Surface multi-factor acquisition sensing unit, use method and system

Abstract

The invention discloses a surface multi-factor acquisition sensing unit of an insulated wire clamp, a use method and a system, and belongs to the technical field of power transmission line equipment electric power fitting monitoring. A PDMS flexible sensing unit comprising a unique adhesion layer, a strain transmission layer and a protection layer sandwich structure is poured by adopting a layer-by-layer pouring process, and a first FBG strain sensor, a second FBG strain sensor, an FBG vibration sensor and an FBG temperature sensor are pre-embedded, so that a complete insulation wire clamp surface multi-factor monitoring system is constructed. The problems that an insulation wire clamp in the prior art cannot accurately monitor various mechanical states in real time, early warn potential faults and recognize and sense self faults are solved, and the technical effect of remarkably improving operation reliability and safety of a power transmission line is achieved.

Description

Technical Field

[0001] This application relates to the field of power fittings monitoring technology for transmission line equipment, specifically to a surface multi-factor acquisition sensing unit for insulated clamps, its usage method, and system. Background Technology

[0002] Insulated clamps play a crucial role in securing conductors and insulators in power lines, and their long-term mechanical condition directly affects line safety. Current technologies lack effective and accurate methods for monitoring clamp surface strain, making it difficult to detect potential mechanical failures in a timely manner. Furthermore, it's challenging to capture abnormal strain in clamps under harsh environments such as salt spray and strong winds, and to prevent failures like breakage and detachment due to reduced structural load-bearing capacity. Simultaneously, sensors age over time and are affected by environmental factors such as humidity and salt spray corrosion, leading to malfunctions. In a traditional standard sensing system, the monitoring system cannot independently determine whether the data obtained by the sensors is accurate or an erroneous signal caused by sensor drift or damage, posing a significant safety hazard, especially in scenarios requiring high reliability, such as power equipment. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this application provides a surface multi-factor acquisition sensing unit, usage method, and system for insulated wire clamps, thereby solving the problems of the lack of effective and accurate monitoring methods for wire clamp surface strain and the inability to identify sensor malfunctions.

[0004] To achieve the above objectives, this application provides the following technical solution: A surface multi-factor acquisition sensing unit for insulated wire clamps is disclosed, for mounting on insulated wire clamps. It is made of polydimethylsiloxane as a base material and has a three-layer encapsulation structure with a C-shaped cross-section. The three-layer encapsulation structure includes, from the inside out, an adhesion layer, a strain transfer layer, and a protective layer. The adhesion layer is used to adhere the insulated wire clamp to be monitored. A first FBG strain sensor is embedded inside the adhesion layer. A second FBG strain sensor and an FBG vibration sensor are embedded between the adhesion layer and the strain transfer layer. The strain transfer layer is doped with a phase change material and is used to transfer the strain of this layer to the second FBG strain sensor. An FBG temperature sensor with a relaxed grating is embedded between the strain transfer layer and the protective layer. The protective layer is doped with an ultraviolet-resistant material for protecting the inner sensors and structure. The first FBG strain sensor, the second FBG strain sensor, the FBG vibration sensor, and the FBG temperature sensor are arranged on the non-open side of the C-shape, parallel to or perpendicular to the non-open side of the cross-section.

[0005] Preferably, the three-layer wrapping structure is manufactured using a layer-by-layer casting process.

[0006] Preferably, the adhesive layer uses a mixture of a curing agent and an acrylic pressure-sensitive adhesive.

[0007] Preferably, the phase change material uses phase change microcapsules, and the phase change temperature of the microcapsule core is 50°C.

[0008] Preferably, the strain transfer layer is further doped with a fluorescent dye.

[0009] Preferably, the protective layer uses a mixture of nano-silica, ultraviolet absorber, and antioxidant, and the ultraviolet absorber is a benzotriazole substance.

