation is a local interference signal, rather than a true change in the overall tension of the guy wire, and thus filters out this interference data.

[0099] This multi-layered combination of digital filtering algorithms suppresses and eliminates interference signals from different angles, effectively improving data stability and reliability. Compared with traditional single-filtering methods, this design fully utilizes the redundant information from dual-point monitoring, achieving intelligent identification and precise filtering of interference signals, significantly reducing the system's false alarm rate. The filtered tension data more accurately reflects the actual stress on the guy wire, providing a high-quality data foundation for subsequent early warning logic judgment and data analysis. This ensures that the system can identify the true abnormal state of the guy wire in a timely and accurate manner, providing reliable protection for the safe operation of transmission lines.

[0100] In some implementations, the sleep / wake-up mechanism of the power supply module specifically includes:

[0101] During non-collection periods, power to AD converter 2 and 4G communication module 6 shall be turned off;

[0102] The system is woken up every minute by a timer interrupt to collect data.

[0103] Static power consumption is controlled below 5mA;

[0104] It also includes an event-triggered emergency wake-up mechanism: when the rate of change of the value detected by any tension sensor exceeds a preset emergency threshold, the system immediately exits the sleep state and enters the high-frequency acquisition and transmission mode.

[0105] In this embodiment, the power supply module's sleep / wake-up mechanism achieves a perfect balance between low power consumption and fast response through intelligent control. During non-data acquisition periods, the STM32 microcontroller 4 issues control commands to shut down the power supply to the AD converter 2 and the 4G communication module 6. At this time, the entire system retains only a weak power supply to the core control circuit, entering a low-power sleep state, effectively reducing power consumption. Simultaneously, the system's internal timer starts counting, triggering interrupt signals at preset minute intervals to wake the system from sleep mode and enter data acquisition mode.

[0106] Upon waking, the system immediately powers the AD converter 2 and the 4G communication module 6. The S-shaped tension sensor 1 and the temperature sensor 3 simultaneously collect data on the tension of the tension cable and the ambient temperature. After AD conversion and data processing, the valid data is transmitted to the maintenance platform via the 4G communication module 6. After data transmission, the system enters sleep mode again, and this cycle repeats. In addition, the system is equipped with an event-triggered emergency wake-up mechanism. When the rate of change of the tension value detected by any S-shaped tension sensor 1 exceeds the preset emergency threshold, the system will immediately exit sleep mode, regardless of whether it is in a sleep cycle, and quickly start the high-frequency acquisition and transmission mode to capture detailed data on the tension change in real time, and push the warning information to the maintenance platform as soon as possible.

[0107] The hibernation-wake-up mechanism effectively solves the problems of high power consumption and short battery life of outdoor monitoring equipment, strictly controlling the system's static power consumption to below 5mA. Combined with the dual power supply mode of solar panel 8 and lithium battery 9, it ensures that the system can still operate normally for more than 7 consecutive days of cloudy and rainy weather. The emergency wake-up mechanism ensures the system's rapid response capability to emergencies. When there are signs of cable breakage or tower impacts, the emergency monitoring mode can be activated immediately, buying valuable time for maintenance personnel and effectively preventing the accident from escalating. This intelligent power management method extends the lifespan of lithium battery 9 and ensures the timely monitoring of the system, providing strong support for the long-term stable operation of the system.

[0108] In some implementations, the warning logic is designed as a multi-level threshold judgment:

[0109] Level 1 warning: When the monitored value exceeds the preset threshold by ±10%, the audible and visual alarm 7 will flash.

[0110] Level 2 warning: When the error exceeds ±20%, an alarm message will be simultaneously pushed to the operation and maintenance platform;

[0111] It also includes predictive warnings based on the deviation of the historical tensile-temperature curve: when the real-time data curve deviates significantly and continuously from the curve shape under historical healthy conditions, an early warning is triggered even if the absolute value threshold is not reached.

[0112] In this embodiment, the system's early warning logic achieves comprehensive and accurate early warning of abnormal tension in the guy wire through multi-level judgment and predictive analysis. During daily monitoring, the STM32 microcontroller 4 compares the tension data, after temperature compensation and digital filtering, with a preset tension threshold in real time. When the monitored value exceeds ±10% of the preset threshold, the system triggers a first-level early warning. At this time, the audible and visual alarm 7 starts flashing to inform nearby staff of the potential risk, facilitating timely on-site verification.

