Method for additionally installing monitoring sensor on intelligent insulating soft sling
By installing flexible thin-film sensors on insulated soft slings and automatically wrapping them, the problem of sling monitoring in ultra-high voltage environments has been solved, achieving efficient and accurate monitoring results while ensuring the structural integrity and insulation performance of the slings.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- 湖北省超能电力有限责任公司
- Filing Date
- 2025-12-15
- Publication Date
- 2026-05-08
AI Technical Summary
In ultra-high voltage environments, how can we achieve real-time monitoring of the load-bearing capacity and insulation performance of insulated slings to ensure they are always in a safe and reliable working state, while the monitoring system should not affect the structural integrity and insulation performance of the slings and should have wireless transmission capabilities?
A flexible thin-film sensor is installed on an insulating soft sling. The sensor is automatically fixed, and adhesive and encapsulation materials are sprayed and coated using an integrated installation device to ensure a tight bond between the sensor and the sling. The sensor is then cured at high temperature. PDMS sol is used to make the sensor encapsulation layer to ensure the sensor's detection accuracy and insulation performance.
It enables real-time monitoring of insulated slings, improves detection accuracy and insulation performance, reduces equipment costs, ensures tight connection between sensors and slings and protective effect, and meets the needs of UHV live-line work.
Smart Images
Figure CN122000811A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of insulating flexible sling technology, and relates to a method for installing monitoring sensors on slings, particularly a method for installing monitoring sensors on intelligent insulating flexible slings. Background Technology
[0002] In high-voltage power systems such as ultra-high-voltage direct current (UHVDC) transmission lines, live-line working has become a crucial means of ensuring stable power supply and efficient operation and maintenance. However, live-line working carries extremely high safety risks; improper operation can endanger the lives of workers and potentially lead to serious power grid accidents. The rigid insulating rods used in traditional transmission line live-line work for replacing insulators and fittings are excessively long and heavy when applied to ultra-high-voltage and UHVDC lines, making transportation, storage, and operation extremely inconvenient and significantly impacting the efficiency of UHVDC live-line work. Furthermore, with the technological development and widespread application of UHVDC transmission in my country, the electrical and mechanical performance requirements for live-line working tools exceed the limits of traditional electrical materials. To meet the stringent electrical and mechanical performance requirements of UHVDC live-line working tools, cross-disciplinary and multi-disciplinary innovation is essential.
[0003] Since 2011, State Grid Hubei Ultra-High Voltage Company has been seeking alternatives to rigid insulated slings and has begun independent research and development. Currently, the company has designed an ultra-high voltage (UHV) live-line working insulating sling that meets the insulation and load-bearing requirements. This sling uses a high-strength fiber insulation sling with low specific gravity and light weight. The main body of the sling is a flexible strip-shaped insulator formed by vacuum impregnation of multiple layers of high-strength insulating fiber fabric with liquid silicone, which can greatly improve the efficiency of live-line work.
[0004] However, during initial application and testing, some problems were found that the insulated sling product still has some urgent issues to be addressed. In ultra-high voltage environments, how to achieve real-time monitoring of the sling's load-bearing capacity and insulation performance to ensure it remains in a safe and reliable working state is a major challenge currently facing insulated sling products. At the same time, the introduction of the monitoring system should not affect the structural integrity and insulation performance of the sling itself, and it must have wireless transmission capabilities in ultra-high voltage scenarios. Summary of the Invention
[0005] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a method for installing monitoring sensors on intelligent insulated soft slings. The technical problem this invention aims to solve is: how to install monitoring sensors on insulated soft slings while ensuring the detection performance of the monitoring sensors.
[0006] The objective of this invention can be achieved through the following technical solutions: A method for installing monitoring sensors on a smart insulated flexible sling includes the following steps: S1. Use the sling ends to fix the soft sling body to the tensioning mechanism, and use the tensioning mechanism to straighten the soft sling body under a tension of 50-70KN. S2. Use a 40-60℃ hot compress to clean the surface of the soft suspender body by blowing air. S3. Use a spraying mechanism to spray adhesive onto the upper surface of the soft sling, then straighten the flexible film sensor and attach it to the upper surface of the soft sling, and press it for 5-8 minutes. S4. The soft sling body and the flexible thin film sensor are covered with a covering material and then heated and cured.
[0007] The method for preparing the flexible thin-film sensor is as follows: first, cut PI adhesive paper, apply uncured PDMS liquid to a silicon plate or other flat plate, paste the PI adhesive paper onto the PDMS, and then place it in an oven to heat and solidify; after solidification, place the base plate with the PI adhesive paper pasted on it into a laser printer; position the laser red dot, and use a laser movement speed of 200mm / s and a laser power of 7.5w to laser burn the PI adhesive paper.
[0008] The coating material is a mixture of silicone rubber and polyurethane, with a mass ratio of silicone rubber to polyurethane of 3:1.
