Preparation device and method of magnetostrictive fiber array film sensor

Abstract

The application relates to the technical field of mechanical engineering electromagnetic detection, and discloses a preparation device and a preparation method of a magnetostrictive fiber array film sensor, which comprise a supporting device, a position control platform and a fiber placement control platform; the supporting device is used for forming an outer frame, and the position control platform is located in the frame space area of the supporting device; the top of the supporting device is used for arranging magnetostrictive fiber monofilaments in an array and parallel to each other, and the two ends of each magnetostrictive fiber monofilament are tensioned by the same tension force; the top of the position control platform is used for clamping and fixing the fiber placement control platform, and the height position and the horizontal position of the fiber placement control platform are adjusted through the position control platform; the fiber placement control platform is used for adhering the magnetostrictive fiber array from bottom to top after the array arrangement of the magnetostrictive fiber monofilaments is completed, and then the magnetostrictive fiber array film is prepared. The magnetostrictive sensitive unit is thinned and arranged in an array.

Description

Technical Field

[0001] This invention relates to the field of electromagnetic detection technology in mechanical engineering, and in particular, to a fabrication apparatus and method for a magnetostrictive fiber array thin film sensor. Background Technology

[0002] Magnetostrictive materials possess unique magnetomechanical coupling properties, meaning that their internal magnetization state changes under mechanical stress (a phenomenon known as the magnetostrictive effect). Sensors based on this effect can achieve non-contact sensing of physical quantities such as stress, strain, torque, and magnetic fields, offering advantages such as fast response speed, long service life, and high reliability. Therefore, they show promising application prospects in the fields of non-destructive testing and structural health monitoring.

[0003] However, existing magnetostrictive sensors still have certain limitations in structural design and fabrication processes. For example, some sensor structures are quite thick, making it difficult to adapt to the conformal fitting requirements of objects with complex curved surfaces, thus limiting their application in space-constrained environments. Furthermore, some sensors require an external power supply, preventing truly contactless detection and increasing system complexity and operating costs.

[0004] Chinese invention patent CN103762306A discloses a magnetoelectric composite material and its preparation method, which uses hollow piezoelectric fibers filled with a mixture of magnetostrictive particles and resin inside and outside the fibers. However, this structure involves a complex radial polarization process and an inner and outer electrode coating process, making the preparation process cumbersome, and the hollow fiber structure may affect the mechanical strength and reliability of the material. Chinese invention patent CN110319955A discloses a sensor device containing multiple piezoelectric films, but its overall structure is still relatively thick, with space limitations, and requires an external power supply, which cannot meet the application requirements of ultra-thin, flexible, and completely contactless sensing. Summary of the Invention

[0005] This invention provides a fabrication apparatus and method for a magnetostrictive fiber array thin-film sensor, which enables the thin-film and arrayed arrangement of magnetostrictive sensitive units, thereby fabricating a sensor with small thickness, good flexibility, and conformal fit to complex curved surfaces. It also fully leverages the inherent non-contact sensing advantages of magnetostrictive materials to solve the technical problem that sensors based on the magnetostrictive principle are difficult to simultaneously achieve ultra-thin and flexible structures as well as precise, high-quality, and uniform arrangement of magnetostrictive fibers in the fabrication process.

[0006] According to one aspect of the present invention, an apparatus for fabricating a magnetostrictive fiber array thin-film sensor is provided, comprising a support device, a position control platform, and a fiber placement control platform. The support device forms an outer frame, and the position control platform is located within the frame space of the support device. The top of the support device is used to arrange magnetostrictive fiber monofilaments in an array and parallel to each other, ensuring that both ends of each magnetostrictive fiber monofilament are tensioned by the same preset tension force, thereby ensuring that all magnetostrictive fiber monofilaments are in a consistent preset pre-stretched state during the pre-forming stage and keeping the arranged magnetostrictive fiber array stationary. The top of the position control platform is used to clamp and fix the fibers. A fiber placement control platform is used to adjust the height and horizontal position of the fiber placement control platform. The fiber placement control platform is used to bond the magnetostrictive fiber array from bottom to top after the magnetostrictive fiber monofilament array is arranged, thereby preparing the magnetostrictive fiber array film. While ensuring that the magnetostrictive fiber array remains stationary on the support device, the horizontal and vertical precision movement of the position control platform aligns it with the magnetostrictive fiber array vertically and vertically. The fiber placement control platform then bonds the magnetostrictive fiber array from bottom to top, thereby ensuring the arrangement accuracy of the magnetostrictive fiber array and improving the arrangement speed.