[0010] Based on the same inventive concept, this application also achieves this through the following technical solutions: A method for using a surface multi-factor acquisition sensing unit of an insulated wire clamp, characterized by comprising the following steps: The aforementioned multi-factor surface sensing unit for the insulating clamp is installed in the strain concentration area on the surface of the insulating clamp; The pigtails of all sensors in the surface multi-factor acquisition sensing unit of the insulated clamp are connected to the fiber optic grating demodulator via fiber optic patch cords. The fiber optic grating demodulator is connected to the computer via a data interface, and the computer is connected to the remote platform via a remote communication interface. Start monitoring, establish the monitoring baseline of all sensors of the surface multi-factor monitoring sensor of the insulated clamp under windless and normal temperature reference conditions, and set safety thresholds to initialize the monitoring system; Real-time monitoring is initiated, and an early warning is sent to the remote platform when the early warning conditions are met.

[0011] Preferably, the strain concentration region on the surface of the insulating clamp is determined using finite element analysis.

[0012] Preferably, the remote communication interface is based on the LoRa standard.

[0013] Based on the same inventive concept, this application also achieves this through the following technical solutions: A surface multi-factor monitoring system for insulated wire clamps includes a monitoring and analysis unit and at least one surface multi-factor acquisition and sensing unit for the aforementioned insulated wire clamps. A method for using the aforementioned surface multi-factor acquisition and sensing unit for the insulated wire clamps is described. The monitoring and analysis unit includes a grating fiber demodulator, a computer, and a remote platform. The surface multi-factor acquisition and sensing unit for the insulated wire clamps is connected to the grating fiber demodulator. The grating fiber demodulator is connected to the computer via a data interface. The computer uses a LoRa-based remote communication interface to wirelessly communicate with the remote platform.

[0014] Compared to existing technologies, the advantages of this solution are as follows: The surface multi-factor acquisition sensing unit of the insulated clamp in this application is designed with the structure and position strictly based on the strain concentration point experienced by the insulated clamp in contact with the conductor and insulator. Through the three-layer sandwich structure design of the surface multi-factor acquisition sensing unit and the design of four FBG sensors in different positions, the problem of cross-sensitivity between temperature and strain in the FBG sensing field is solved. By deploying the outermost FBG temperature sensor in a free manner very close to the other sensors, it is ensured that it is in the same temperature field. However, the periphery of the grating is relaxed and not sensitive to strain, only sensing temperature changes. Therefore, the data simultaneously sensing temperature and strain can be compensated and corrected by subtracting the wavelength drift of the outermost layer, thus separating the strain-induced drift. The second FBG strain sensor and strain... The design of the transfer layer allows for cross-validation of the FBG temperature sensor, ensuring that the overall multi-factor acquisition does not rely on the temperature collected by a single FBG temperature sensor. When a single FBG temperature sensor malfunctions, the phase change material with a corresponding threshold embedded in the strain transfer layer enables the system to sense the actual and precise temperature reached. The introduction of the phase change material is equivalent to adding a physical, immutable witness, thereby utilizing the physical phase change phenomenon to achieve "self-diagnosis" and "cross-validation" of the sensor's own health status. The cross-validation mechanism can prompt maintenance personnel to replace or calibrate the acquisition component before it provides erroneous data that could cause serious consequences, upgrading the monitoring system from a "data acquisition device" to an "intelligent diagnostic terminal." This provides higher safety assurance and decision support for applications such as unattended substations and remote status monitoring. The design of the second FBG strain sensor and strain transfer layer simplifies the backend algorithm, identifying a significant nonlinear inflection point. This is simpler and more reliable than setting an absolute temperature threshold and dealing with noise and drift issues from the temperature sensor. It also provides a "thermal history" record, informing maintenance personnel that the equipment has experienced a severe overheating event, and even if it appears normal now, its internal materials may be damaged, requiring priority maintenance. In summary, this solution upgrades a common strain sensor into an intelligent sensing terminal capable of distinguishing different problems. It can not only measure data but also identify events. This preliminary ability to determine the root cause of faults has irreplaceable practical value in achieving the leap from "condition monitoring" to "condition assessment and fault early warning." The unique design is crucial for assessing the mechanical condition of the clamps, thereby reducing line faults and power outages to ensure operational safety and power supply reliability. Attached Figure Description