[0009] The equipment used in steps S1-S4 is an integrated installation device. This integrated installation device includes a body, inside which a drive motor is fixed. A bidirectional threaded rod is fixed to the output shaft end of the drive motor. Two movable seats are threadedly connected to the two threaded portions of the bidirectional threaded rod. Several support rods are fixed to the movable seats, and pull rods are fixed to the support rods. Several first electric telescopic rods are fixed to the lower end of the body. A first support plate is fixed to the telescopic end of each first electric telescopic rod, and several arc-shaped covers are fixed to the support plate. A crossbeam is fixed to the upper end of the body, and several second electric telescopic rods are fixed to the lower side of the crossbeam. A second support plate is fixed to the telescopic end of each second electric telescopic rod. Several arc-shaped covers are also fixed to the lower side of the second support plate. A liquid supply chamber is opened in the upper arc-shaped cover. An adhesive box is fixed on the second support plate. A spray pump is fixed on the adhesive box. The spray pump is connected to the liquid supply chamber through a pipe. Several grooves are opened on the inner circumference of the upper arc-shaped cover. A nozzle connected to the liquid supply chamber is fixed in the groove. A sealing cover is slidably connected to the inner circumference of the arc-shaped cover. A driving mechanism is set between the sealing cover and the arc-shaped cover. Sealing plates are fixed at both ends of the arc-shaped cover. Several clearance grooves corresponding to the arc-shaped cover are opened on the sealing plates. A liquid supply seat is fixed on the sealing plate. A sealing box is fixed on the crossbeam. The sealing box is connected to the liquid supply seat through a liquid supply pipe. The liquid supply seat is connected to the inside of the arc-shaped cover.
[0010] Using the above structure, during operation, the sling ends at both ends of the flexible sling body are respectively fitted onto the corresponding pull rods at both ends. Then, the drive motor drives the bidirectional threaded rod to rotate, causing the two moving seats to move in opposite directions, thereby straightening the flexible sling body under a tension of 50-70KN. External equipment is used to clean the surface of the flexible sling body by applying heat at 40-60℃. The drive mechanism causes the closure to deviate from the groove, thus exposing the nozzle. Adhesive is sprayed onto the upper surface of the flexible sling using the nozzle. The arc-shaped cover can constrain the sprayed adhesive and reduce splashing around it. Then, the flexible film sensor is straightened and attached to the upper surface of the flexible sling, and the drive mechanism causes the closure to... The groove is sealed, and then the second electric telescopic rod lowers the sealing cover and attaches it to the flexible film sensor, pressing for 5-8 minutes. After pressing, the first electric telescopic rod raises the first support plate, so that the upper and lower corresponding arc-shaped covers are spliced into a cylinder. The sealing plate, together with the soft sling body, seals both ends. Then, the encapsulation material in the encapsulation box is fed into the cylinder through the liquid supply seat to encapsulate the soft sling body and the flexible film sensor. It is then heated and cured. The whole process is highly automated, with a simple structure and high synergy between components. It can be used for multiple purposes, greatly reducing the cost of the equipment. It can be installed in one go without multiple transfers, which greatly ensures the quality of processing.
[0011] The machine body has several blocking grooves on both the left and right sides inside. The movable seat has a sliding cavity inside. A telescopic motor is fixed inside the sliding cavity. A screw is fixed to the output shaft end of the telescopic motor. A positioning plate is slidably connected inside the sliding cavity. The positioning plate is threadedly connected to the screw. The positioning plate and the blocking groove cooperate with each other. A guide rod is fixed inside the sliding cavity. A guide groove is opened on the positioning plate. The guide rod is slidably connected to the guide groove.
[0012] With the above structure, after the soft sling body is stretched by the movable seat, the positioning plate is moved by the telescopic motor, so that the positioning plate is inserted into the corresponding blocking groove. This allows the positioning plate to provide certain support for the movable seat, thereby reducing the pressure on the screw, protecting the screw, and extending the screw's service life.
[0013] The driving mechanism includes a rotary motor, arc-shaped grooves at both ends of the inner circumference of the arc-shaped cover, arc-shaped toothed plates fixed at both ends of the outer circumference of the closed cover, the arc-shaped toothed plates slidingly connected to the arc-shaped grooves, a driving groove communicating with the arc-shaped grooves inside the arc-shaped cover, a rotary motor fixed inside the driving grooves, a driving gear fixed at the output shaft end of the rotary motor, and the driving gear meshing with the arc-shaped toothed plates.
[0014] With the above structure, when adhesive needs to be sprayed, the drive gear is rotated by a rotary motor, which in turn moves the sealing cover along the arc-shaped groove under the action of the arc-shaped toothed plate, thus exposing the nozzle. When sealing is required, the sealing cover is returned to its original position to ensure the smoothness of the inner circumference.
[0015] The movable seat has an elastic groove inside, a first spring is fixed inside the elastic groove, a baffle is fixed to the other end of the first spring, a slide is fixed to the baffle, a support rod is fixed to the slide, an insert rod is slidably connected to the support rod, and a positioning mechanism is provided between the insert rod and the slide.
[0016] With the above structure, when fixing the soft slings, one end of the sling can be hung on the pull rod on one side, and then the soft sling can be pulled to compress the first spring, allowing the other end of the sling to be fitted onto the pull rod on the other side. This arrangement not only ensures that the slings will not bend when hanging them, thus preventing them from affecting the hanging of multiple slings, but also prevents the movable seats on both sides from interfering with the lower arc-shaped cover, ensuring the normal operation of the work.
