Corrosion activated sensor

Abstract

The application discloses a kind of corrosion touch sensor, it is related to intelligent sensing technical field, including sensor main body, sensor main body has drive assembly, deformation response structure, deformation monitoring component and guide layer in it;Drive assembly is arranged in deformation response structure, guide layer is set in the downside of drive assembly;Guide layer is used to introduce corrosive medium, drive assembly can produce axial displacement under the action of corrosion, and deformation response structure is used to receive and amplify axial displacement;Deformation monitoring component is used to monitor the deformation of deformation response structure and output signal;Drive assembly includes elastic energy storage element, corrosion crushing element, and corrosion crushing element is fixed to the outside of elastic energy storage element by pre-stretching energy storage.The application realizes the fast direct response and continuous process monitoring to micron level thinning in the early stage of metal corrosion by pre-stretching elastic energy storage, multiple sub-unit section loss accumulation amplification, corrosion product reliable crushing, deformation response amplification, etc., improves early warning accuracy and reliability.

Description

Technical Field

[0001] This invention relates to the field of intelligent sensing technology, and specifically to a corrosion-sensitive sensor. Background Technology

[0002] Currently, metal corrosion detection technology has gradually evolved from traditional offline detection to online real-time monitoring. Corrosion detection sensors, as core sensing devices, directly determine the accuracy, efficiency, and reliability of corrosion monitoring. The mainstream corrosion detection sensors are mainly divided into two categories: one is based on electrochemical principles, including three-electrode systems, thermocouples, and resistance probes. These sensors indirectly reflect the corrosion state by monitoring electrochemical signals such as potential, current, and resistance generated during metal corrosion. They can only qualitatively describe the degree of corrosion of reinforcing bars, and the measurement results are easily affected by external environmental factors, resulting in poor stability. The other category is based on physical changes. These sensors use the expansion force of corrosion products to drive the sensing element (such as fiber optic gratings and resistance strain gauges) to generate strain, thus monitoring the corrosion state. However, because the expansion force of corrosion products is severely affected by constraints, the measurement results are not accurate enough. In addition to the above problems, existing corrosion monitoring sensors also have the following shortcomings in practical applications: First, most sensors can only monitor relatively severe corrosion phenomena. They cannot respond in time and output effective signals for changes in material properties caused by initial minor corrosion, resulting in corrosion hazards not being detected early and missing the best time for prevention and control.

[0003] Secondly, the physical deformation generated during the corrosion of metallic materials is usually very small, and existing sensors have difficulty converting the small displacement into a signal that can be accurately monitored, resulting in large monitoring errors. At the same time, most sensors can only achieve single-point corrosion monitoring and cannot achieve simultaneous monitoring of multiple measurement points, making it difficult to accurately locate the corrosion position.

[0004] Furthermore, most sensor elements use general-purpose materials, which differ from the tested metal materials in terms of electrochemical corrosion potential, corrosion morphology, and corrosion rate. This results in asynchronous corrosion behavior and makes it impossible to accurately reflect the corrosion process of the tested metal materials. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the purpose of this invention is to provide a corrosion-triggered sensor that achieves rapid and direct response to and continuous monitoring of the initial micron-level thinning of metal corrosion through pre-stretched elastic energy storage, multi-sub-unit cross-sectional loss accumulation amplification, reliable crushing of corrosion products, and deformation response amplification, thereby improving the accuracy and reliability of early warning.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution: An embodiment of the present invention provides a corrosion-sensitive sensor, including a sensor body, wherein the sensor body has a driving component, a deformation response structure, a deformation monitoring component, and a guiding layer; The driving component is disposed in the deformation response structure, and the guiding layer is disposed below the driving component; the guiding layer is used to introduce a corrosive medium, and the driving component can generate axial displacement under the action of corrosion; the deformation response structure is used to receive and amplify the axial displacement; the deformation monitoring component is used to monitor the deformation generated by the deformation response structure and output a signal. The drive assembly includes an elastic energy storage element and a corrosion crushing element. The corrosion crushing element is fixed to the outside of the pre-stretched elastic energy storage element to form a tension-compression balance.

[0007] As a further implementation, the drive assembly also includes anchors, the corrosion crushing element is coaxially arranged on the outside of the elastic energy storage element, and the anchors are connected to both ends of the elastic energy storage element.

[0008] As a further implementation, the corrosion crushing element adopts one of the following types: collar type, bead type, spiral type, and graded collar type. Each type of corrosion crushing element contains at least one sub-unit, which is connected in series along the axial direction outside the elastic energy storage element.

[0009] As a further implementation, the deformation response structure includes an eccentric deformation structure or a symmetrical deformation structure, wherein the eccentric deformation structure is provided with a set of driving components, and the symmetrical deformation structure is provided with an even number of driving components.

[0010] As a further implementation, a connecting slot is provided on one side of the eccentric deformation structure, and the connecting slot is located at both ends of the eccentric deformation structure. The drive component engages with the connecting slot.

[0011] As a further implementation, the symmetrical deformation structure has symmetrical drive slots on both sides of the radial direction, and the drive slots are arranged through the axis. The drive component is housed within the drive card slot.

[0012] As a further implementation, the deformation monitoring component includes a resistance strain gauge and a temperature-compensated strain gauge, wherein the resistance strain gauge is bonded and fixed to the deformation response structure, and the temperature-compensated strain gauge is disposed above the resistance strain gauge.