[0007] Furthermore, the position control platform includes a vertical adjustment module, a horizontal adjustment module, and a horizontal positioning module; the horizontal adjustment module is located in the movable part of the vertical adjustment module, and the horizontal positioning module is located in the movable part of the horizontal adjustment module, and the horizontal positioning module is used to clamp and fix the fiber placement control platform; or the vertical adjustment module is located in the movable part of the horizontal adjustment module, and the horizontal positioning module is located in the movable part of the vertical adjustment module, and the horizontal positioning module is used to clamp and fix the fiber placement control platform.

[0008] Furthermore, the vertical adjustment module adopts a scissor-type upgrading mechanism and is upgraded and adjusted by a vertical adjustment knob; and / or the horizontal adjustment module adopts a horizontal slide rail mechanism and is adjusted horizontally by a horizontal adjustment knob; and / or the horizontal locking module adopts a parallel clamping mechanism and is clamped and controlled by a horizontal locking knob.

[0009] Furthermore, the support device includes legs, crossbeams, and V-groove beams. The legs, crossbeams, and V-groove beams are detachably connected to form an outer frame. A V-groove support is provided on the top of the outer frame. Two sets of V-groove support are arranged relatively at intervals and symmetrically. The corresponding V-grooves on the two sets of V-groove support are coaxially arranged, and a magnetostrictive fiber monofilament is placed on the two coaxially arranged V-grooves. The arrangement direction of the two sets of V-groove support is perpendicular to the clamping direction of the position control platform.

[0010] Furthermore, the support device also includes adhesive counterweights located outside the V-groove bearing platform. The adhesive counterweights are used to bond the ends of the array of magnetostrictive fibers arranged in an array. Both ends of the magnetostrictive fiber array are tensioned by the suspended adhesive counterweights and thus arranged in an array on the support device.

[0011] Furthermore, the fiber placement control platform adopts a regular smooth plate with a smooth upper surface, and double-sided adhesive is provided at both ends of the regular smooth plate. The double-sided adhesive is used to adhere to the magnetostrictive fiber array arranged in an array on the support device when the fiber placement control platform rises with the position control platform, thereby realizing the fixed positioning of the magnetostrictive fiber array.

[0012] According to another aspect of the present invention, a method for fabricating a magnetostrictive fiber array thin film sensor is also provided, which uses the above-mentioned fabrication apparatus for a magnetostrictive fiber array thin film sensor and includes the following steps: S100, fabrication of a magnetostrictive fiber array; S200, fabrication of a magnetostrictive fiber array thin film; S300, fabrication of a magnetostrictive fiber array thin film sensor.

[0013] Further, the preparation of the magnetostrictive fiber array in step S100 is specifically as follows: S101, take magnetostrictive fiber monofilaments with a length of 150mm to 200mm for later use; S102, adjust the horizontal positioning knob to fix the regular smooth plate on the horizontal adjustment module; S103, adjust the vertical adjustment knob so that the horizontal position of the regular smooth plate is 3mm-8mm lower than the V-groove of the V-groove support; S104, arrange the prepared magnetostrictive fiber monofilaments according to the V-groove of the V-groove support. S105. Attach the two ends of the magnetostrictive fiber monofilament to the adhesive weight and place them in the corresponding V-groove; S106. Adjust the vertical adjustment knob so that the horizontal position of the regular smooth plate is 3mm-8mm higher than the V-groove of the V-groove support; S107. Cut the two ends of the magnetostrictive fiber monofilament outside the regular smooth plate and remove the adhesive weight; S108. Adjust the horizontal adjustment knob, move it a certain distance, and repeat steps S103-S106 until the magnetostrictive fiber array reaches the preset width.

[0014] Further, the preparation of the magnetostrictive fiber array film in step S200 is specifically as follows: S201, a layer of PI film is tightly adhered to the surface of a regular smooth plate, and a layer of double-sided adhesive is attached to both ends of the smooth plate; S202, the prepared magnetostrictive fiber array along with the regular smooth plate is removed by operating the horizontal locking knob; S203, double-sided adhesive of the same size is simultaneously attached to the same position as the double-sided adhesive in step S201; S204, epoxy resin is poured; S205, a second regular smooth plate with a layer of PI film also adhered to its surface is taken, and the side with the PI film is pressed onto the epoxy resin; S206, after the epoxy resin has cured, the two regular smooth plates are peeled off from the adhered PI film, and the effective part is cut to obtain the magnetostrictive fiber array film.