[0113] When the monitored value exceeds the preset threshold by ±20%, the system immediately triggers a level-two warning. In addition to the continuous operation of the audible and visual alarm 7, the 4G communication module 6 will simultaneously push detailed alarm information, including the location of the abnormal guy wire, real-time tension value, temperature data, etc., to the remote operation and maintenance platform, enabling operation and maintenance personnel to grasp the fault situation as soon as possible and quickly formulate a handling plan. In addition, the system also has a predictive warning function based on the deviation of the historical tension-temperature curve. The operation and maintenance platform will store the historical tension-temperature curve data of the guy wire in a healthy state, and compare the currently collected tension-temperature data curve with the historical curve in real time, and determine the status of the guy wire by calculating the curve deviation.

[0114] When the real-time data curve deviates significantly and continuously from the historical health curve, the system will trigger an early warning even if the current tension value has not reached the preset absolute threshold, prompting maintenance personnel to pay attention to changes in the status of the guy wire. This multi-level warning logic design not only enables timely response to obvious anomalies but also allows for early detection of potential faults, achieving a shift from passive response to proactive prevention. Precise warning grading makes maintenance work more targeted, effectively reducing ineffective inspections and improving maintenance efficiency. It also significantly reduces the probability of serious accidents such as tilting or collapsing of concrete poles due to guy wire faults, providing multi-layered protection for the safe and stable operation of transmission lines.

[0115] In some implementations, the 4G communication module 6 supports:

[0116] Encrypted data transmission based on the MQTT protocol;

[0117] Automatic reconnection after disconnection and data caching mechanism;

[0118] It also supports software over-the-air (FOTA) upgrades for the communication module and dynamic adjustment of system operating parameters by receiving cloud commands.

[0119] In this embodiment, the 4G communication module 6 serves as a data transmission bridge between the system and the remote operation and maintenance platform, undertaking important functions such as data transmission and remote maintenance. During data transmission, the 4G communication module 6 uses the MQTT protocol to encrypt the monitoring data, ensuring the security and confidentiality of the data during transmission and effectively preventing data theft or tampering. In the event of sudden situations such as network signal interruption, the module has an automatic reconnection function. It continuously monitors the network status, and once the network is restored, it immediately re-establishes the connection and completely uploads the monitoring data cached during the disconnection to the operation and maintenance platform, ensuring the continuity and integrity of data transmission and avoiding data loss due to network problems.

[0120] To address system function upgrades and parameter adjustments, the 4G communication module 6 supports remote wireless software upgrades. Maintenance personnel can download new firmware to the module via a cloud platform. Upon receiving the firmware, the STM32 microcontroller 4 automatically verifies and updates it. The entire upgrade process eliminates the need for personnel to climb the tower, significantly reducing maintenance costs and security risks. Simultaneously, the module can receive remote commands from the cloud platform and dynamically adjust system operating parameters according to actual maintenance needs. For example, it can adjust data acquisition frequency based on seasonal weather characteristics, adjust warning thresholds based on the aging of guy wires, and adjust sleep duration based on changes in grid load, enabling the system to flexibly adapt to different working scenarios and operational requirements.

[0121] The functional design of the 4G communication module 6 significantly improves the maintainability and flexibility of the system. Stable and reliable data transmission ensures that maintenance personnel can monitor the operating status of the guy wires in real time, while remote upgrade and parameter configuration functions allow the system to continuously optimize performance according to actual needs without requiring large-scale on-site modifications. Its strong network adaptability and anti-interference performance ensure stable operation in harsh communication environments such as remote areas and complex terrains, providing solid communication support for the digital and intelligent operation and maintenance of the entire guy wire tension monitoring system.

[0122] This invention also provides a method for monitoring the tension of a guy wire based on the system described above, comprising the following steps:

[0123] Simultaneous acquisition of tension and temperature data of the guy wire using dual-point sensors;

[0124] Data is processed using temperature compensation and digital filtering algorithms;

[0125] The tension status is determined based on multi-level thresholds, and corresponding warnings are triggered accordingly.

[0126] Data is encrypted and transmitted to the cloud platform via 4G network;

[0127] It also includes: the cloud platform performs fusion analysis on the received dual-point data to establish a digital twin model of the guy wire system, which is used to simulate the stress state under different working conditions and predict the lifespan.

[0128] In this embodiment, the monitoring method achieves accurate monitoring and intelligent analysis of the tension of the guy wire throughout its entire lifecycle, following a standardized process. First, the dual-point sensors deployed on the guy wire handle 101 and the guy wire lower handle 102 are activated simultaneously. The S-shaped tension sensor 1 collects the tension data of the guy wire in real time, and the temperature sensor 3 collects the corresponding ambient temperature data simultaneously, ensuring the spatiotemporal consistency of the two types of data and providing accurate basic data for subsequent data processing.