[0017] A top post is fixed to the baffle, and the length of the top post is 1 / 2 of the length of the first spring.
[0018] With the above structure, when stretching the soft sling, the top column can be placed against the moving seat, reducing the pressure on the first spring, preventing the first spring from being damaged, extending the service life of the first spring, and ensuring the stability of the operation.
[0019] The positioning mechanism includes a positioning cavity inside the insertion rod, a pressure rod slidably connected to the positioning cavity, one end of the pressure rod extending out of the insertion rod, and a drive rod rotatably connected to the upper and lower sides of the other end of the pressure rod. A positioning block is rotatably connected to the other end of the drive rod. The positioning block is slidably connected to the insertion rod. A positioning groove is provided on the slide block, and the positioning groove cooperates with the positioning block. A first vertical plate is fixed on the pressure rod, a second vertical plate is fixed inside the positioning cavity, and a second spring is fixed between the second vertical plate and the first vertical plate.
[0020] Using the above mechanism, during operation, the upper part of the end can be pressed and positioned by the insertion rod, which not only prevents the end from slipping but also prevents the pull rod from bending, ensuring the accuracy of the stretching. After the insertion rod is inserted into the slide, the positioning block is inserted into the positioning groove for positioning under the action of the second spring. When disassembly is required, press down on the pressure rod to move it to the right. Under the action of the drive rod, the positioning block disengages from the positioning groove, and the insertion rod can be pulled out. The operation is simple and convenient.
[0021] Compared with existing technologies, this method of adding monitoring sensors to intelligent insulated flexible slings has the following advantages: 1. The method of adding monitoring sensors according to the present invention can greatly improve the tightness of the combination between the flexible film sensor and the soft sling. Furthermore, the flexible sensor is added after the soft sling has been stretched to a certain extent. In later use, the influence of factors such as pressure and stretching on the flexible film sensor can be greatly reduced, ensuring the detection accuracy of the flexible film sensor. The setting of the covering material can better protect the flexible film sensor and the soft sling.
[0022] 2. The flexible thin-film sensor of this invention uses PDMS sol to create the sensor's encapsulation layer. The surface shape of the sensor can be designed by utilizing the fluidity of PDMS before solidification. Based on the design expectation of the strain thin-film sensor conforming to the surface of the object being measured to measure its deformation, the surface of the sensor's encapsulation structure should have the same smoothness as the substrate. Simultaneously, to ensure the uniformity of the internal microstructure of multiple sensors and to prevent irregular air chambers from remaining within the sensor due to the failure to release air bubbles during PDMS sol solidification, most air bubbles should be removed using a vacuum negative pressure device before the PDMS sol in the encapsulation layer solidifies, ensuring a consistent and pure internal structure. Since the shape of the sensor's PDMS soft gel affects its bending and vibration performance, the PDMS soft gel structure of multiple sensors of the same model should be identical to ensure consistent structural dimensions, deformation performance, and sensing performance. From an aesthetic perspective, after the PDMS soft gel in the sensor encapsulation layer solidifies, its edges should be cut so that the shape of the sensor's PDMS soft gel is identical to the LIG graphic, consisting of two concentric rectangles with parallel sides.
[0023] 3. The encapsulation layer of this invention greatly improves the moisture-proof and insulation properties of the insulated soft sling.
[0024] 4. During operation, the sling ends at both ends of the flexible sling body are respectively fitted onto the corresponding pull rods at both ends. Then, the drive motor drives the bidirectional threaded rod to rotate, causing the two moving seats to move in opposite directions, thereby straightening the flexible sling body under a tension of 50-70KN. External equipment is used to clean the surface of the flexible sling body using a 40-60℃ heat treatment. The drive mechanism is used to deviate the sealed cover from the groove, thus exposing the nozzle. Adhesive is sprayed onto the upper surface of the flexible sling using the nozzle. The arc-shaped cover can constrain the sprayed adhesive, reducing splashing around the edges. Then, the flexible film sensor is straightened and attached to the upper surface of the flexible sling. Specifically, one flexible film sensor can be placed on the flexible sling every 1m, evenly distributed, with a length of 20-40cm, ensuring... While ensuring monitoring accuracy, the system reduces the impact of stretching on the sensor and saves costs. A drive mechanism seals the groove with a closed cover, and then a second electric telescopic rod lowers the cover, attaching it to the flexible film sensor and pressing it for 5-8 minutes. After pressing, a first electric telescopic rod raises the first support plate, allowing the corresponding arc-shaped covers to be joined into a cylinder. A sealing plate, in conjunction with a flexible sling, seals both ends. A liquid supply seat then delivers the encapsulation material from the packaging box into the cylinder, encapsulating the flexible sling and the flexible film sensor. The process is then heated and cured. The entire process is highly automated, with a simple structure and excellent synergy between components. It is multi-functional, significantly reducing equipment costs. Furthermore, it can be installed in one go, eliminating the need for multiple transfers and greatly ensuring processing quality.