[0013] As a further implementation, the deformation monitoring component includes multiple fiber gratings and corresponding temperature-compensated fiber gratings arranged sequentially along the axis of a single optical fiber, used to achieve synchronous monitoring of multiple measurement points and location of corrosion.

[0014] As a further implementation, the sensor body includes a housing, one end of which is connected to an end cap, and a wire extends out to the outside through the end cap; The outer shell has a working channel and a temperature compensation channel arranged in parallel inside it, and the working channel has several guide holes on the bonding surface with the guide layer.

[0015] As a further implementation, the deformation monitoring component is connected to a signal acquisition device on the outside of the sensor body via a wire, and the output end of the signal acquisition device is sequentially connected to a central processing unit and an early warning device.

[0016] As a further implementation, the central processing unit determines the signal amplitude, rate of change, and cumulative change based on real-time signals from the deformation monitoring component according to preset multi-level thresholds, and triggers graded early warnings. The graded early warning system classifies the metal corrosion state into multiple levels based on the progressive failure of the corrosion crushing element, the axial displacement released by the elastic energy storage element, and the strain increment generated by the deformation response structure, thereby realizing the phased identification and processing of the metal corrosion process.

[0017] As a further implementation, the corrosion crushing element is made of the same material as the metal being tested, and the elastic energy storage element and anchor are made of inert or highly corrosion-resistant materials. Furthermore, the corrosion resistance of the corrosion crushing element is lower than that of the elastic energy storage element, anchor, and deformation response structure.

[0018] As a further implementation, the strength of the corrosion product of the corrosion-crushing element is less than the compressive stress of the elastic energy storage element on the corrosion-crushing element, which is less than the original strength of the corrosion-crushing element.

[0019] The beneficial effects of the above embodiments of the present invention are as follows: (1) The metal corrosion trigger sensor of the present invention includes a driving component, a deformation response structure, a deformation monitoring component and a guiding layer. The driving component includes an elastic energy storage element and a corrosion crushing element. The guiding layer is used to introduce a corrosive medium into the sensor. The driving component generates an axial displacement under the action of corrosion. The deformation response structure is used to receive and amplify the axial displacement. The deformation monitoring component is used to monitor the deformation generated by the deformation response structure and output a signal. Thus, through pre-stretching elastic energy storage, multi-sub-unit cross-sectional loss accumulation amplification, reliable crushing of corrosion products, deformation response amplification, etc., a rapid and direct response to the micron-level thinning in the early stage of metal corrosion and continuous process monitoring are achieved, thereby improving the accuracy and reliability of early warning.

[0020] (2) The corrosion crushing element of the present invention adopts one of the following types: collar type, bead type, spiral type, and graded collar type, each containing multiple sub-units; the elastic energy storage element is pre-stretched and cooperates with the corrosion crushing element to realize the cumulative amplification of the cross-sectional loss of multiple sub-units. Combined with the design that the pre-compression stress is greater than the yield strength of the corrosion product, the product is reliably crushed, and the displacement amplification of the small changes in the early stage of corrosion is realized, thereby improving the response capability to the small damage in the early stage of corrosion.

[0021] (3) The deformation response structure of the present invention includes an eccentric deformation structure or a symmetrical deformation structure. The eccentric deformation structure can amplify local strain, improve signal amplitude and anti-interference ability, and realize continuous and quantitative monitoring. The symmetrical deformation structure can realize the transformation of axial displacement into uniform axial tensile and compressive deformation.

[0022] (4) The corrosion crushing element of the present invention uses the same material as the component under test or has a high degree of similar electrochemical performance, and exposes it to the same corrosion environment through the guide channel, so as to ensure that the corrosion behavior of the sensor and the component under test are synchronized and improve the reliability of detection. Attached Figure Description

[0023] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0024] Figure 1 This is an exploded view of Embodiment 1 of the present invention; Figure 2 This is a cross-sectional view of the sensor packaging shell according to Embodiment 1 of the present invention; Figure 3 This is a cross-sectional view of Embodiment 1 of the present invention; Figure 4(a) is a bottom view of the sensor housing of Embodiment 1 of the present invention; Figure 4(b) is a side view of the sensor housing of Embodiment 1 of the present invention; Figure 5 This is a schematic diagram of the sensor installation and signal transmission system according to Embodiment 1 of the present invention; Figure 6 This is a diagram of the equipment for fabricating the drive component according to Embodiment 1 of the present invention; Figure 7 This is a schematic diagram of the manufacturing process of the drive component in Embodiment 1 of the present invention; Figure 8 This is a schematic diagram of the structure of the sensor working assembly described in Embodiment 1 of the present invention; Figure 9 This is a top view of the sensor working assembly described in Embodiment 1 of the present invention; Figure 10 This is a diagram illustrating the corrosion monitoring mechanism of Embodiment 1 of the present invention; Figure 11This is a diagram illustrating the sensitivity enhancement mechanism of the driving component in Embodiment 1 of the present invention; Figure 12 This is an experimental diagram of accelerated corrosion of the working component in Embodiment 1 of the present invention; Figure 13 This is a schematic diagram of the fabrication process of the beaded drive component in Embodiment 2 of the present invention; Figure 14 This is a schematic diagram of the fabrication process of the spiral drive component in Embodiment 3 of the present invention; Figure 15 This is a schematic diagram of the hierarchical ring-type drive assembly structure of Embodiment 4 of the present invention; Figure 16 This is a schematic diagram of the hierarchical ring-type drive component mechanism of Embodiment 4 of the present invention; Figure 17 This is a schematic diagram of the structure of Embodiment 5 of the present invention; Figure 18 This is a cross-sectional view of Embodiment 5 of the present invention; Figure 19 This is a schematic diagram of the preparation process in Example 5 of the present invention; Figure 20 This is an exploded view of Embodiment 6 of the present invention; Figure 21 This is a schematic diagram of the structure of Embodiment 6 of the present invention; Figure 22 This is a front view of Embodiment 6 of the present invention; Figure 23 This is a schematic diagram of the structure of Embodiment 7 of the present invention.

