Sensor reliability design method in complex and hard environment

Abstract

The invention discloses a sensor reliability design method in a complex and hard environment, and belongs to the technical field of reliability design, and the method comprises the following steps: carrying out the structural dynamics modeling of a vibration load in a target application scene, and quantifying the actual load characteristics of a sensor in a high vibration environment; based on an environmental load result, modal analysis and resonance avoidance design are carried out on a sensitive element and a supporting structure of the sensor, and effective attenuation of high-frequency vibration energy is realized through optimization of a vibration isolation layer and a damping material; a multi-stage sealing and moisture-proof coating design is implemented on the basis of an anti-vibration structure, and corrosion and performance drift caused by damp-heat coupling are reduced through a nano hydrophobic material and an airtight compartment structure; and signal self-correction is realized through multi-sensor redundancy layout and weighted fusion. By the adoption of the method, real-time correction of vibration offset is achieved, and the sensor can still keep stable measurement precision under the continuous strong vibration working condition.

Description

Technical Field

[0001] This invention relates to the field of reliability design technology, and in particular to a sensor reliability design method for complex and challenging environments. Background Technology

[0002] In industrial sites such as coal mines, coal shafts, crushing plants, and vibrating screens, equipment is subjected to long-term intense mechanical vibration, periodic impacts, and wide-frequency random excitation environments. Various sensors installed on these devices (acceleration, displacement, pressure, force, strain, etc.) often experience a series of reliability problems due to vibration loads. For example, continuous vibration can lead to fatigue damage to sensitive elements, microcracks in structural components, or weld detachment; resonance can cause measurement distortion or even device failure; high-amplitude vibrations can cause loose connections, internal friction, and structural deformation, further resulting in zero-point drift and transmission errors; random impacts can cause unstable sensor output and significantly shorten sensor lifespan. Existing sensor reliability designs mostly rely on empirical methods such as rubber vibration isolation or thickened structural components, lacking a systematic design framework based on vibration spectra, dynamic stress distribution, and fatigue life prediction. They also lack structural vibration-resistant design methods and dynamic compensation strategies suitable for harsh, high-vibration environments.

[0003] Therefore, how to construct a systematic sensor vibration-resistant structure design method in high-vibration environments to improve the reliability and measurement stability of sensors under harsh actual working conditions has become an urgent technical problem to be solved. Summary of the Invention

[0004] The purpose of this invention is to provide a sensor reliability design method for complex and challenging environments, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, this invention provides a sensor reliability design method for complex and challenging environments, comprising the following steps: S1. By modeling the structural dynamics of vibration loads in the target application scenario, the actual load characteristics of the sensor in a high vibration environment are quantified. S2. Based on the environmental load results, modal analysis and resonance avoidance design are carried out on the sensor's sensitive element and support structure. The effective attenuation of high-frequency vibration energy is achieved through the optimization of vibration isolation layer and damping material. S3. Implement a multi-level sealing and moisture-proof coating design on the basis of the vibration-resistant structure, and reduce corrosion and performance drift caused by moisture-heat coupling through nano-hydrophobic materials and airtight compartment structure. S4. Signal self-calibration is achieved through redundant multi-sensor layout and weighted fusion, and the measurement stability and accuracy of the sensor in complex environments are improved by using a multi-parameter correction model of temperature, humidity and vibration.

[0006] Preferably, step S1 includes: S11. Deploy multi-point acquisition modules in the target application environment of the sensor to measure the time-series signal, impact peak value and spectral distribution of triaxial vibration acceleration, and establish a vibration condition database. S12. Based on the collected data, establish a dynamic finite element model, transform the vibration time sequence signal into time-varying boundary conditions, and solve the dynamic stress, displacement response and local natural frequency of the sensor housing, sensitive element and support structure. S13. Based on the simulation analysis results, identify the locations of stress concentration areas, resonance areas, and high-risk areas of structural fatigue, and form a distribution map of key nodes.

[0007] Preferably, step S2 includes: S21. Based on the dynamic finite element model in step S12, calculate the natural frequencies and mode shapes of the sensor housing and support structure, and find the frequency bands that overlap with the environmental excitation spectrum. S22. The mass-stiffness distribution of the shell and support structure is optimized by using a topology optimization algorithm. By reasonably adding stiffeners or honeycomb sandwich layers, the main frequency avoids the excitation frequency band. S23. Introduce magnetorheological dampers or electro-elastic layers at key connection points to achieve variable damping and variable stiffness characteristics, and adjust the structural response online through control signals.

[0008] Preferably, step S3 includes: S31. Based on the structural features output in step S2, construct a three-layer sealing system consisting of an outer protective shield, a middle main sealing ring, and an inner sensitive cavity secondary encapsulation. S32. A composite material of shape memory polymer and fluororubber is used at the main sealing ring. When vibration causes a gap, it can automatically recover the compression deformation and maintain the sealing performance. S33. A replaceable miniature desiccant box or electrochemical dehumidifier is installed inside the sensitive chamber, and inert gas is introduced for filling. The internal humidity and pressure are controlled and stabilized through a pressure balancing valve.