[0129] After the acquired raw data is transmitted to the STM32 microcontroller, the system immediately initiates temperature compensation and digital filtering algorithms to process the data. The temperature compensation algorithm corrects the original tensile force value based on real-time temperature data, eliminating the impact of temperature changes on measurement accuracy. The digital filtering algorithm, through a multi-layered filtering mechanism, effectively removes pulse interference and mechanical vibration noise, obtaining effective data that truly reflects the tension state of the tension wire. Subsequently, the system judges the processed data according to preset multi-level warning thresholds. If the data exceeds the corresponding threshold, it immediately triggers the corresponding audible and visual alarm and remote push action, ensuring that abnormal situations can be detected and responded to in a timely manner.

[0130] Simultaneously, the 4G communication module 6 transmits the processed data to the cloud platform via encryption. The cloud platform performs in-depth fusion analysis on the received dual-point data, combining information such as the material characteristics, design parameters, and historical operating data of the guy wires to establish a digital twin model of the guy wire system. This model can accurately simulate the stress state of the guy wires under different weather conditions and load conditions. Through simulation analysis of the model, the remaining service life of the guy wires can be predicted, providing a scientific basis for maintenance personnel to formulate targeted maintenance plans.

[0131] This monitoring method achieves intelligent operation throughout the entire process, from data acquisition, processing, early warning to analysis and prediction. It not only solves the problems of low accuracy and poor efficiency of traditional monitoring methods but also elevates monitoring capabilities to a new level through digital twin technology. It can predict potential faults in power lines in advance, enabling early warning and transforming maintenance work from reactive emergency repairs to proactive prevention. This significantly reduces the operational risks and maintenance costs of transmission lines, providing a feasible technical solution for intelligent operation and maintenance of the power grid.

[0132] In some implementations, it also includes:

[0133] The operations and maintenance platform generates a line health curve based on historical data;

[0134] The data collection frequency and early warning threshold can be dynamically adjusted via a remote parameter configuration interface.

[0135] It also includes: the platform automatically sends instructions to the guy wire monitoring system in a specific area based on alarm information from the regional power grid and meteorological disaster warnings, temporarily increasing the collection frequency and warning level.

[0136] In this embodiment, the operation and maintenance platform acts as the central hub of the entire monitoring system. Through in-depth data mining and intelligent control, it achieves refined management of the guy wire status. After receiving real-time data from various monitoring terminals, the platform automatically generates a health curve for each guy wire based on historically accumulated data such as tension and temperature. This curve can intuitively reflect the stress change trend and stability of the guy wire at different times. By viewing the health curve, operation and maintenance personnel can quickly determine the overall operating status of the guy wire and promptly detect potential anomalies.

[0137] For different regions and types of guy wires, maintenance personnel can dynamically adjust the operating parameters of monitoring terminals through the platform's remote parameter configuration interface. For example, for guy wires in high-risk areas, the data acquisition frequency can be appropriately increased to ensure timely capture of subtle status changes; for guy wires with stable operation, the acquisition frequency can be reduced to save energy. Simultaneously, the platform has the capability to link with regional power grid alarm systems and meteorological disaster early warning systems. When it receives early warning information for meteorological disasters such as typhoons, hail, or heavy rainfall, or when a fault alarm occurs on a nearby line, the platform automatically analyzes the affected guy wire range and sends instructions to all monitoring terminals within that area to temporarily increase the acquisition frequency and early warning level, putting the system into enhanced monitoring mode.

[0138] This intelligent platform management model effectively improves the targeting and efficiency of operation and maintenance work. Health curves provide data support for operation and maintenance decisions, avoiding blind inspections; remote parameter configuration reduces the workload and cost of on-site maintenance; and linkage with external systems enables proactive defense against emergencies, allowing for advance emergency preparation and minimizing disaster losses. Through unified management of the operation and maintenance platform, centralized control of distributed guy wire monitoring terminals is achieved, improving the digitalization level and emergency response capabilities of the entire transmission line operation and maintenance, and providing strong management support for the safe and stable operation of the power grid.

[0139] This invention also provides an installation structure for a guy wire tension monitoring system, applied to the guy wire tension intelligent early warning system described above, comprising:

[0140] The rain cover and the IP67 housing are connected by a snap-on sealing ring 1;

[0141] The solar panel 8 is fixed to the side of the tower with an adjustable tilt bracket;

[0142] All cables are introduced into the housing via waterproof connectors;

[0143] It also includes an on-site calibration structure for calibrating the sensor zero point: the structure includes a handheld standard force gauge that can be temporarily connected in parallel with a pull wire, and a calibration button on the housing. When pressed, the system enters calibration mode, reads the current standard value, and corrects the sensor zero point.