[0015] Further, the fabrication of the magnetostrictive fiber array thin film sensor in step S300 is specifically as follows: S301, attaching the magnetostrictive fiber array thin film to the surface of the sample under test; S302, placing a magnetic field generator along the fiber axis of the magnetostrictive fiber array thin film, the magnetic field generator being generated by a permanent magnet or an AC coil; S303, installing a magnetic flux induction probe near the magnetostrictive fiber array thin film; S304, recording the magnetic flux induction probe data when the force on the sample under test changes; S305, comparing the obtained magnetic flux induction probe data with normal values, and then analyzing whether the sample under test is damaged or the degree of damage.

[0016] The present invention has the following beneficial effects: 1. Achieving high-precision and highly consistent array arrangement of fibers: The support device not only provides a structural framework but also enables multiple magnetostrictive fiber monofilaments to be arranged in an array and parallel to each other. It ensures that both ends of each magnetostrictive fiber monofilament are tensioned by the same preset tension (such as applying a static configuration block or attaching the end to the support device). This ensures that all magnetostrictive fibers are in a consistent and constant preset pre-stretched state during the pre-forming stage, avoiding problems such as uneven array spacing, magnetostrictive fiber bending, magnetostrictive fiber relaxation, and magnetostrictive fiber breakage caused by inconsistent tension of the magnetostrictive fiber monofilaments. This lays the foundation for preparing films with uniform and regular sensitive unit arrays.

[0017] 2. Ensure the uniformity and quality control of the thin film preparation process: The position control platform can precisely adjust the height and horizontal position of the fiber placement control platform, so that when the fiber placement control platform is bonding the fiber array from bottom to top, it can contact the stationary magnetostrictive fiber array with constant and optimal pressure and posture. This avoids defects such as resin coating thickness fluctuation, fiber displacement or poor wetting caused by bonding angle deviation or uneven pressure, thus ensuring that the final formed thin film sensor has good structural consistency.

[0018] 3. Optimize the process flow to achieve integrated preparation of thin film structures: The three processes of arranging magnetostrictive fibers on the support device and keeping them stationary, positioning them through the position control platform, and forming the thin film on the fiber placement control platform are integrated into one system. After the fiber array is arranged, subsequent film preparation steps such as coating and curing can be carried out directly without transfer. This integrated design simplifies the operation process and reduces the disturbance or contamination that may be caused to the precisely arranged fiber array by intermediate transfer links, which is conducive to improving production efficiency and product yield.

[0019] 4. Provides a hardware foundation for the fabrication of ultrathin, flexible sensors: By ensuring the parallelism, tension, flatness, and stillness of the magnetostrictive fiber array, and combining it with a controllable bonding process, it is possible to prepare an ultrathin composite film with uniform fiber distribution and encapsulated in a resin matrix. This results in a final product with small thickness and good flexibility, which can adapt to the conformal bonding requirements of complex curved surfaces.

[0020] In addition to the objectives, features, and advantages described above, the present invention has other objectives, features, and advantages. The invention will now be described in further detail with reference to the figures. Attached Figure Description

[0021] 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 undue limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of the fabrication apparatus for a magnetostrictive fiber array thin film sensor according to a preferred embodiment of the present invention; Figure 2 This is a schematic diagram of the support device according to a preferred embodiment of the present invention; Figure 3 This is a schematic diagram of the position control platform according to a preferred embodiment of the present invention; Figure 4 This is a schematic diagram of the fiber placement control platform according to a preferred embodiment of the present invention; Figure 5 This is a flowchart of a preferred embodiment of the fabrication method of a magnetostrictive fiber array thin film sensor of the present invention, wherein... Figure 5 (a) is a diagram of the sensor fabrication process. Figure 5 (b) is a flowchart of the sensor fabrication process. Figure 5 (c) is a diagram showing the fabrication process of the fiber array thin film. Figure 5 (d) is a flowchart of the fabrication process of fiber array thin films; Figure 6 This is a schematic diagram illustrating the sensing performance principle of a magnetostrictive fiber array thin film sensor according to a preferred embodiment of the present invention.