[0025] 5. After the soft sling body is stretched using the movable seat, the positioning plate is moved by the telescopic motor, so that the positioning plate is inserted into the corresponding blocking groove. This allows the positioning plate to provide some support for the movable seat, thereby reducing the pressure on the screw, protecting the screw, and extending the screw's service life. Attached Figure Description
[0026] Figure 1 This is a process flow diagram of the present invention.
[0027] Figure 2 This is a schematic diagram of the integrated installation equipment in this invention.
[0028] Figure 3 This is a side sectional view of the present invention.
[0029] Figure 4 This is a schematic diagram of the structure of the stretching part in this invention.
[0030] Figure 5 yes Figure 4 A magnified view of a portion of point A in the middle.
[0031] Figure 6 This is a schematic diagram of the installation structure of the arc-shaped cover in this invention.
[0032] Figure 7 This is a schematic diagram of the movable base in this invention.
[0033] Figure 8 This is the first cross-sectional view of the arc-shaped cover in this invention.
[0034] Figure 9 This is the second cross-sectional view of the arc-shaped cover in this invention.
[0035] Figure 10 This is a side sectional view of the movable seat in this invention.
[0036] Figure 11 yes Figure 10 A magnified view of a portion of point A in the middle.
[0037] Figure 12 Line graphs showing the resistance changes of different curved surfaces of molds with different curvatures attached to different surfaces of the same set of sensors.
[0038] Figure 13 This is a performance test data table for the experimental example.
[0039] In the diagram: 1. Body; 2. Crossbeam; 3. Packaging box; 4. Second electric telescopic rod; 5. Second support plate; 6. Adhesive box; 7. First electric telescopic rod; 8. First support plate; 9. Bidirectional threaded rod; 10. Moving seat; 11. Drive motor; 12. Support rod; 13. Pull rod; 14. Limiting rod; 15. Arc-shaped cover; 16. Sealing plate; 17. Liquid supply seat; 18. Liquid supply pipe; 19. Clearance groove; 20. Blocking groove; 21. Sliding cavity; 22. Telescopic motor; 23. 24. Screw; 25. Positioning plate; 26. Guide groove; 27. Guide rod; 28. Liquid supply chamber; 29. Groove; 30. Nozzle; 31. Enclosed cover; 32. Arc-shaped groove; 33. Arc-shaped toothed plate; 34. Drive chamber; 35. Drive gear; 36. Elastic groove; 37. Slide; 38. Baffle; 39. Top column; 40. Pressure rod; 41. First vertical plate; 42. Second vertical plate; 43. Second spring; 44. Drive rod; 45. Positioning block; 46. Positioning groove. Detailed Implementation
[0040] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.
[0041] like Figure 1 As shown, the method for installing monitoring sensors on this intelligent insulated flexible sling includes the following steps: S1. Use the sling ends to fix the soft sling body to the tensioning mechanism, and use the tensioning mechanism to straighten the soft sling body under a tension of 50-70KN. S2. Use a 40-60℃ hot compress to clean the surface of the soft suspender body by blowing air. S3. Use a spraying mechanism to spray adhesive onto the upper surface of the soft sling, then straighten the flexible film sensor and attach it to the upper surface of the soft sling, and press it for 5-8 minutes. S4. The soft sling body and the flexible thin film sensor are covered with a covering material and then heated and cured.
[0042] The method for preparing the flexible thin-film sensor is as follows: first, cut PI adhesive paper, apply uncured PDMS liquid to a silicon plate or other flat plate, paste the PI adhesive paper onto the PDMS, and then place it in an oven to heat and solidify; after solidification, place the base plate with the PI adhesive paper pasted on it into a laser printer; position the laser red dot, and use a laser movement speed of 200mm / s and a laser power of 7.5w to laser burn the PI adhesive paper.
[0043] The flexible thin-film sensor encapsulation layer in this study is highly functional. Besides utilizing the material properties of the encapsulation layer to achieve some functions, the remaining functions are realized through the encapsulation layer structure. Using PDMS sol to fabricate the sensor's encapsulation layer allows for the design of the sensor's surface shape by leveraging the flowability of PDMS before solidification. Given the design expectation of strain thin-film sensors conforming to the surface of the measured object to measure deformation, the surface of the sensor's encapsulation structure should have the same smoothness as the substrate. Simultaneously, to ensure the uniformity of the internal microstructure of multiple sensors and prevent irregular air chambers from remaining within the sensor due to the failure to release air bubbles during PDMS sol solidification, most air bubbles should be removed using a vacuum negative pressure device before the PDMS sol in the encapsulation layer solidifies, ensuring a consistent and pure internal structure. Since the shape of the sensor's PDMS soft adhesive affects its bending and vibration performance, the PDMS soft adhesive structure of multiple sensors of the same model should be identical to ensure consistent structural dimensions, deformation performance, and sensing performance. From an aesthetic point of view, after the PDMS soft glue of the sensor encapsulation layer has solidified, its edges should be cut so that the shape of the PDMS soft glue of the sensor is the same as the LIG pattern, which are two concentric rectangles with parallel sides.