[0015] Figure 1 This is a three-dimensional structural schematic diagram of the second surface multi-factor acquisition sensing unit in one embodiment of the present solution. Figure 2This is a three-dimensional structural schematic diagram of the first surface multi-factor acquisition sensing unit, which is another embodiment of the surface multi-factor acquisition sensing unit of this scheme. Figure 3 This is a connection diagram of an embodiment of the surface multi-factor monitoring system of this scheme; Figure 4 This is a schematic diagram of the external flow field during fluid-structure interaction analysis when the surface strain concentration region of the insulated clamp in one embodiment of the present solution is determined using the finite element method. Figure 5 This is a cloud map showing the strain concentration of the conductor fixing ring of the insulating clamp under gripping force conditions, when the surface strain concentration area of ​​the insulating clamp is determined using the finite element analysis method in one embodiment of the method of this scheme. Figure 6 This is a strain concentration cloud diagram of the insulator fixing ring under lateral force conditions, used to determine the surface strain concentration region of the insulator clamp in one embodiment of the method of this scheme using the finite element analysis method. Among them, 1-surface multi-factor acquisition sensing unit, 1a-first surface multi-factor acquisition sensing unit, 1b-second surface multi-factor acquisition sensing unit, 11-adhesion layer, 111-trapezoidal structure, 1111-protrusion strip, 112-first shape memory alloy strip, 113-triangular thickened part, 1131-first rounded corner, 1132-triangular bevel, 12-strain transfer layer, 13-protective layer, 14-first FBG strain sensor, 15-second FBG strain sensor, 16-FBG vibration sensor, 17-FBG temperature sensor, 2-insulated wire clamp, 21-first position, 22-second position, 3-fiber grating demodulator, 4-computer, 5-remote platform. Detailed Implementation

[0016] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0017] This application provides two embodiments of surface multi-factor acquisition sensing units for insulating clamps 2, which are installed on insulating clamps 2. They are made of polydimethylsiloxane (PDMS) as the base material and have a three-layer wrapping structure with a C-shaped cross-section. The three-layer wrapping structure includes an adhesive layer 11, a strain transfer layer 12 and a protective layer 13 from the inside to the outside. In both embodiments, the thickness of each layer is 1 mm. The adhesive layer 11 is used to adhere the insulating clamp to be monitored.

[0018] The first surface multi-factor acquisition sensing unit 1a of the first embodiment has a right-angled C-shaped cross section perpendicular to the extension direction, and the extension direction is an arc shape with an arc angle of 50°. The length of the non-opening side cross section is 20mm. All sensors are arranged perpendicular to the non-opening side cross section, that is, along the extension direction. The center of the inner edge of the non-opening side of the C-shaped adhesive layer 11 has a sensor groove with a radius of 0.5mm for placing the first FBG strain sensor 14. On the horizontal line of the circumference of the 7mm symmetrical ring around the centerline at the contact area between the adhesive layer 11 and the strain transmission layer 12, there are semi-circular through holes with a radius of 0.4mm for placing the second FBG strain sensor 15 and the FBG vibration sensor 16. On the contact surface between the strain transmission layer 12 and the protective layer 13, there are semi-circular through holes with a radius of 0.4mm along the centerline for placing the FBG temperature sensor 17.

[0019] In the second embodiment, the cross-section of the second surface multi-factor acquisition sensing unit 1b perpendicular to the extension direction is also a right-angled C-shape, but the non-open side is arc-shaped and has a wire outlet hole. The extension direction is very short, much smaller than the size of the C-shaped cross-section. In this embodiment, the extension thickness is 3mm, the length of the open side cross-section is 20mm, and all sensors are arranged parallel to the non-open side cross-section, that is, perpendicular to the extension direction. The mounting through holes of the first FBG strain sensor 14, the second FBG strain sensor 15, the FBG vibration sensor 16, and the FBG temperature sensor 17 are similar to those in the first embodiment, and the coating layer is made of acrylate.