[0025] Among them, 1-sensor body, 2-metal to be tested, 3-binding component, 4-wire, 5-signal acquisition instrument, 6-central processing unit, 7-early warning device, 8-tensioning device; 11-Drive component, 12-Deformation response structure, 13-Deformation monitoring component, 14-Guide layer, 15-Outer shell, 16-End cap; 81-Support frame, 82-Fixed base, 83-Pulley, 84-Weight; 111-Elastic energy storage element; 112-Corrosion crushing element; 113-Anchor; 121-Eccentric deformation structure; 122-Symmetric deformation structure; 123-Temperature compensation structure; 131-Resistance strain gauge; 132-Temperature compensation strain gauge; 133-Fiber grating; 134-Temperature compensation fiber grating; 135-Fiber core; 136-Cladding; 137-Protective sleeve; 151-Guide hole; 152-Working channel; 153-Temperature compensation channel; 154-Separating platform; 155-Fixing slot. 1211-First connecting end, 1212-Second connecting end, 1213-Connecting card slot, 1214-Monitoring card slot; 1221-Drive card slot, 1222-Filling cavity. Detailed Implementation

[0026] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0027] For ease of description, the words "up," "down," "left," and "right" appearing in this invention only indicate that they are consistent with the up, down, left, and right directions of the accompanying drawings themselves, and do not limit the structure. They are merely for the purpose of facilitating the description of this invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0028] Example 1: This embodiment provides a corrosion-sensitive sensor that can be used for corrosion monitoring of metallic and non-metallic materials, such as... Figures 1-3 As shown in Figures 4(a) and 4(b), the sensor includes a sensor body 1, which comprises a housing 5 and a drive assembly 11, a deformation response structure 12, a deformation monitoring assembly 13, and a guide layer 14 disposed within the housing 5. One end of the housing 5 is connected to an end cap 16, and a wire 4 extends outward through the end cap 16. The guide layer 14 is used to introduce a corrosive medium. Under the action of corrosion, the drive assembly 11 generates axial displacement. The deformation response structure 12 is used to receive and amplify the axial displacement of the drive assembly 11, and the deformation monitoring assembly 13 is used to monitor and amplify the deformation.

[0029] In this embodiment, the outer shell 15 has a slender cylindrical structure, such as... Figure 2 and Figure 3 As shown, a working channel 152 and a temperature compensation channel 153 are arranged in parallel inside the outer casing 15. Following the view direction, the temperature compensation channel 153 is located above the working channel 152. Both are axially aligned and separated by a partition 154, allowing the working component and temperature compensation component to be arranged independently and without interference. Multiple guide holes 151 are evenly distributed at the bottom of the working channel 152, and a guide layer 14 is attached to the upper side of the guide holes 151. The guide layer 14 is a thin capillary layer, preferably made of a corrosion-resistant material with high permeability and small pore size, such as a hydrophilic polymer porous membrane or polymer fiber felt.

[0030] like Figure 1 and Figure 3As shown, the drive assembly 11 includes an elastic energy storage element 111, a corrosion-crushing element 112, and anchors 113. The two ends of the elastic energy storage element 111 are respectively connected to the anchors 113, and the portion of the elastic energy storage element 111 between the two anchors 113 is fitted with the corrosion-crushing element 112. The elastic energy storage element 111 has a rod-like structure and is preferably made of a material with excellent elastic recovery and corrosion resistance, such as high-strength nylon fiber. The anchors 113 are used to constrain the elastic energy storage element 111 and the corrosion-crushing element 112 to prevent prestress loss.

[0031] The elastic energy storage element 111 and the anchor 113 are made of inert or highly corrosion-resistant materials, satisfying the corrosion resistance inequality: corrosion-crushing element 112 < (elastic energy storage element 111, anchor 113, deformation response structure 12). Furthermore, the strength of the corrosion products of the corrosion-crushing element 112 < the initial compressive stress of the elastic energy storage element 111 on the corrosion-crushing element 112 < the strength of the corrosion-crushing element 112.

[0032] Because the bottom of the housing 15 is provided with a guide hole 151, the external corrosive medium is introduced into the working channel 152 and directly contacts the drive component 11. When corrosion occurs, the cross section of the corrosion crushing element 112 is thinned to produce low-intensity corrosion products. The corrosion products are crushed under the action of pre-compression stress, which causes the elastic energy storage element 111 to release elastic potential energy and generate axial displacement.

[0033] In this embodiment, the corrosion crushing element 112 adopts a ring-type structure, that is, the corrosion crushing element 112 is composed of multiple thin-walled metal rings axially stacked on the outside of the elastic energy storage element; the corrosion crushing element 112 preferably uses a metal that is the same as or has a high degree of similar electrochemical performance as the metal component to be tested, so as to achieve material-matched corrosion behavior.