[0009] Preferably, step S4 includes: S41. Adopt a heterogeneous redundancy layout on key measurement units to ensure that a single failure does not affect the system output; S42. Residual sequences are formed by comparing the differences in output from multiple channels. When the adaptive threshold is exceeded, it is judged as a faulty or degraded unit; S43. Adjust the fusion weights based on the unit health status and noise variance.

[0010] Preferably, the expression for the fusion weight is: ; ; in, This represents the integrated output signal after fusion. Indicates the number of redundant channels. Indicates the first The weighting coefficients for each channel, Indicates the first The output signal of each channel Indicates the first The output variance of each channel For the first Degradation or environmental penalty factors in each channel.

[0011] Preferably, the acquisition module includes a sensor and a sensitive element.

[0012] Preferably, both the sensor and the sensing element are small-sized components.

[0013] Preferably, the sensor includes an attitude sensor and a crystal oscillator, both of which employ a dual-redundant design.

[0014] Therefore, the present invention adopts the above-mentioned sensor reliability design method in complex and harsh environments, which has the following beneficial effects: by adopting design methods such as topology optimization, finite element vibration response analysis, and key component strengthening, the stress concentration of the sensor under broadband vibration is significantly reduced, the fatigue life is extended, and the probability of structural failure is significantly reduced; at the same time, resonance is avoided, and the overall stability is improved.

[0015] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0016] Figure 1 This is a flowchart illustrating a sensor reliability design method for complex and challenging environments, as described in an embodiment of the present invention. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, not all, of the embodiments of the present invention. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0018] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0019] Example like Figure 1 As shown, this invention provides a sensor reliability design method for complex and challenging environments, comprising the following steps: S1. By modeling the structural dynamics of vibration loads in the target application scenario, the actual load characteristics of the sensor in a high vibration environment are quantified, providing load boundary conditions for subsequent structural and material design.

[0020] In this embodiment, S1 includes: S11. Deploy multi-point acquisition modules (including sensors and sensitive elements) in the target application environment of the sensors (such as high-vibration environments like coal mines, mine shafts, crushing plants, and vibrating screens) to measure the time-series signals, impact peak values, and spectral distribution of triaxial vibration acceleration, and establish a vibration condition database. Both the sensors and sensitive elements use small-sized components, which can effectively resist vibration. The sensors include attitude sensors and crystal oscillators, both of which employ a dual-redundant design.

[0021] S12. Based on the collected data, establish a dynamic finite element model, transform the vibration time sequence signal into time-varying boundary conditions, and solve for the dynamic stress, displacement response and local natural frequency of the sensor housing, sensitive element and support structure.

[0022] S13. Based on the simulation analysis results, identify the locations of stress concentration areas, resonance areas, and high-risk areas of structural fatigue, and form a distribution map of key nodes.

[0023] S2. Based on the environmental load results, modal analysis and resonance avoidance design are carried out on the sensor's sensitive element and support structure. The effective attenuation of high-frequency vibration energy is achieved through the optimization of vibration isolation layer and damping material.

[0024] In this embodiment, S2 includes: S21. Based on the dynamic finite element model in step S12, calculate the natural frequencies and mode shapes of the sensor housing and support structure, and identify the frequency bands that overlap with the environmental excitation spectrum.

[0025] S22. The topology optimization algorithm is used to optimize the mass-stiffness distribution of the shell and support structure. By reasonably adding reinforcing ribs or honeycomb interlayers, the main frequency avoids the excitation frequency band.

[0026] S23. Introduce magnetorheological dampers or electrovariable elastic layers at key connection points to achieve variable damping and variable stiffness characteristics, and adjust the structural vibration response online through control signals.

[0027] S3. Implement multi-level sealing and moisture-proof coating design on the basis of vibration-resistant structure, and reduce corrosion and performance drift caused by moisture-heat coupling through nano-hydrophobic materials and airtight compartment structure.

[0028] In this embodiment, S3 includes: S31. Based on the structural features output in step S2, construct a three-layer sealing system consisting of an outer protective shield, a middle main sealing ring, and an inner sensitive cavity secondary encapsulation.

[0029] S32. A composite material of shape memory polymer (SMP) and fluororubber is used at the main sealing ring. When vibration causes a gap, it can automatically recover the compression deformation and maintain the sealing performance.

[0030] S33. A replaceable miniature desiccant box or electrochemical dehumidifier is installed inside the sensitive chamber, and inert gas is introduced for filling. The internal humidity and pressure are controlled and stabilized through a pressure balancing valve.

[0031] S4. Signal self-calibration is achieved through redundant multi-sensor layout and weighted fusion, and the measurement stability and accuracy of the sensor in complex environments are improved by using a multi-parameter correction model of temperature, humidity and vibration.

[0032] In this embodiment, S4 includes: S41. Adopt a heterogeneous redundant layout (such as using piezoresistive and capacitive types simultaneously) on key measurement units to ensure that a single failure does not affect the system output.