[0044] The bending test of the sensor involves measuring the change in the sensor's resistance value when the thin-film sensor is bent to different curvatures in the normal direction, observing the changes, and summarizing the patterns. Before the experiment, molds with different bending radii (10 mm, 20 mm, 30 mm~100 mm) need to be prepared. The surfaces of the molds with different curvatures must be smooth and continuous to ensure that the area and position of pressure exerted on different sensors on the mold surface are the same when the same bending curvature mold is used in the experiment. After preparation, the sensor substrate side and the encapsulation layer side are sequentially attached to the mold surfaces with different bending curvatures, and their resistance is measured.
[0045] Although the material of the encapsulation layer of this flexible thin-film sensor is the same as that of the substrate layer, if the thickness of the encapsulation layer is inconsistent with that of the substrate layer, the resistance measurement results will be completely different. As envisioned, the main functional element of the sensor's resistance lies in its internal LIG layer. The above-mentioned situation, where the resistance values differ due to the different orientations of the sensor against the surface of the object being measured, indicates that when the sensor's surface is bonded to the curved surface of the object being measured with different orientations, the strain conditions occurring within the PDMS soft adhesive layer of the sensor are different, causing strain differences in the LIG layer and thus different resistances.
[0046] The sensor substrate and encapsulation layer sides are sequentially bonded to curved surfaces of different curvatures, with the substrate layer thickness exceeding the encapsulation layer thickness. The resistance is then measured to obtain... Figure 12 A line graph of resistance data.
[0047] Figure 12 Line graphs showing the resistance changes of different surfaces of the same set of sensors bonded to curved surfaces of different curvatures. (a) Resistance of the substrate bonded to curved surfaces of different curvatures / kΩ; (b) Resistance of the encapsulation layer bonded to curved surfaces of different curvature radii / kΩ.
[0048] Therefore, although the material of the flexible thin-film sensor's encapsulation layer is the same as the substrate layer, if the thickness of the encapsulation layer is inconsistent with that of the substrate layer, the resulting resistance measurements will be completely different. As envisioned, the main functional element of the sensor's resistance lies in its internal LIG layer. The aforementioned situation, where the resistance values differ due to the different orientations of the sensor against the surface of the measured object, indicates that the strain conditions within the PDMS soft adhesive layer of the sensor differ when the sensor's surface is bonded to a curved surface of the measured object with different orientations. This results in strain differences in the LIG layer, leading to different resistances. The sensor's substrate side and encapsulation layer side were sequentially bonded to curved surfaces with different curvatures, where the thickness of the sensor's substrate layer is greater than the thickness of the encapsulation layer. Resistance was then measured. When the thinner of the two PDMS soft adhesive layers was bonded to the curved surface, the smaller the radius of curvature of the curved surface, the lower the resistance. In this state, because the radius of curvature of the LIG layer is smaller than the thickness midline, the LIG layer is below the thickness midline, thus compressing its length. The new length is smaller than the length of the LIG layer in its flat state. At this point, the length of the resistor is indirectly reduced, thus decreasing the distance between carbon atoms in the LIG layer. Conversely, if the thicker of the two PDMS soft adhesive layers adheres to the curved surface, the smaller the radius of curvature of the curved surface, the greater the resistance. In this state, because the radius of curvature of the LIG layer is greater than the thickness midline, and the LIG layer is above the thickness midline, the length of the LIG layer is stretched, and the new length is greater than the length of the LIG layer in its flat state. Therefore, the length of the resistor is increased, and the distance between carbon atoms in the LIG layer is increased.
[0049] Based on the above-mentioned principle and experiments, the optimal flexible thin-film sensor in this application was obtained.
[0050] The coating material is a mixture of silicone rubber and polyurethane, with a mass ratio of silicone rubber to polyurethane of 3:1.
[0051] like Figures 2-11As shown, the equipment used in steps S1-S4 is an integrated installation device. The integrated installation device includes a body 1. A drive motor 11 is fixed inside the body 1. A bidirectional threaded rod 9 is fixed to the output shaft end of the drive motor 11. Two movable seats 10 are threadedly connected to the two threaded portions of the bidirectional threaded rod 9. Several support rods 12 are fixed to the movable seats 10, and pull rods 13 are fixed to the support rods 12. Several first electric telescopic rods 7 are fixed to the lower end of the body 1. A first support plate 8 is fixed to the telescopic end of the first electric telescopic rods 7. Several arc-shaped covers 15 are fixed to the support plate. A crossbeam 2 is fixed to the upper end of the body 1. Several second electric telescopic rods 4 are fixed to the lower side of the crossbeam 2. A second support plate 5 is fixed to the telescopic end of the second electric telescopic rods 4. The lower side of the second support plate 5 is also fixed with... There are several arc-shaped covers 15. The upper arc-shaped cover 15 has a liquid supply chamber 27. An adhesive box 6 is fixed on the second support plate 5. A spray pump is fixed on the adhesive box 6. The spray pump is connected to the liquid supply chamber 27 through a pipe. Several grooves 28 are formed on the inner circumference of the upper arc-shaped cover 15. A nozzle 29 connected to the liquid supply chamber 27 is fixed in the groove 28. A sealing cover 30 is slidably connected to the inner circumference of the arc-shaped cover 15. A driving mechanism is provided between the sealing cover 30 and the arc-shaped cover 15. Sealing plates 16 are fixed at both ends of the arc-shaped cover 15. Several clearance grooves 19 corresponding to the arc-shaped cover 15 are formed on the sealing plates 16. A liquid supply seat 17 is fixed on the sealing plate 16. A sealing box 3 is fixed on the crossbeam 2. The sealing box 3 is connected to the liquid supply seat 17 through a liquid supply pipe 18. The liquid supply seat 17 is connected to the interior of the arc-shaped cover 15.