[0034] like Figure 6 and Figure 7 As shown, the manufacturing process of the drive component 11 is as follows: First, the elastic energy storage element 111 is pre-stretched using the tensioning device 8, and a prestress σ0 is applied; then, while maintaining the pre-tightened state, multiple collars are sequentially stacked axially and fitted in; finally, the two ends are fixed with anchors 113, and after the external tension is removed, the corrosion crushing element 112 is tightly squeezed under the residual tensile stress σ1 of the elastic energy storage element 111, generating a compressive stress σ. c Ultimately, the two reach a tension-compression balance. The applied prestress σ0 is greater than the yield strength of the corrosion products to ensure that subsequent corrosion products are reliably crushed.

[0035] In this embodiment, the tensioning device 8 includes a support frame 81, a fixed seat 82, a pulley 83, and a weight 84. The fixed seat 82 is installed at one end of the support frame 81, and the pulley 83 is installed at the other end. One end of the elastic energy storage element 111 is fixed to the fixed seat 82, and the other end is connected to a traction rope. The traction rope passes around the pulley 83 and connects to the weight 84. The weight of the weight 84 is used to stretch the elastic energy storage element 111.

[0036] like Figure 3 , Figure 8 and Figure 9 As shown, the deformation response structure 12 of this embodiment includes an eccentric deformation structure 121 and a temperature compensation structure 123. The driving assembly 11 is disposed within the eccentric deformation structure 121, and the temperature compensation structure 123 is disposed within the temperature compensation channel 153. The temperature compensation structure 123 adopts a slender strip-like design, with its cross-sectional dimensions and material consistent with the eccentric deformation structure 121, but omitting the connecting ends protruding along the height direction at both ends to avoid introducing additional bending moments. The deformation response structure 12 is preferably made of a material with good elastic deformation capacity, high fatigue resistance, and a low coefficient of thermal expansion. Figure 1 In the indicated direction, the eccentric deformation structure 121 wraps around the upper side of the drive assembly 11, and the guide layer 14 is disposed on the lower side of the drive assembly 11. In this embodiment, the drive assembly 11 is eccentrically positioned to convert axial displacement into bending deformation driven by eccentric torque, further amplifying the strain signal.

[0037] In this embodiment, the eccentric deformation structure 121 is generally in the shape of a long, thin strip, and has a first connecting end 1211 and a second connecting end 1212. The first connecting end 1211 and the second connecting end 1212 protrude along the height direction, forming a unilateral eccentric arrangement, which makes it easy to undergo bending deformation and strain concentration under axial force. Both the first connecting end 1211 and the second connecting end 1212 are provided with connecting grooves 1213. The connecting grooves 1213 have a certain length, and by setting the connecting grooves 1213, the first connecting end 1211 and the second connecting end 1212 form a U-shaped structure.

[0038] Anchor 113 is engaged within connecting slot 1213. To achieve effective anchoring, in this embodiment, anchor 113 includes a column structure and an end plate connected to one end of the main structure. The diameter of the column structure is adapted to the width of connecting slot 1213, and the end plate is larger than the diameter of the main structure, so that it is located outside the connecting end after the column structure and connecting slot 1213, forming a limiting position. To further ensure a stable connection between the drive assembly 11 and the eccentric deformation structure 121, after anchor 113 is engaged in connecting slot 1213, it is fixed thereto by adhesive, so that displacement is directly transmitted to the eccentric deformation structure 121.

[0039] The deformation monitoring component 13 employs at least two measuring elements and performs differential calculations. The measuring elements are selected from strain gauges, fiber Bragg gratings, or other strain sensors to suppress common-mode interference and extract the net strain signal. In this embodiment, the deformation monitoring component 13 includes a resistance strain gauge 131 and a temperature-compensated strain gauge 132, such as... Figure 3 As shown, a temperature-compensated strain gauge 132 is disposed on the upper side of the temperature compensation structure 123, and the temperature compensation structure 123 and the temperature-compensated strain gauge 132 constitute a temperature compensation assembly; a resistance strain gauge 131 is disposed on the upper side of the eccentric deformation structure 121, and the drive assembly 11, the eccentric deformation structure 121, and the resistance strain gauge 131 constitute a working assembly for integrated corrosion response and deformation monitoring. By performing differential processing on the measurement signals of the resistance strain gauge 131 and the temperature-compensated strain gauge 132, common-mode interference such as temperature changes is eliminated, and the net strain signal caused by the release displacement of the drive assembly 11 is extracted.

[0040] Furthermore, the resistance strain gauge 131 is attached to the high strain zone on the upper surface of the eccentric deformation structure 121, with the sensitive grid direction consistent with the main force direction, ensuring high sensitivity to minute displacements.

[0041] It should be noted that the resistance strain gauge 131 and temperature compensation strain gauge 132 in this embodiment are functional names for easy differentiation and do not change the structure of the strain gauges.

[0042] like Figure 5 As shown, the sensor body 1 can be directly installed on the surface of the metal to be tested 2 and fixed by the binding member 3 to ensure that it is exposed to the same corrosive environment. The deformation monitoring component 13 is electrically connected to the wire 4. The output end of the wire 4 is connected in sequence to the signal acquisition instrument 5, the central processing unit 6 and the early warning device 7. The output signal of the deformation monitoring component 13 is transmitted to the signal acquisition instrument 5 via the wire 4 and further transmitted to the central processing unit 6 for real-time analysis and processing. When the monitoring signal reaches the preset corrosion threshold, the central processing unit 6 sends an early warning command to the early warning device 7 to realize real-time monitoring and early warning of the metal corrosion status.