[0020] To avoid spectral overlap, acrylate fiber grating sensors with different wavelengths are used for monitoring the second surface multi-factor acquisition sensing unit 1b and the first surface multi-factor acquisition sensing unit 1a. For example, the first FBG strain sensor 14 of the first surface multi-factor acquisition sensing unit 1a uses a sensor with a wavelength of 1537nm, while the first FBG strain sensor 14 of the second surface multi-factor acquisition sensing unit 1b uses a sensor with a wavelength of 1532nm. When monitoring local strain, the spatial distribution rate is required to be ≤5mm, and the spatial distribution rate is approximately equal to the grating length / 2. For example, the first FBG strain sensor 14 of the first surface multi-factor acquisition sensing unit 1a is selected with a grating length of 8mm, while the first FBG strain sensor 14 of the second surface multi-factor acquisition sensing unit 1b is selected with a grating length of 6mm.

[0021] The three-layer encapsulation structure is fabricated using a layer-by-layer casting process. First, a mold is made using methods such as 3D printing. An annular positioning groove for fixing the first FBG strain sensor 14 can be pre-cut on the inner side of the mold. The casting method for each layer is as follows: For the casting of the adhesion layer 11: The first FBG strain sensor 14 can be pre-positioned, that is, the grid area is precisely placed into the positioning groove of the mold to ensure that it is straight, and then the two ends of the fiber optic pigtail are temporarily fixed to the mold with high-temperature resistant tape to prevent displacement during casting. Mix the PDMS base adhesive and curing agent at a mass ratio of 10:1, and then add 5% by mass of acrylic pressure-sensitive adhesive such as 2-ethylhexyl acrylate or isooctyl acrylate. Stir the mixture clockwise with a glass rod for 10 minutes until the mixture is uniform and without streaks. Then place it in a vacuum drying oven for 5 minutes for vacuum degassing until no obvious bubbles emerge from the liquid surface. This process can be repeated 1-2 times to ensure thorough degassing; then slowly inject the treated solution into the mold, controlling the thickness to 1mm, and finally place it in a 75℃ oven for pre-curing for 15 minutes to form a semi-cured adhesion layer 11. The addition of acrylic pressure-sensitive adhesive enhances the adhesion to the wire clamp surface. In the adhesion layer 11, the strain measured by the first FBG strain sensor 14 at the insulating clamp 2 is closest to the actual structural strain, providing the entire monitoring system with a reference to the original mechanical state without intermediate layer modification. It can also be used to calibrate the signal of the strain transfer layer 12, ensuring the efficiency of strain transfer, such as establishing the signal relationship between the two strain transfer sensors, such as the ratio. When this signal relationship changes significantly, it can provide an early warning of potential failures such as aging, cracking, or interface debonding in the adhesion layer 11 or the strain transfer layer 12. The semi-cured state of the adhesion layer 11 provides an ideal bonding interface for the casting of the composite sensing layer, ensuring a strong interlayer bond and preventing delamination.

[0022] For strain transfer layer 12: Prepare a "PCM-PDMS" composite sensing layer solution. First, mix PDMS base adhesive and curing agent at a mass ratio of 10:1. Then, add phase change microcapsules at a mass ratio of 15% to 20%, the phase change temperature threshold of which can be set according to the warning requirements; in this embodiment, 50℃ is used. To facilitate visual calibration, 0.5% fluorescent dye can be added as needed. Stir the mixture for 20 minutes to ensure uniform dispersion of the phase change microcapsules, followed by vacuum degassing. Pour the composite solution onto the semi-cured adhesion layer 11, controlling the thickness to 1 mm, and process two semi-circular through holes with an upper and lower radius of 0.4 mm along the central symmetry line. The two semi-circular through holes are processed using a UV precision laser. Subsequently, accurately install the second FBG strain sensor 15 and the FBG vibration sensor 16 in the through holes, ensuring that the second FBG strain sensor 15 is tightly coupled to the PCM composite substrate to sensitively detect the volumetric strain signal caused by the phase change. The FBG sensor in this layer provides the foundation for intelligent early warning. When the insulator's temperature rises to the PCM phase transition threshold of 50°C due to abnormal heating caused by fault current or poor contact, the PCM undergoes a solid-liquid phase transition, resulting in a significant volume change and generating additional micro-strain within the composite matrix. This strain is sensitively captured by the tightly coupled second FBG strain sensor 15, providing a non-electrical, intrinsically safe direct early warning signal for temperature exceeding the limit. Its sensitivity far surpasses traditional temperature monitoring, and it can also be cross-validated against the outer FBG temperature sensor 17. The addition of phase change microcapsules microscopically alters the mechanical properties of the PDMS matrix. Before the phase transition, their uniform dispersion helps maintain matrix flexibility and ensures strain transfer efficiency. During the phase transition, local volume changes can amplify or modulate the mechanical strain signal, making the second FBG strain sensor 15 more sensitive to abnormal operating conditions such as mechanical stress changes accompanying overheating. The function of the embedded FBG vibration sensor 16 is that the oscillations generated by the conductor galloping cause the insulating clamp 2 to vibrate under pressure. The FBG vibration sensor 16, integrated into the strain transfer layer 12, has its grating period change with the minute vibrations of the fixing ring body, resulting in high-frequency, periodic strain changes and thus synchronous modulation of the reflected wavelength. When galloping occurs, the conductor applies a low-frequency, periodic alternating force to the insulating clamp 2 and the strain transfer layer 12. This force excites the strain transfer layer 12 to produce a vibration response that is the same frequency or a harmonic of the galloping frequency. The FBG vibration sensor 16 captures this response signal.