[0052] Using the above structure, during operation, the sling ends at both ends of the flexible sling body are respectively fitted onto the corresponding pull rods 13 at both ends. Then, the drive motor 11 drives the bidirectional threaded rod 9 to rotate, causing the two moving seats 10 to move in opposite directions, thereby straightening the flexible sling body under a tension of 50-70KN. External equipment is used to clean the surface of the flexible sling body by applying heat at 40-60℃. Using the drive mechanism, the closed cover 30 is offset from the groove 28, thereby exposing the nozzle 29. Adhesive is sprayed onto the upper surface of the flexible sling using the nozzle 29. The arc-shaped cover 15 can constrain the sprayed adhesive and reduce splashing around it. Then, after straightening, the flexible film sensor is attached to the upper surface of the flexible sling. Specifically, one flexible film sensor can be placed on the flexible sling every 1m for even distribution, and the length of the flexible film sensor is 20-40cm. While ensuring monitoring accuracy, the impact of stretching on the sensor is reduced, and costs are saved. The sealing cover 30 is used to close the groove 28 through the drive mechanism. Then, the sealing cover 30 is lowered by the second electric telescopic rod 4 and attached to the flexible film sensor for 5-8 minutes of pressing. After pressing, the first support plate 8 is raised by the first electric telescopic rod 7, so that the upper and lower corresponding arc-shaped covers 15 are spliced into a cylinder. The sealing plate 16 and the soft sling body are used to seal both ends. Then, the encapsulation material in the encapsulation box 3 is fed into the cylinder through the liquid supply seat 17 to encapsulate the soft sling body and the flexible film sensor. The material is then heated and cured. The whole process is highly automated, with a simple structure and high synergy between components. It can be used for multiple purposes, which greatly reduces the cost of the equipment. It can be installed in one go without multiple transfers, which greatly ensures the quality of processing.
[0053] The machine body 1 has several blocking grooves 20 on both the left and right sides inside. The movable seat 10 has a sliding cavity 21 inside. A telescopic motor 22 is fixed inside the sliding cavity 21. A screw 23 is fixed to the output shaft end of the telescopic motor 22. A positioning plate 24 is slidably connected inside the sliding cavity 21. The positioning plate 24 is threadedly connected to the screw 23. The positioning plate 24 and the blocking grooves 20 cooperate with each other. A guide rod 26 is fixed inside the sliding cavity 21. A guide groove 25 is opened on the positioning plate 24. The guide rod 26 is slidably connected to the guide groove 25.
[0054] With the above structure, after the soft sling body is stretched by the movable seat 10, the positioning plate 24 is moved by the telescopic motor 22, so that the positioning plate 24 is inserted into the corresponding blocking groove 20. This allows the positioning plate 24 to provide certain support for the movable seat 10, thereby reducing the pressure on the screw 23, protecting the screw 23 and extending its service life.
[0055] The driving mechanism includes a rotary motor. Arc grooves 31 are provided at both ends of the inner circumference of the arc-shaped cover 15. Arc toothed plates 32 are fixed at both ends of the outer circumference of the closed cover 30. The arc toothed plates 32 are slidably connected to the arc grooves 31. A driving groove 33 communicating with the arc grooves 31 is provided inside the arc-shaped cover 15. A rotary motor is fixed inside the driving groove 33. A driving gear 34 is fixed at the output shaft end of the rotary motor. The driving gear 34 meshes with the arc toothed plates 32.
[0056] With the above structure, when adhesive needs to be sprayed, the drive gear 34 is rotated by a rotary motor, which in turn moves the sealing cover 30 along the arc groove 31 under the action of the arc toothed plate 32, thus exposing the spray nozzle 29. When sealing is required, the sealing cover 30 is returned to its original position to ensure the smoothness of the inner circumference.
[0057] The movable seat 10 has an elastic groove 35 inside, and a first spring 38 is fixed inside the elastic groove 35. A baffle 37 is fixed to the other end of the first spring 38. A slide 36 is fixed on the baffle 37. A support rod 12 is fixed on the slide 36. An insert rod 14 is slidably connected to the support rod 12. A positioning mechanism is provided between the insert rod 14 and the slide 36.
[0058] With the above structure, when fixing the soft sling, one end of the sling can be hung on the pull rod 13 on one side, and then the soft sling can be pulled to compress the first spring 38, so that the other end of the sling can be fitted onto the pull rod 13 on the other side. This setting not only ensures that the sling will not bend when hanging the sling, thus preventing it from affecting the hanging of multiple slings, but also ensures that the movable seats 10 on both sides will not interfere with the arc-shaped cover 15 on the lower side, thus ensuring the normal operation of the work.