[0043] The corrosion monitoring principle of the working components is as follows Figure 10 As shown, it is divided into three stages: initial stable state, corrosion release state, and recovery equilibrium state. Figure 10 In the diagram, a) represents the initial stable state, where the corrosion-crushing element 112 bears the prestress of the elastic energy storage element 111, maintaining the tension and compression balance in the drive assembly 11. The eccentric moment M0 of the eccentric deformation structure 121 is 0, and the resistance strain gauge 131 has no strain output.

[0044] (b) Indicating the corrosion release state, under the action of the corrosive medium, the wall thickness of the collar decreases, causing the effective stress-bearing cross-section thickness of the collar to gradually decrease. Under the elastic restoring force of the elastic energy storage element 111, the compressive stress Δσ of the remaining collar continuously increases, and the elastic energy storage element 111 subsequently contracts continuously, gradually approaching its initial free length. This gradual contraction process generates an inward axial tensile force. Due to the eccentric arrangement of the drive assembly 11, this tensile force forms an eccentric moment ΔM on the eccentric deformation structure 121, driving the deformation response structure to gradually bend and deform to one side. The resistance strain gauge 131 monitors the continuously increasing strain Δε, forming a... Figure 12 The continuous strain-time curve shown.

[0045] c) indicates the return to equilibrium state, the collar fails due to corrosion, all corrosion products are crushed, the elastic energy is basically released, it shrinks to near the initial length, the working component reaches a new mechanical equilibrium state, the eccentric torque ΔM of the eccentric deformation structure 121 reaches its maximum, and the output strain Δε.

[0046] The corrosion-sensitive sensor in this embodiment has high sensitivity, and its high sensitivity mechanism is as follows: Figure 11 As shown, a) represents the prestress σ1 in the elastic energy storage element 111 and the compressive stress σ on the corrosion-crushed element 112 when the drive component 11 is not corroded. c Phase balance, drive assembly 11 maintains its original length l0. b) indicates that after corrosion occurs, each collar in the corrosion crushing element 112 is thinned by corrosion, and the gap Δt between the collars is filled by corrosion products; however, the yield stress σ of the corrosion products... s Much smaller than the compressive stress σ in the corrosion-crushing element 112 c The corrosion products are crushed, causing the elastic potential energy stored in the elastic energy storage element 111 to be released and generate axial displacement. When n collars are distributed in series, the cross-sectional thinning of the corrosion crushing element 112 is equivalent to the accumulation of all collar gaps in the axial direction, with a total displacement Δl = n·Δt. Therefore, the more collars n there are, the greater the cumulative displacement, and the sensitivity is linearly amplified. After the gaps are filled with low-intensity corrosion products, they are crushed, and the cumulative amplification of the total axial displacement by the failure of multiple collars achieves a high-sensitivity response to the micron-level thinning in the early stage of corrosion.

[0047] Secondly, the eccentric deformation structure 121 converts the axial displacement of the drive component 11 into bending deformation. By increasing the eccentricity or adjusting the cross section, the bending strain can be significantly amplified, further enhancing the strain signal amplitude and achieving a high-sensitivity response to micron-level deformation in the early stage of corrosion.

[0048] To verify the high sensitivity and reliability of the corrosion-sensitive sensor in this embodiment, accelerated corrosion experiments were conducted on the working components, such as... Figure 12As shown, after the experiment, obvious corrosion products were generated on the surface of the working component, and visible bending occurred in the eccentrically deformed structure 121. The strain-time curve recorded by the signal acquisition instrument 5 showed a continuous and gradual upward trend, indicating that even small early corrosion triggered a significant strain increment, confirming the effectiveness of the cumulative amplification effect of the loss of multiple ring sections.

[0049] This embodiment achieves early warning of metal corrosion with high sensitivity, material matching, and continuous process monitoring through a synergistic mechanism of pre-stretched elastic energy storage, multi-ring cumulative corrosion sensitivity, eccentric structure amplification response, and differential strain measurement. It is suitable for long-term health monitoring in harsh environments such as buildings, bridges, and offshore platforms, and has significant advantages such as simple structure, low cost, and reliable response.

[0050] Example 2: This embodiment provides a corrosion-activated sensor, which differs from Embodiment 1 in that the driving assembly 11 uses a beaded corrosion crushing element 112 instead of a collar-type element, such as... Figure 13 As shown, the corrosion crushing element 112 is composed of multiple metal beads connected in series along the axial direction of the elastic energy storage element 111. Each metal bead has a through-hole adapted to the elastic energy storage element 111. The material of each metal bead is the same as or has highly similar electrochemical properties to the metal being tested, ensuring synchronized corrosion behavior with material matching.

[0051] The manufacturing process of the drive component 11 in this embodiment is as follows: First, a prestress σ0 is applied to the elastic energy storage element 111 using the tensioning device 8; then, while maintaining the pre-tensioned state, multiple metal beads are sequentially threaded onto the elastic energy storage element 111; finally, the metal beads at both ends of the column are fixed with anchors 113. After the external tension is removed, the residual tensile stress σ1 of the elastic energy storage element 111 causes the metal beads to compress against each other, generating compressive stress σ. c This creates a balance between tension and compression.

[0052] Compared to Example 1, this example uses a beaded corrosion crushing element 112, which has lower requirements for processing and assembly precision, and a relatively simplified manufacturing process, making it more suitable for large-scale industrial production. Because each individual metal column unit has a large volume, it can still provide stable mechanical support under severe corrosion or long-term service conditions, which is beneficial for continuous monitoring of the corrosion state in the mid-to-late stages. Therefore, this example is more suitable for applications requiring high ease of fabrication, structural reliability, and long-term stability, such as highways, bridges, and tunnels.