[0023] Final casting and curing of protective layer 13: Prepare the PDMS solution for the protective layer by mixing the base adhesive and curing agent at a mass ratio of 10:1, then add 3% nano-silica (SiO2), 2% benzotriazole UV absorber, and 1% antioxidant. Benzotriazole substances include, but are not limited to, materials with trade names such as UV-350, UV-320, UV-328, and UV327. Hindered phenols can be used as antioxidants. After stirring for 15 minutes, vacuum degassing is performed. The solution is then poured onto the cured sensing layer, with a thickness controlled to 1mm. A 0.5mm radius semi-circular through-hole is also fabricated using UV laser drilling for the FBG temperature sensor 17. The FBG temperature sensor 17 is installed in the hole, ensuring the grating area is relatively relaxed to avoid strain sensitivity. Slight vibration is applied to remove interface bubbles. Finally, it is cured in an 85℃ oven for 60 minutes. Heating accelerates the cross-linking reaction of PDMS, forming a stable elastomer. The purpose of protective layer 13 is to protect the internal sensitive PCM composite layer and fiber optic sensor from long-term corrosion by ultraviolet rays, ozone, moisture, acids, and alkalis, ensuring the long-term stability of the device in harsh outdoor environments such as high temperature, extreme cold, and exposure to sun and rain. The FBG temperature sensor 17 in this layer monitors the ambient temperature and the overall temperature of the package, providing a global temperature compensation reference for all strain and vibration sensors, effectively distinguishing between wavelength drift caused by changes in ambient temperature and drift caused by mechanical strain or PCM phase transitions.

[0024] Final demolding and post-processing: After curing, turn off the oven power and allow the mold to cool naturally to room temperature. After cooling, take advantage of the flexibility of PDMS to gently remove the molded flexible sensing unit from the mold. Trim any flash and excess material with a tool, and check the center wavelength of all FBG sensors after demolding using a fiber optic demodulator 3. Compare the wavelength with that before packaging to ensure that they were not damaged during manufacturing and that the spectral quality is good.

[0025] Based on the same inventive concept, this application also discloses an embodiment of a method for using a surface multi-factor acquisition sensing unit of an insulated wire clamp, comprising the following steps: The aforementioned multi-factor surface sensing unit 1 of the insulating clamp is installed in the strain concentration area on the surface of the insulating clamp 2; The strain concentration region on the surface of the insulating clamp was determined using finite element analysis. In this embodiment, for Figure 3 The insulating clamp 2 in the model uses a variety of finite element analysis methods, such as static finite element analysis simulation of the surface strain of the insulating clamp under the test conditions of gripping force and lateral force, and unidirectional fluid-structure coupling finite element analysis simulation of the surface strain of the insulating clamp under different wind speeds. The results of the two finite element analysis are combined and the optimal arrangement position of the multi-factor acquisition sensing unit 1 for monitoring the surface strain of the clamp is determined.