[0059] A top post 39 is fixed on the baffle 37, and the length of the top post 39 is 1 / 2 the length of the first spring 38.
[0060] With the above structure, when the soft sling is stretched, the top post 39 can be pressed against the movable seat 10, reducing the pressure on the first spring 38, preventing the first spring 38 from being damaged, extending the service life of the first spring 38, and ensuring the stability of the operation.
[0061] The positioning mechanism includes a positioning cavity inside the insertion rod 14, a pressure rod 40 slidably connected to the positioning cavity, one end of the pressure rod 40 extending out of the insertion rod 14, and a drive rod 44 rotatably connected to the upper and lower sides of the other end of the pressure rod 40. A positioning block 45 is rotatably connected to the other end of the drive rod 44. The positioning block 45 is slidably connected to the insertion rod 14. A positioning groove 46 is provided on the slide 36, which cooperates with the positioning block 45. A first vertical plate 41 is fixed on the pressure rod 40, a second vertical plate 42 is fixed inside the positioning cavity, and a second spring 43 is fixed between the second vertical plate 42 and the first vertical plate 41.
[0062] Using the above mechanism, during operation, the upper part of the end can be pressed and positioned by the insertion rod 14, which not only prevents the end from slipping but also prevents the pull rod 13 from bending, ensuring the accuracy of the stretching. After the insertion rod 14 is inserted into the slide block 36, under the action of the second spring 43, the positioning block 45 is inserted into the positioning groove 46 for positioning. When disassembly is required, press down on the pressure rod 40, causing the pressure rod 40 to move to the right. Under the action of the drive rod 44, the positioning block 45 disengages from the positioning groove 46, and the insertion rod 14 can be pulled out. The operation is simple and convenient.
[0063] Experimental Example 1 S1. Use the sling ends to fix the soft sling body to the tensioning mechanism, and use the tensioning mechanism to make the soft sling body straight under a tension of 60KN. S2. Clean the surface of the soft suspender body by blowing air using a 50°C hot compress; S3. Apply adhesive to the upper surface of the soft sling using a spraying mechanism, then straighten the flexible film sensor and attach it to the upper surface of the soft sling, and press it for 6.5 minutes. S4. The soft sling body and the flexible thin film sensor are covered with a covering material and then heated and cured.
[0064] Simultaneously adopting the integrated installation equipment of this application Experiment Example 2 The difference between this experimental example and Experiment 1 is that the tensile pressure is 50KN and the pressing time is 8min.
[0065] Experimental Example 3 The difference between this experimental example and Experiment 1 is that the tensile pressure is 70KN and the pressing time is 5min.
[0066] To test product performance, key parameters of the woven suspenders were tested. The test results are as follows: Figure 13 ; Breaking strength and elongation at break: Tested using a universal testing machine in accordance with standard GB / T 8834; Insulation strength: Tested using a withstand voltage tester in accordance with standard GB / T 3048.8; Anti-kink performance: Custom test, one end of a 1-meter long sling is fixed, and a torque of 5 Nm is applied to the other end. The angle of torsional deformation is recorded, and the recovery after the torque is removed is observed. Abrasion resistance: Refer to standard GB / T 9867, use a rotary drum abrasion tester, and record the number of friction cycles when the sample breaks; Cyclic bending fatigue life: The number of cycles until the sling breaks is tested on a dedicated fatigue testing machine in accordance with standard ISO 2307.
[0067] Furthermore, during the aforementioned experiment, the thin-film sensor did not malfunction in detecting the performance of the insulated soft sling and maintained normal operation. Moreover, the introduction of the thin-film sensor did not affect the structural integrity, insulation, or other properties of the sling itself.
[0068] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.
Claims
1. A method for installing monitoring sensors on an intelligent insulated flexible sling, characterized in that, Includes the following steps: S1. Fix the flexible sling body to the tensioning mechanism using the sling ends, and use the tensioning mechanism to straighten the flexible sling body under a tension of 50-70KN; S2. Clean the surface of the flexible sling body by blowing air using a heat treatment at 40-60℃; S3. Spray adhesive onto the upper surface of the flexible sling using a spraying mechanism, then straighten the flexible film sensor and attach it to the upper surface of the flexible sling, and press it for 5-8 minutes; S4. Cover the flexible sling body and the flexible film sensor with a covering material and heat-cur them.
2. The method for installing a monitoring sensor on an intelligent insulated flexible sling according to claim 1, characterized in that, The method for preparing the flexible thin-film sensor is as follows: first, cut PI adhesive paper, apply uncured PDMS liquid to a silicon plate or other flat plate, paste the PI adhesive paper onto the PDMS, and then place it in an oven to heat and solidify; after solidification, place the base plate with the PI adhesive paper pasted on it into a laser printer; position the laser red dot, and use a laser movement speed of 200mm / s and a laser power of 7.5w to laser burn the PI adhesive paper.
3. The method for installing a monitoring sensor on an intelligent insulated flexible sling according to claim 1, characterized in that, The coating material is a mixture of silicone rubber and polyurethane, with a mass ratio of silicone rubber to polyurethane of 3:
1.