[0053] The other structures are the same as in Example 1, and will not be described again here.

[0054] Example 3: This embodiment provides a corrosion-activated sensor, which differs from Embodiment 1 in that the driving assembly 11 uses a spiral-type corrosion-crushing element 112 instead of a collar-type element, such as... Figure 14As shown, the spiral corrosion crushing element 112 is formed by tightly winding fine metal wires around the outer surface of the elastic energy storage element 111 according to a predetermined pitch; wherein, the metal wire material is the same as or has a high degree of similar electrochemical performance as the metal to be tested, ensuring that it has a consistent or similar corrosion rate and corrosion morphology under the same corrosion environment.

[0055] The manufacturing process of the drive component 11 in this embodiment is as follows: First, a prestress σ0 is applied to the elastic energy storage element 111 using the tensioning device 8; then, while maintaining the pre-tension state, the metal wire is continuously spirally wound around the outside of the elastic energy storage element according to the set pitch, ensuring tightness, uniformity, and no overlapping defects; after the winding is completed, the two ends of the metal wire are fixed with anchors 113. After the external tension is removed, the residual tensile stress σ1 of the elastic energy storage element 111 causes radial and axial compressive stress σ in the spiral winding layer. c This creates a balance between tension and compression.

[0056] Compared to Example 1, the spiral corrosion crushing element 112 in this embodiment also exhibits high sensitivity to early corrosion; furthermore, by adjusting the diameter, pitch, and number of turns of the metal wire, the sensitivity and response range of the sensor can be flexibly designed and controlled. Therefore, this embodiment is more suitable for precision applications requiring high accuracy in early corrosion warning and adjustable response, such as energy transportation pipelines.

[0057] The other structures are the same as in Example 1, and will not be described again here.

[0058] Example 4: This embodiment provides a corrosion-activated sensor, which differs from Embodiment 1 in that the driving assembly 11 uses a graded ring-type corrosion crushing element 112 instead of a single ring-type element. Figure 15 As shown, the graded collar-type corrosion crushing element 112 is composed of multiple collar groups connected in series along the axial direction of the elastic energy storage element 111.

[0059] Each ring group comprises multiple rings with the same inner diameter but different outer diameters, or in other words, multiple rings with different wall thicknesses. For each ring group, the wall thickness of each ring gradually decreases from one end to the other of the elastic energy storage element 111. In this embodiment, each ring group consists of three rings with successively decreasing wall thicknesses, corresponding to different corrosion thresholds. Preferably, the rings are made of the same material as the metal component being tested or have similar electrochemical properties to ensure that the rings exhibit corrosion behavior similar to that of the component being tested in the actual environment.

[0060] like Figure 16As shown, the graded collar-type corrosion crushing element 112 realizes the segmented triggering and step-by-step mechanical release of the corrosion process. In the early stage of corrosion, the wall thickness of the low-threshold collar rapidly thins to the critical value, and crushing failure occurs first. The elastic energy storage element 111 recovers and contracts Δl1, driving the eccentric deformation structure 121 to produce bending deformation. The resistance strain gauge 131 outputs the corresponding strain, and the early warning device 7 issues a Class I corrosion signal. As corrosion progresses, the medium-threshold collars fail one after another, triggering a larger recovery contraction Δl2 and strain increment, corresponding to the tested metal entering the Class II corrosion state. In the later stage of corrosion, the high-threshold collar fails, the elastic energy storage element 111 produces the maximum recovery contraction Δl3, and the output strain increases again, corresponding to the tested metal being in the Class III corrosion state.

[0061] In this embodiment, N rings with different wall thicknesses can be set to form a graded ring-type corrosion crushing element 112, corresponding to a preset N-level corrosion threshold. Corrosion warnings of the corresponding level are output according to the progressive failure of the graded ring-type corrosion crushing element 112.

[0062] Compared to Example 1, the graded ring-type corrosion crushing element 112 used in this example can sequentially trigger multiple corrosion thresholds and output staged early warning signals, thereby covering the monitoring needs of the entire life cycle of metal from early corrosion to severe damage. Therefore, this example is more suitable for engineering structures that require full life cycle graded assessment and long-term service, such as main cables of large bridges and steel structures of offshore platforms.

[0063] The other structures are the same as in Example 1, and will not be described again here.

[0064] Example 5: This embodiment provides a corrosion-sensitive sensor, which differs from Embodiment 1 in that: the deformation response structure 12 adopts a symmetrical deformation structure 122 instead of an eccentric deformation structure 121. The symmetrical deformation structure 122 is preferably made of a material with good elastic deformation capability, corrosion resistance and stable mechanical properties.

[0065] like Figures 17-19 As shown, the symmetrical deformation structure 122 is an elongated cylindrical structure with a filling cavity 1222 at its center. One end of the filling cavity 1222 is closed, and the other end is open. A resistance strain gauge 131 is fixed in the filling cavity 1222. Driving slots 1221 are symmetrically provided on both radial sides of the symmetrical deformation structure 122. The driving slots 1221 extend through the symmetrical deformation structure 122 axially, but are not radially connected to the filling cavity 1222. Driving components 11 are disposed within the driving slots 1221. Therefore, in this embodiment, the symmetrical deformation structure 122 is equipped with two driving components 11, converting axial displacement into uniform axial tensile and compressive deformation.