[0026] The specific steps of the static analysis are as follows: a) Structural modeling: In Solidworks software, create a fixed assembly containing the insulating clamp 2 and fasteners, i.e., a precise assembly model including the insulating clamp and M8 hexagonal flange toothed bolts; convert it into an .xt file, i.e., save it as a Parasolid file with the extension .x_t, and import it into the Static Structural module of Ansys finite element analysis software; b) Material settings: Set the material of the insulating clamp 2 to the Mooney-Rivlin hyperelastic model. In this embodiment, the parameters are set to C10=2.356MPa, C01=0.88MPa, and the density is the density of vulcanized rubber. In this embodiment, the density is set to 1100 kg / m³. 3 The material of the M8 hexagonal flange bolts is structural steel, with a density of 7850 kg / m³, an elastic modulus of 200 GPa, and a Poisson's ratio of 0.3 in this embodiment; c) Boundary condition settings: The contact form between the conductor and the insulating clamp 2 is set to frictional; the normal force parameter of the insulator to the insulator fixing ring of the insulating clamp 2 along the surface of the contact point is set; the preload force on the insulating clamp 2 when tightening the bolt is set to 450N; a horizontal tensile force is superimposed on the inner side of the conductor fixing ring of the insulating clamp 2 with a loading load of 40N each time, from 0N until the load is increased to 520N; a loading load of 40N each time is applied to the contact area between the conductor fixing ring of the insulating clamp 2 and the conductor. A lateral force perpendicular to the conductor axis is applied, from 0N to 800N, to simulate lateral loads under conditions such as strong winds; d) Mesh generation: A refined mesh setting is adopted for the insulating clamp 2, with a global unit size of 5mm and the mesh size of the outer surface of the U-shaped conductor fixing ring is refined to 2mm, with a total of 14006 meshes to ensure a balance between calculation accuracy and efficiency; e) Solver settings: Due to the geometric and material nonlinearity of rubber materials, a nonlinear iterative solver is used to solve the problem. After the solution is completed, the equivalent contour plot of the model is viewed.

[0027] The specific steps of the fluid-structure interaction analysis are as follows: a) Setting the external flow field calculation dimensions: Based on the dimensions of the insulating clamp 2, the external flow field calculation dimensions are designed as follows: length 600mm, width 400mm, height 200mm. The dimensions of the internal mesh refinement zone are: length 147mm, width 110mm, height 63mm. The resulting flow field domain is as follows: Figure 4As shown. b) Mesh generation: Unstructured meshing is used. The flow field near the insulating clamp 2 is refined, and the number of expansion layers is set to 13 layers. The height of the first layer is 0.031618 mm. The overall mesh is smoothed, and the number of meshes is 621,000. c) Boundary condition setting: In the Fluent module, the velocity inlet of the flow field is set as inlet, the pressure outlet is set as outlet, and the other four walls are set as wall. The interface on the BOI flow field side and the interface on the insulating clamp 2 side are set to form the interior boundary. d) Constraints of insulating clamp 2 and application of external flow field pressure: In the static structure module of Ansys simulation software, a preload of 450 N is applied to the bolt holes of the insulating clamp 2, and the contact state between the conductor and the inner surface of the conductor fixing ring of the clamp is set to fixed support. The pressure exerted on the clamp surface by the external flow field under different inlet velocities is imported. This pressure is transmitted to the coupling surface through the clamp's outer surface and the interface with the flow field. Combined with the normal force acting on the insulator fixing ring, the strain state of the insulating clamp 2 is solved in the statics module. e) Result Analysis: The strain contour plots from the statics module are analyzed comprehensively. The combined results of the two finite element analyses lead to the following conclusions: Under gripping force conditions, the region of maximum equivalent strain appears at the intersection of the U-shaped outer surface of the conductor fixing ring and the vertical plane. Under lateral force conditions, when the load increases to over 400N, the strain concentration region shifts to the contact point between the inner surface of the conductor fixing ring and the conductor, and a high-strain region appears near the connection line between the outer surface of the conductor fixing ring and the insulator fixing ring. The maximum deformation always occurs near the bottom of the outer surface of the insulator fixing ring, with the strain exhibiting a crescent-shaped distribution. Therefore, in this embodiment, the horizontal center point 2.5mm below the intersection of the U-shaped outer surface of the conductor fixing ring of the insulating clamp 2 and the vertical plane is taken as the strain sensing monitoring point. The second surface multi-factor acquisition sensing unit 1b is installed here, and the first surface multi-factor acquisition sensing unit 1a is installed 5mm above the bottom of the windward outer surface of the insulator fixing ring. During installation, anhydrous alcohol is used to clean the two monitoring points on the surface of the insulating clamp 2 to remove oil and dust, ensuring that the surface multi-factor acquisition sensing unit 1b is completely fitted to the curved surface of the insulating clamp 2 without air bubbles.