[0144] In this embodiment, the system's installation structure fully considers adaptability to outdoor environments and ease of maintenance, ensuring long-term stable operation. During installation, the rain cover and IP67 housing are tightly connected by a snap-fit ​​sealing ring 1, forming a double-protection structure that effectively prevents rainwater, dust, and other impurities from entering the housing, protecting core components such as the main control module and power supply module from damage. The solar panel 8 is fixed to the side of the tower using an adjustable tilt bracket. Maintenance personnel can flexibly adjust the tilt angle of the solar panel 8 according to local sunlight conditions to maximize solar energy collection efficiency and ensure that the power supply module receives sufficient power.

[0145] All connecting cables are routed into the IP67 housing via waterproof connectors, preventing cable connections from becoming weak points in waterproofing and dustproofing, thus further enhancing the overall protection performance of the system. In addition, the system features a specially designed on-site calibration structure for calibrating the sensor's zero point. During initial installation or later maintenance, maintenance personnel can temporarily connect a handheld standard force gauge in parallel to the tension cable, secure it with a special clamp, and tighten it to a stable standard tension value. Then, pressing the calibration button on the IP67 housing immediately puts the system into calibration mode. The STM32 microcontroller reads the measured value of the current S-shaped tension sensor 1 and compares it with the value of the standard force gauge, automatically calculating and storing the zero-point offset, thus completing the precise correction of the sensor's zero point.

[0146] The installation structure is designed to ensure reliable operation of the system in harsh outdoor environments. Its IP67 protection rating and comprehensive waterproof and dustproof design enable the system to operate in a wide temperature range of -40℃ to 70℃ and in high-humidity, dusty environments. Adjustable-tilt solar panels improve energy efficiency and ensure stable power supply. The on-site calibration structure solves the problem of zero-point offset after sensor installation, ensuring the accuracy of measurement data. The calibration process is simple and convenient, requiring no complex equipment or professional skills, thus reducing maintenance difficulty and costs. The overall rationality and practicality of the installation structure provide a solid hardware guarantee for the long-term stable operation and accurate monitoring of the system.

[0147] In a laboratory environment, using a tensile testing machine to simulate different loads ranging from 0-50kN, the sensor's linearity error was verified to be <±0.8%, and repeatability error <±0.5%. In outdoor tests in areas with frequent lightning strikes, high humidity, and strong winds, the system operated continuously for six months without failure, meeting electromagnetic interference resistance standards, and exhibiting no corrosion on the anti-corrosion structure. Practical application in transmission lines of different voltage levels from 35kV to 220kV shows that the system's tensile force measurement error is stably controlled within ±1.5%, with a warning accuracy rate ≥99.2%, significantly reducing operation and maintenance costs. It possesses clear industrial application value and broad prospects for widespread adoption.

[0148] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the devices, apparatuses, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0149] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and these modifications or substitutions should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A smart early warning system for guy wire tension based on dual-point monitoring, characterized in that, include: The tension sensing module includes two S-shaped tension sensors (1) mechanically connected to the cable handle (101) and the cable lower handle (102) respectively. The sensors are fixed by a high-strength aluminum alloy clamp and connected to a 16-bit AD converter (2). Environmental compensation module: includes a temperature sensor (3) connected in parallel with each S-shaped tensile sensor (1) for collecting ambient temperature data; Main control module: It adopts an STM32 microcontroller (4), whose input end is connected to the AD converter (2) and temperature sensor (3) via a ribbon cable, and whose output end is connected to the 4G communication module (6) and the sound and light alarm (7). Power supply module: includes solar panel (8), lithium battery (9) and power management chip. The solar panel (8) is fixed by a rain cover and is connected to the power supply module (12) together with the lithium battery (9). Structural protection module: includes an IP67-rated housing that accommodates the main control module and power supply module, and is filled with thermally conductive silicone. In addition, a data analysis module is used to identify potential loosening or non-uniform deformation of the guy wire structure based on the difference rate of change and covariance analysis of the tension data at two points.