[0066] In this embodiment, the drive assembly 11 is arranged along the axial direction of the symmetrical deformation structure 122, and the anchor 113 is engaged with the drive slot 1221. When the corrosion crushing element 112 gradually fails under the action of the corrosive medium, the elastic energy storage element 111 releases the pre-stored elastic potential energy and generates an axial contraction displacement. This displacement is symmetrically transmitted to the deformation response structure through the drive assembly 11, causing it to undergo axial tensile and compressive deformation.

[0067] like Figure 19 As shown, a groove is provided in the filling cavity 1222, and a resistance strain gauge 131 is arranged in the groove and located in the axial high strain region. The resistance strain gauge 131 is fixed with adhesive, and the axial strain change caused by the release of the drive component 11 is monitored in real time through the resistance strain gauge 131. Due to the symmetrical force distribution of the overall structure and the uniform strain distribution, the output signal has good linearity and stability.

[0068] Compared to Example 1, the symmetrical deformation structure 122 in this example exhibits a more uniform stress distribution, effectively avoiding unilateral stress concentration that may occur under eccentric loading conditions. This significantly reduces the risk of fatigue damage to the deformation response structure during service, thereby improving the sensor's durability and lifespan. Furthermore, the structure in this example possesses stronger resistance to external interference and can effectively reduce deformation response caused by non-corrosive factors. Therefore, this example is more suitable for engineering applications with complex environments and high requirements for long-term stability and linearity of monitoring signals, such as offshore wind turbines and bridge cables.

[0069] The other structures are the same as in Example 1, and will not be described again here.

[0070] Example 6: This embodiment provides a corrosion-sensitive sensor, which differs from Embodiment 1 in that the deformation monitoring component 13 uses fiber Bragg grating 133 and temperature-compensated fiber Bragg grating 134 instead of resistance strain gauge 131 and temperature-compensated strain gauge 132 to achieve single-point fiber Bragg grating measurement.

[0071] like Figures 20-22 As shown, a monitoring slot 1214 is provided on the upper side of the eccentric deformation structure 121, and the monitoring slot 1214 is a through structure along the axial direction; connecting slots 1213 are respectively provided at both ends of the lower side of the eccentric deformation structure 121. The deformation monitoring component 13 includes a fiber grating 133, a temperature-compensated fiber grating 134, a fiber core 135, a cladding 136, and a protective sleeve 137. The temperature-compensated fiber grating 134 is connected to one end of the fiber grating 133, and the fiber cores 135 of the two are arranged coaxially, with the cladding 136 covering the outside of the fiber core 135; the fiber grating 133 is fixed in the monitoring slot 1214 by adhesive, and the center of its grating area is aligned with the middle part of the eccentric deformation structure 121 to sense the maximum strain change.

[0072] Temperature-compensated fiber Bragg grating 134 is positioned where it is not subjected to mechanical tension or compression, and a protective sleeve 137 is fitted over its cladding 136 to provide mechanical protection, ensuring that it responds only to changes in ambient temperature. Fiber Bragg grating 133 and temperature-compensated fiber Bragg grating 134 constitute a pair of fiber Bragg grating sensor units. Both are inscribed on the same optical fiber, with a pigtail leading out and connected to an external demodulator. By differentially processing the center wavelength drift signals of the two fiber Bragg gratings, the influence of temperature changes on the measurement results can be effectively eliminated, thereby obtaining the net strain information caused by corrosion-triggered displacement.

[0073] To improve the reliability and measurement stability of optical fibers under long-term service conditions, the bonding between the optical fiber and the deformation response structure preferably uses low-modulus, high-bond-strength epoxy or silicone-based adhesives to reduce the risk of interface slippage while ensuring effective strain transfer. Simultaneously, a corrosion-resistant buffer coating is applied to the outer surface of the cladding 136 to enhance the optical fiber's adaptability to harsh environments such as humidity and salt spray.

[0074] Compared to the resistance strain gauge scheme in Example 1, the fiber Bragg grating sensor unit used in this example has advantages such as strong anti-electromagnetic interference capability, excellent corrosion resistance, high long-term stability, and zero drift, making it particularly suitable for harsh service environments such as strong electromagnetic fields and marine salt spray. Furthermore, the clearly defined working area corresponding to a single-point fiber Bragg grating facilitates high-precision, quantitative monitoring of corrosion deformation at key sensitive locations such as anchorage zones and crack-prone areas.

[0075] The other structures are the same as in Example 1, and will not be described again here.

[0076] Example 7: This embodiment provides a corrosion-sensitive sensor, which differs from Embodiment 6 in that the deformation monitoring component 13 adopts a multi-point fiber optic grating array structure arranged along a single optical fiber to achieve synchronous monitoring at multiple locations.

[0077] like Figure 23 As shown, the deformation monitoring component 13 includes a continuous long optical fiber, on which multiple fiber gratings 133 are etched at axial intervals along the fiber core 135. Each fiber grating 133 has a different center wavelength, which is distinguished by wavelength division multiplexing, thereby realizing independent identification and synchronous acquisition of signals from multiple measurement points. Each fiber grating 133 is connected to an eccentric deformation structure 121, i.e., multiple eccentric deformation structures 121 are provided; wherein, the center of the grating area of ​​each fiber grating 133 is aligned with the middle part of its corresponding monitoring slot 1214 to maximize the axial strain change caused by the corrosion deformation of the driving component 11.