4. The method for installing a monitoring sensor on an intelligent insulated soft sling according to claim 1, characterized in that, The equipment used in steps S1-S4 is an integrated installation device. The integrated installation device includes a body (1). A drive motor (11) is fixed inside the body (1). A bidirectional threaded rod (9) is fixed to the output shaft end of the drive motor (11). Two movable seats (10) are threadedly connected to the two threaded parts of the bidirectional threaded rod (9). Several support rods (12) are fixed on the movable seats (10). Pull rods (13) are fixed on the support rods (12). Several first electric telescopic rods (7) are fixed to the lower end of the body (1). A first support plate (8) is fixed to the telescopic end of the first electric telescopic rod (7). Several arc-shaped covers (15) are fixed to the support plate. A crossbeam (2) is fixed to the upper end of the body (1). Several second electric telescopic rods (4) are fixed to the lower side of the crossbeam (2). A second support plate (5) is fixed to the telescopic end of the second electric telescopic rod (4). Several arc-shaped covers (15) are also fixed to the lower side of the second support plate (5). The upper arc-shaped cover (15) has a liquid supply chamber (27) inside. An adhesive box (6) is fixed on the second support plate (5). A spray pump is fixed on the adhesive box (6). The spray pump is connected to the liquid supply chamber (27) through a pipe. Several grooves (28) are opened on the inner circumference of the upper arc-shaped cover (15). A nozzle (29) connected to the liquid supply chamber (27) is fixed in the groove (28). A sealing cover (30) is slidably connected to the inner circumference of the arc-shaped cover (15). A drive mechanism is provided between the arc-shaped cover (15) and the arc-shaped cover (15). Both ends of the arc-shaped cover (15) are fixed with a sealing plate (16). Several clearance grooves (19) corresponding to the arc-shaped cover (15) are opened on the sealing plate (16). A liquid supply seat (17) is fixed on the sealing plate (16). A sealing box (3) is fixed on the crossbeam (2). The sealing box (3) is connected to the liquid supply seat (17) through the liquid supply pipe (18). The liquid supply seat (17) is connected to the interior of the arc-shaped cover (15).
5. The method for installing a monitoring sensor on an intelligent insulated soft sling according to claim 4, characterized in that, The machine body (1) has several blocking grooves (20) on both the left and right sides inside. The movable seat (10) has a sliding cavity (21) inside. A telescopic motor (22) is fixed inside the sliding cavity (21). A screw (23) is fixed at the output shaft end of the telescopic motor (22). A positioning plate (24) is slidably connected inside the sliding cavity (21). The positioning plate (24) is threadedly connected to the screw (23). The positioning plate (24) and the blocking groove (20) cooperate with each other. A guide rod (26) is fixed inside the sliding cavity (21). A guide groove (25) is opened on the positioning plate (24). The guide rod (26) is slidably connected to the guide groove (25).
6. The method for installing a monitoring sensor on an intelligent insulated soft sling according to claim 4, characterized in that, The driving mechanism includes a rotary motor. Arc grooves (31) are provided at both ends of the inner periphery of the arc-shaped cover (15). Arc toothed plates (32) are fixed at both ends of the outer periphery of the closed cover (30). The arc toothed plates (32) are slidably connected to the arc grooves (31). A driving groove (33) communicating with the arc grooves (31) is provided inside the arc-shaped cover (15). A rotary motor is fixed inside the driving groove (33). A driving gear (34) is fixed at the output shaft end of the rotary motor. The driving gear (34) meshes with the arc toothed plates (32).
7. The method for installing a monitoring sensor on an intelligent insulated soft sling according to claim 4, characterized in that, The movable seat (10) has an elastic groove (35) inside, and a first spring (38) is fixed inside the elastic groove (35). A baffle (37) is fixed at the other end of the first spring (38). A slide (36) is fixed on the baffle (37). A support rod (12) is fixed on the slide (36). An insert rod (14) is slidably connected on the support rod (12). A positioning mechanism is provided between the insert rod (14) and the slide (36).
8. The method for installing a monitoring sensor on an intelligent insulated flexible sling according to claim 7, characterized in that, A top post (39) is fixed on the baffle (37), and the length of the top post (39) is 1 / 2 of the length of the first spring (38).
9. A method for installing a monitoring sensor on an intelligent insulated soft sling according to claim 7, characterized in that, The positioning mechanism includes a positioning cavity opened in the insert rod (14), a pressure rod (40) is slidably connected to the positioning cavity, one end of the pressure rod (40) extends out of the insert rod (14), the upper and lower sides of the other end of the pressure rod (40) are rotatably connected to a drive rod (44), the other end of the drive rod (44) is rotatably connected to a positioning block (45), the positioning block (45) is slidably connected to the insert rod (14), a positioning groove (46) is opened on the slide (36), the positioning groove (46) cooperates with the positioning block (45), a first vertical plate (41) is fixed on the pressure rod (40), a second vertical plate (42) is fixed in the positioning cavity, and a second spring (43) is fixed between the second vertical plate (42) and the first vertical plate (41).