[0033] S42. Residual sequences are formed by comparing the differences in output from multiple channels. When the threshold is exceeded, it is judged as a faulty or degraded unit.

[0034] S43. Adjust the fusion weights based on the unit health status and noise variance: ; ; in, This represents the integrated output signal after fusion. Indicates the number of redundant channels. Indicates the first The weighting coefficients for each channel, Indicates the first The output signal of each channel Indicates the first The output variance of each channel For the first Degradation or environmental penalty factors in each channel.

[0035] Therefore, the present invention adopts the above-mentioned sensor reliability design method in complex and harsh environments. Through vibration load modeling, structural vibration resistance optimization, stability enhancement and dynamic compensation fusion mechanism, the present invention improves the structural strength, fatigue resistance and signal stability of the sensor in high vibration environment, and achieves reduced measurement error, extended life and significantly improved reliability.

[0036] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. A sensor reliability design method for complex and challenging environments, characterized in that, Includes the following steps: S1. By modeling the structural dynamics of vibration loads in the target application scenario, the actual load characteristics of the sensor in a high vibration environment are quantified. S2. Based on the environmental load results, modal analysis and resonance avoidance design are carried out on the sensor's sensitive element and support structure. The effective attenuation of high-frequency vibration energy is achieved through the optimization of vibration isolation layer and damping material. S3. Implement a multi-level sealing and moisture-proof coating design on the basis of the vibration-resistant structure, and reduce corrosion and performance drift caused by moisture-heat coupling through nano-hydrophobic materials and airtight compartment structure. S4. Signal self-calibration is achieved through redundant multi-sensor layout and weighted fusion, and the measurement stability and accuracy of the sensor in complex environments are improved by using a multi-parameter correction model of temperature, humidity and vibration.

2. The sensor reliability design method for complex and challenging environments according to claim 1, characterized in that, Step S1 includes: S11. Deploy multi-point acquisition modules in the target application environment of the sensor to measure the time-series signal, impact peak value and spectral distribution of triaxial vibration acceleration, and establish a vibration condition database. S12. Based on the collected data, establish a dynamic finite element model, transform the vibration time sequence signal into time-varying boundary conditions, and solve the dynamic stress, displacement response and local natural frequency of the sensor housing, sensitive element and support structure. S13. Based on the simulation analysis results, identify the locations of stress concentration areas, resonance areas, and high-risk areas of structural fatigue, and form a distribution map of key nodes.

3. The sensor reliability design method for complex and challenging environments according to claim 2, characterized in that, Step S2 includes: S21. Based on the dynamic finite element model in step S12, calculate the natural frequencies and mode shapes of the sensor housing and support structure, and find the frequency bands that overlap with the environmental excitation spectrum. S22. The mass-stiffness distribution of the shell and support structure is optimized by using a topology optimization algorithm. By reasonably adding stiffeners or honeycomb sandwich layers, the main frequency avoids the excitation frequency band. S23. Introduce magnetorheological dampers or electro-elastic layers at key connection points to achieve variable damping and variable stiffness characteristics, and adjust the structural response online through control signals.

4. The sensor reliability design method for complex and challenging environments according to claim 3, characterized in that, Step S3 includes: S31. Based on the structural features output in step S2, construct a three-layer sealing system consisting of an outer protective shield, a middle main sealing ring, and an inner sensitive cavity secondary encapsulation. S32. A composite material of shape memory polymer and fluororubber is used at the main sealing ring. When vibration causes a gap, it can automatically recover the compression deformation and maintain the sealing performance. S33. A replaceable miniature desiccant box or electrochemical dehumidifier is installed inside the sensitive chamber, and inert gas is introduced for filling. The internal humidity and pressure are controlled and stabilized through a pressure balancing valve.

5. The sensor reliability design method for complex and challenging environments according to claim 2, characterized in that, Step S4 includes: S41. Adopt a heterogeneous redundancy layout on key measurement units to ensure that a single failure does not affect the system output; S42. Residual sequences are formed by comparing the differences in output from multiple channels. When the adaptive threshold is exceeded, it is judged as a faulty or degraded unit; S43. Adjust the fusion weights based on the unit health status and noise variance.

6. The sensor reliability design method for complex and challenging environments according to claim 5, characterized in that, The expression for the fusion weight is: ； ； in, This represents the integrated output signal after fusion. Indicates the number of redundant channels. Indicates the first The weighting coefficients for each channel, Indicates the first The output signal of each channel Indicates the first The output variance of each channel For the first Degradation or environmental penalty factors in each channel.

7. The sensor reliability design method for complex and challenging environments according to claim 2, characterized in that, The data acquisition module includes sensors and sensitive elements.

8. The sensor reliability design method for complex and challenging environments according to claim 7, characterized in that, Both the sensor and the sensing element use small-sized components.

9. The sensor reliability design method for complex and challenging environments according to claim 8, characterized in that, The sensors include an attitude sensor and a crystal oscillator, both of which employ a dual-redundancy design.

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