[0078] In this embodiment, multiple temperature-compensated fiber gratings 134 can be further set on the same optical fiber. The temperature-compensated fiber gratings 134 are arranged in a position that does not bear mechanical tension or compression, but is at the same ambient temperature as the fiber gratings 133. By performing differential processing on the wavelength drift signal of each fiber grating 133 and the wavelength drift signal of the temperature-compensated fiber grating 134, the net strain information of the corresponding measuring point can be obtained.

[0079] The optical signals from each fiber Bragg grating are led out through the same optical fiber and connected to an external fiber optic demodulator, enabling centralized demodulation and data acquisition at multiple measurement points. The central processing unit performs real-time analysis of the strain data from multiple measurement points, thereby locating the corrosion site.

[0080] To ensure efficient strain transfer and long-term reliability of multi-point monitoring, the bonding between the optical fiber and the deformation response structure preferably uses low-modulus, high-bond-strength epoxy resin or silicone-based adhesive to optimize strain transfer and reduce the risk of interface slippage. Simultaneously, a corrosion-resistant buffer coating is applied to the cladding 136 to further enhance durability in harsh environments.

[0081] Compared to the single-point fiber Bragg grating monitoring method in Example 6, this embodiment integrates multiple fiber Bragg gratings 133 on a single optical fiber, enabling simultaneous multi-position monitoring of the metal component under test along its length. This facilitates precise location of corrosion occurrence and its propagation process. Therefore, this embodiment is more suitable for engineering applications with large structural dimensions that require pinpointing corrosion locations, such as bridge main cables, cables, pipelines, and tunnels.

[0082] The other structures are the same as in Example 6, and will not be described again here.

[0083] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A corrosion-sensitive sensor, characterized in that, The sensor body includes a driving component, a deformation response structure, a deformation monitoring component, and a guiding layer. The driving component is disposed in the deformation response structure, and the guiding layer is disposed below the driving component; the guiding layer is used to introduce a corrosive medium, and the driving component can generate axial displacement under the action of corrosion; the deformation response structure is used to receive and amplify the axial displacement; the deformation monitoring component is used to monitor the deformation generated by the deformation response structure and output a signal. The drive assembly includes an elastic energy storage element and a corrosion crushing element. The corrosion crushing element is fixed to the outside of the pre-stretched elastic energy storage element to form a tension-compression balance.

2. The corrosion-sensitive sensor according to claim 1, characterized in that, The drive assembly also includes anchors, the corrosion crushing element is coaxially arranged on the outside of the elastic energy storage element, and the two ends of the elastic energy storage element are respectively connected to the anchors.

3. A corrosion-sensitive sensor according to claim 1 or 2, characterized in that, The corrosion crushing element adopts one of the following types: collar type, bead type, spiral type, and graded collar type. Each type of corrosion crushing element contains at least one sub-unit, which is connected in series along the axial direction outside the elastic energy storage element.

4. A corrosion-sensitive sensor according to claim 1 or 2, characterized in that, The deformation response structure includes an eccentric deformation structure or a symmetrical deformation structure. The eccentric deformation structure is provided with a set of driving components, and the symmetrical deformation structure is provided with an even number of driving components.

5. A corrosion-sensitive sensor according to claim 4, characterized in that, The eccentric deformation structure is provided with a connecting slot on one side, and the connecting slot is located at both ends of the eccentric deformation structure. The drive component engages with the connecting slot.

6. A corrosion-sensitive sensor according to claim 4, characterized in that, The symmetrical deformation structure has symmetrical drive slots on both sides of the radial direction, and the drive slots are arranged through the axis. The drive component is housed within the drive card slot.

7. A corrosion-sensitive sensor according to claim 1, characterized in that, The deformation monitoring component includes a resistance strain gauge and a temperature-compensated strain gauge. The resistance strain gauge is bonded and fixed to the deformation response structure, and the temperature-compensated strain gauge is positioned above the resistance strain gauge.

8. A corrosion-sensitive sensor according to claim 1, characterized in that, The deformation monitoring component includes multiple fiber gratings and corresponding temperature-compensated fiber gratings arranged sequentially along the axis of a single optical fiber, used to achieve synchronous monitoring of multiple measurement points and location of corrosion.

9. A corrosion-sensitive sensor according to claim 1, characterized in that, The sensor body includes a housing, one end of which is connected to an end cap, and a wire extends out to the outside through the end cap. The outer shell has a working channel and a temperature compensation channel arranged in parallel inside it, and the working channel has several guide holes on the bonding surface with the guide layer.

10. A corrosion-sensitive sensor according to claim 1 or 9, characterized in that, The deformation monitoring component is connected to a signal acquisition device on the outside of the sensor body via a wire. The output end of the signal acquisition device is connected to a central processing unit and an early warning device in sequence. The output signal of the deformation monitoring component is analyzed by the central processing unit and triggers a graded early warning.

11. A corrosion-sensitive sensor according to claim 2, characterized in that, The corrosion-crushing element is made of the same material as the metal being tested, and the elastic energy storage element and anchor are made of inert or highly corrosion-resistant materials. The corrosion resistance of the corrosion-crushing element is lower than that of the elastic energy storage element, anchor, and deformation response structure.

12. A corrosion-sensitive sensor according to claim 1, characterized in that, The strength of the corrosion product of the corrosion-crushing element is less than the compressive stress of the elastic energy storage element on the corrosion-crushing element, which is less than the original strength of the corrosion-crushing element.

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