[0028] The pigtails of all sensors from the first surface multi-factor acquisition sensing unit 1a and the second surface multi-factor acquisition sensing unit 1b of the insulating clamp 2 are connected to the fiber optic demodulator 3 via fiber optic patch cords. The fiber optic pigtails of all internally packaged FBG sensors leading out from the two surface multi-factor acquisition sensing units 1 can be routed along the surface of the insulating clamp 2. The pigtails are fixed to the insulating clamp 2 every 10-15cm using aluminum foil tape. A small margin should be left in the fiber optic cable during fixing to avoid stress concentration. All FBG sensors are connected to the fiber optic patch cords using fiber optic flanges. The fiber optic patch cords should have a margin of 1-2m. The routing should avoid sharp edges and areas that may be worn. This fixing method can prevent the influence of excessive wind vibration. The connection port of the fiber optic demodulator 3 is cleaned with anhydrous alcohol. Then, the other end of the fiber optic patch cord is connected to the fiber optic demodulator 3 using a fiber optic flange. The fiber optic demodulator 3 is connected to the computer 4 via a data interface. The computer 4 is connected to the remote platform 5 via a remote communication interface.

[0029] Start monitoring, establish the monitoring baseline of all sensors of the surface multi-factor monitoring sensor of the insulated clamp under windless and normal temperature reference conditions, and set safety thresholds to initialize the monitoring system.

[0030] After the system is running, staff can squeeze and stretch the two parts of the insulated clamp 2 conductor fixing ring and the insulation fixing ring to observe whether the system can calculate the strain amplitude, temperature, frequency, etc. in real time and evaluate the dynamic load.

[0031] Real-time monitoring is initiated, and warnings are sent to a remote platform when warning conditions are met. For example, if the vibration frequency exceeds a safety threshold, it is determined whether a galloping warning can be immediately sent to a remote computer terminal via the LoRa network. Warnings include those related to the temperature, strain, or vibration of the insulation clamp itself, or warnings about malfunctions in the surface multi-factor acquisition sensing unit. For instance, if a phase change occurs in the strain transfer layer, and the second FBG strain sensor 15 produces a sudden strain change, but the temperature of the FBG temperature sensor 17 is below the phase change threshold, the system can determine that the temperature of the FBG temperature sensor 17 is unreliable, and thus issue a sensor maintenance alarm. This alerts personnel to inspect the surface multi-factor acquisition sensing unit 1, preventing unnecessary power outages and wasted manpower and resources due to a faulty FBG temperature sensor 17 issuing a false high-temperature alarm.

[0032] Based on the same inventive concept, this application also achieves this through the following embodiments of technical solutions: A surface multi-factor monitoring system for insulated wire clamps includes a monitoring and analysis unit and two surface multi-factor acquisition and sensing units 1 for insulated wire clamps. Using the aforementioned method for employing the surface multi-factor acquisition and sensing units for insulated wire clamps, the system receives and demodulates signals from FBG sensors and performs data processing and analysis. The monitoring and analysis unit includes a grating fiber demodulator 3, a computer 4, and a remote platform 5. The surface multi-factor acquisition and sensing units 1 for insulated wire clamps are connected to the grating fiber demodulator 3. The grating fiber demodulator 3 is connected to the computer 4 via a data interface. The FBG demodulator 3 used in the system also has an embedded independent ARM Cortex-M4 core edge computing unit. The computer is connected to a LoRa remote communication chip via a UART interface, enabling wireless communication with the remote platform 5 using a LoRa-based remote communication interface.

[0033] The above description is only a preferred embodiment of the present solution, but the scope of protection claimed by the present solution is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in this application, based on the technical solution and inventive concept of this application, should be included within the scope of protection of this application.