[0022] Legend: 100. Support device; 101. Support leg; 102. Crossbeam; 103. V-groove beam; 104. V-groove support platform; 105. Adhesive counterweight; 200. Position control platform; 201. Vertical adjustment module; 2011. Vertical adjustment knob; 202. Horizontal adjustment module; 2021. Horizontal adjustment knob; 203. Horizontal positioning module; 2031. Horizontal positioning knob; 300. Fiber placement control platform; 301. Regular smooth plate; 302. Double-sided adhesive; 400. Magnetostrictive fiber array.

[0023] 1. Magnetic flux induction probe; 2. Magnetic field generator; 3. Thin film sensor; 4. Magnetostrictive fiber array thin film; 5. Test sample. Detailed Implementation

[0024] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered below.

[0025] like Figure 1As shown, the fabrication apparatus for the magnetostrictive fiber array thin film sensor in this embodiment includes a support device 100, a position control platform 200, and a fiber placement control platform 300. The support device 100 forms an outer frame, and the position control platform 200 is located within the frame space of the support device 100. The top of the support device 100 is used to arrange magnetostrictive fiber monofilaments in an array and parallel to each other, ensuring that both ends of each magnetostrictive fiber monofilament are tensioned by the same preset tension force, guaranteeing that all magnetostrictive fiber monofilaments are in a consistent preset pre-stretched state during the pre-forming stage, and keeping the arranged magnetostrictive fiber array 400 stationary. The top of the position control platform 200 is used to clamp and fix the fiber placement control platform 300. The position control platform 200 adjusts the height and horizontal position of the fiber placement control platform 300. The fiber placement control platform 300 is used to bond the magnetostrictive fiber array 400 from bottom to top after the magnetostrictive fiber monofilament array is arranged, thereby preparing the magnetostrictive fiber array film. While ensuring that the magnetostrictive fiber array 400 remains stationary on the support device 100, the position control platform 200 is precisely moved horizontally and vertically to align with the magnetostrictive fiber array 400 vertically. The fiber placement control platform 300 then bonds the magnetostrictive fiber array 400 from bottom to top, thereby ensuring the arrangement accuracy of the magnetostrictive fiber array 400 and improving the arrangement speed. The fabrication apparatus for the magnetostrictive fiber array thin film sensor of the present invention provides a support device 100 that not only provides a structural framework but also enables multiple magnetostrictive fiber monofilaments to be arranged in an array and parallel to each other. It ensures that both ends of each magnetostrictive fiber monofilament are tensioned by the same preset tension force (e.g., by applying a static configuration block or by attaching the end to the support device 100). This guarantees that all magnetostrictive fibers are in a consistent and constant preset pre-stretched state during the pre-forming stage, avoiding problems such as uneven array spacing, bends, slack, and breakage of magnetostrictive fibers caused by varying tension of the monofilaments. This lays the foundation for fabricating thin films with a uniform and regular array of sensitive units. The position control platform 200 can precisely adjust the height and horizontal position of the fiber placement control platform 300, so that when the fiber placement control platform 300 is bonding the fiber array from bottom to top, it can contact the stationary magnetostrictive fiber array with constant and optimal pressure and posture. This avoids defects such as resin coating thickness fluctuation, fiber displacement or poor wetting caused by bonding angle deviation or uneven pressure, thereby ensuring that the final formed thin film sensor has good structural consistency.The three processes of arranging fibers on the support device 100 and keeping them stationary, positioning them via the position control platform 200, and forming the film on the fiber placement control platform 300 are integrated into one system. After the fiber array is arranged, subsequent film preparation steps such as coating and curing can be performed directly without transfer. This integrated design simplifies the operation process and reduces the disturbance or contamination that may be caused to the precisely arranged fiber array by intermediate transfer links, which is conducive to improving production efficiency and product yield. By ensuring the parallelism, tension, flatness, and stationary position of the magnetostrictive fiber array, and combining it with a controllable bonding process, it is possible to prepare an ultra-thin composite film with uniform fiber distribution and resin matrix encapsulation. This results in a final product with small thickness and good flexibility, thus adapting to the conformal bonding requirements of complex curved surfaces. The fabrication apparatus for the magnetostrictive fiber array thin film sensor of the present invention solves the key process problem of achieving high-precision and high-consistency array integration of magnetostrictive fibers in a thin film matrix through the coordinated cooperation of the support device 100, the position control platform 200 and the fiber placement control platform 300. It can reliably fabricate ultrathin flexible films with uniform and regular fiber arrays, thus providing a structural basis for subsequent realization of high-performance, conformally attachable contactless sensing.