2. The intelligent early warning system for guy wire tension based on dual-point monitoring according to claim 1, characterized in that, The mechanical connection structure between the S-shaped tension sensor (1) and the pull wire includes: The fixture body is made of high-strength aluminum alloy and has a surface anti-corrosion treatment. The adaptive locking mechanism includes a variable diameter clamping groove and anti-loosening bolts to accommodate pull cables of different diameters. The clamping surface of the adaptive locking mechanism is provided with micro-protrusion texture to increase the static friction with the surface of the pull wire, and a piezoelectric thin film sensor is embedded to monitor the long-term stability of the clamping force.

3. The intelligent early warning system for guy wire tension based on dual-point monitoring according to claim 1, characterized in that, The temperature compensation algorithm embedded in the main control module is as follows: F_comp = F_raw + k × (T - T0); Where F_comp is the compensated tensile force value, F_raw is the original measured value, T is the real-time temperature, T0 is the reference temperature, and k is the temperature coefficient; Furthermore, the temperature coefficient k is not a fixed value, but a variable that is dynamically updated through linear regression based on historical data, in order to adapt to the long-term aging characteristics of the sensor material.

4. The intelligent early warning system for guy wire tension based on dual-point monitoring according to claim 1, characterized in that, The digital filtering algorithm executed by the main control module includes: Median filtering based on sliding window to eliminate impulse interference; Band-stop filtering based on wire vibration characteristics to suppress mechanical vibration noise; It also includes joint filtering based on the spatiotemporal correlation of data at both ends of the string: when a single point of data fluctuates drastically while the data at another point remains stable, it is determined to be interference and filtered out.

5. The intelligent early warning system for guy wire tension based on dual-point monitoring according to claim 1, characterized in that, The sleep / wake-up mechanism of the power supply module specifically includes: Power is turned off to the AD converter (2) and the 4G communication module (6) during non-collection periods; The system is woken up every minute by a timer interrupt to collect data. Static power consumption is controlled below 5mA; It also includes an event-triggered emergency wake-up mechanism: when the rate of change of the value detected by any tension sensor exceeds a preset emergency threshold, the system immediately exits the sleep state and enters the high-frequency acquisition and transmission mode.

6. The intelligent early warning system for guy wire tension based on dual-point monitoring according to claim 1, characterized in that, The early warning logic is designed with multi-level threshold judgment: Level 1 warning: When the monitored value exceeds the preset threshold by ±10%, the audible and visual alarm (7) will flash. Level 2 warning: When the error exceeds ±20%, an alarm message will be simultaneously pushed to the operation and maintenance platform; It also includes predictive warnings based on the deviation of the historical tensile-temperature curve: when the real-time data curve deviates significantly and continuously from the curve shape under historical healthy conditions, an early warning is triggered even if the absolute value threshold is not reached.

7. The intelligent early warning system for guy wire tension based on dual-point monitoring according to claim 1, characterized in that, The 4G communication module (6) supports: Encrypted data transmission based on the MQTT protocol; Automatic reconnection after disconnection and data caching mechanism; It also supports remote wireless software upgrades for the communication module, as well as dynamic adjustment of system operating parameters by receiving cloud commands.

8. A method for monitoring guy wire tension based on the dual-point monitoring intelligent early warning system for guy wire tension according to any one of claims 1-7, characterized in that, Including the following steps: Simultaneous acquisition of tension and temperature data of the guy wire using dual-point sensors; Data is processed using temperature compensation and digital filtering algorithms; The tension status is determined based on multi-level thresholds, and corresponding warnings are triggered accordingly. Data is encrypted and transmitted to the cloud platform via 4G network; It also includes: the cloud platform performs fusion analysis on the received dual-point data to establish a digital twin model of the guy wire system, which is used to simulate the stress state under different working conditions and predict the lifespan.

9. The method according to claim 8, characterized in that, Also includes: The operations and maintenance platform generates a line health curve based on historical data; The data collection frequency and early warning threshold can be dynamically adjusted via a remote parameter configuration interface. It also includes: the platform automatically sends instructions to the guy wire monitoring system in a specific area based on alarm information from the regional power grid and meteorological disaster warnings, temporarily increasing the collection frequency and warning level.

10. An installation structure for a guy wire tension monitoring system, applied to the guy wire tension intelligent early warning system according to any one of claims 1-7, characterized in that, include: The rain cover is connected to the IP67 housing via a snap-on sealing ring. The solar panel (8) is fixed to the side of the tower with an adjustable tilt bracket; All cables are introduced into the housing via waterproof connectors; It also includes an on-site calibration structure for calibrating the sensor zero point: the structure includes a handheld standard force gauge that can be temporarily connected in parallel with a pull wire, and a calibration button on the housing. When pressed, the system enters calibration mode, reads the current standard value, and corrects the sensor zero point.

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