Claims

1. A surface multi-factor acquisition sensing unit for insulating wire clamps, used for mounting on insulating wire clamps, characterized in that: Made from polydimethylsiloxane as the base material, it has a three-layer encapsulation structure with a C-shaped cross-section. The three-layer encapsulation structure includes, from the inside out, an adhesion layer (11), a strain transfer layer (12), and a protective layer (13). The adhesion layer (11) is used to adhere the insulating clamp to be monitored. A first FBG strain sensor (14) is embedded inside the adhesion layer (11). A second FBG strain sensor (15) and an FBG vibration sensor (16) are embedded between the adhesion layer (11) and the strain transfer layer (12). The strain transfer layer (12) is doped with a phase change material and used for... The strain of the layer is transmitted to the second FBG strain sensor (15). An FBG temperature sensor (17) with a relaxed grating is embedded between the strain transmission layer (12) and the protective layer (13). The protective layer (13) is doped with UV-resistant material for the protection of the inner sensor and structure. The first FBG strain sensor (14), the second FBG strain sensor (15), the FBG vibration sensor (16) and the FBG temperature sensor (17) are arranged on the surface of the C-shaped non-open side, parallel to or perpendicular to the non-open side section edge.

2. The surface multi-factor acquisition sensing unit of the insulated wire clamp according to claim 1, characterized in that: The three-layer wrapping structure is fabricated using a layer-by-layer casting process.

3. The surface multi-factor acquisition sensing unit for the insulated wire clamp according to claim 1, characterized in that: The adhesive layer (11) uses a mixture of curing agent and acrylic pressure-sensitive adhesive.

4. The surface multi-factor acquisition sensing unit of the insulated wire clamp according to claim 3, characterized in that: The phase change material uses phase change microcapsules, and the phase change temperature of the microcapsule core is 50°C.

5. The surface multi-factor acquisition sensing unit for the insulated wire clamp according to claim 1, characterized in that: The strain transfer layer (12) is also doped with fluorescent dye.

6. The surface multi-factor acquisition sensing unit for the insulated wire clamp according to claim 1, characterized in that: The protective layer (13) uses a mixture of nano-silica, ultraviolet absorber and antioxidant, and the ultraviolet absorber is a benzotriazole substance.

7. A method for using a surface multi-factor acquisition sensing unit for an insulated wire clamp, characterized in that, Includes the following steps: The surface multi-factor acquisition sensing unit of the insulating clamp according to any one of claims 1 to 6 is installed in the surface strain concentration area of ​​the insulating clamp; The pigtails of all sensors in the surface multi-factor acquisition sensing unit of the insulated clamp are connected to the fiber optic grating demodulator via fiber optic patch cords. The fiber optic grating demodulator is connected to the computer via a data interface, and the computer is connected to the remote platform via a remote communication interface. Start monitoring, establish the monitoring baseline of all sensors of the surface multi-factor monitoring sensor of the insulated clamp under windless and normal temperature reference conditions, and set safety thresholds to initialize the monitoring system; Real-time monitoring is initiated, and an early warning is sent to the remote platform when the early warning conditions are met.

8. The method of using the surface multi-factor acquisition sensing unit of the insulated wire clamp according to claim 7, characterized in that: The strain concentration region on the surface of the insulating clamp was determined using the finite element method.

9. The surface multi-factor acquisition sensing unit for the insulated wire clamp according to claim 7, characterized in that: The remote communication interface is based on the LoRa standard.

10. A surface multi-factor monitoring system for an insulated wire clamp, characterized in that: The system includes a monitoring and analysis unit and at least one surface multi-factor acquisition sensing unit for insulated clamps as described in any one of claims 1 to 6. A method for using the surface multi-factor acquisition sensing unit for insulated clamps as described in any one of claims 7 to 9 is also provided. The monitoring and analysis unit includes a grating fiber demodulator, a computer, and a remote platform. The surface multi-factor acquisition sensing unit for insulated clamps is connected to the grating fiber demodulator. The grating fiber demodulator is connected to the computer via a data interface. The computer uses a LoRa-based remote communication interface to wirelessly communicate with the remote platform.

Images