[0026] like Figure 1 and Figure 3As shown, in this embodiment, the position control platform 200 includes a vertical adjustment module 201, a horizontal adjustment module 202, and a horizontal positioning module 203; the horizontal adjustment module 202 is arranged in the movable part of the vertical adjustment module 201, and the horizontal positioning module 203 is arranged in the movable part of the horizontal adjustment module 202, and the horizontal positioning module 203 is used to clamp and fix the fiber placement control platform 300; or the vertical adjustment module 201 is arranged in the movable part of the horizontal adjustment module 202, and the horizontal positioning module 203 is arranged in the movable part of the vertical adjustment module 201, and the horizontal positioning module 203 is used to clamp and fix the fiber placement control platform 300. By setting up dedicated vertical adjustment module 201 and horizontal adjustment module 202, the platform decouples the attitude adjustment of the fiber placement control platform 300 into independent movements in the vertical direction (Z-axis) and horizontal plane (X-axis and / or Y-axis). This allows the operator to control the height and horizontal position of the platform step by step and precisely, avoiding coupling errors that may be caused by a single complex adjustment mechanism. Precise position control is the key to ensuring that the fiber placement control platform 300 can smoothly and uniformly approach and support the fiber array in the best posture. This is directly related to the uniformity of subsequent coating or composite processes, thereby ensuring the quality of the final thin film sensor. The two module layout sequences ("vertical-horizontal" or "horizontal-vertical") of vertical adjustment module 201 and horizontal adjustment module 202 reflect the flexibility of the design. The first method (vertical adjustment module 201 fixed, horizontal adjustment module 202 movable) is more suitable for scenarios that require horizontal positioning over a large area. The second method (horizontal adjustment module 202 fixed, vertical adjustment module 201 movable) is more conducive to the stability of the overall structure. This optional configuration allows the preparation device to be optimized and adapted according to the specific equipment space layout, process flow diagram, or different emphasis on accuracy / stroke, thereby improving the versatility and practicality of the device. An independent horizontal positioning module 203 is specifically designed to clamp and fix the fiber placement control platform 300, separating the clamping and adjustment functions. This allows the horizontal positioning module 203 to be optimized for reliable clamping (e.g., using clamps that apply uniform force) without undertaking adjustment tasks. This avoids minor displacements or vibrations caused by unstable clamping during adjustment, ensuring that the fiber placement control platform 300 is firmly maintained in position after precise positioning, providing a stable and reliable foundation for subsequent film preparation processes. The position control platform 200, through a modular combination of the vertical adjustment module 201, the horizontal adjustment module 202, and the horizontal positioning module 203, and with clearly defined interchangeable arrangements, achieves precise, independent, and stable positional control of the fiber placement control platform 300 in three-dimensional space. This not only directly improves the accuracy and reliability of positioning key components during film preparation but also enhances the adaptability of the entire preparation device to different process requirements through flexible structural configuration.

[0027] like Figure 1 and Figure 3As shown, in this embodiment, the vertical adjustment module 201 adopts a scissor-type upgrading mechanism and is upgraded and adjusted by the vertical adjustment knob 2011; and / or the horizontal adjustment module 202 adopts a horizontal slide rail mechanism and is adjusted horizontally by the horizontal adjustment knob 2021; and / or the horizontal locking module 203 adopts a parallel clamping mechanism and is clamped and controlled by the horizontal locking knob 2031. The vertical adjustment module 201 adopts a scissor lifting mechanism, which has a large support surface and stable structure. It can provide better rigidity and anti-eccentric load capacity than a single lead screw or slide rail during the lifting process, effectively preventing swaying or tilting that may occur when the fiber placement control platform 300 is supported. It is driven by the vertical adjustment knob 2011 (the vertical adjustment knob 2011 is connected to and drives the scissor lifting mechanism through a gear mechanism, worm gear mechanism, and gear rack mechanism), which realizes micron-level or at least high-precision discrete adjustment. The operator can slowly and accurately control the height of the platform to ensure that the fiber placement control platform 300 approaches the fiber array above in a stable and controllable manner, avoiding collisions or disturbances to the precisely positioned fibers due to rapid or coarse adjustments. The horizontal adjustment module 202 adopts a horizontal slide rail mechanism, which ensures that the horizontal movement is linear and smooth, minimizing jamming or crawling. In conjunction with the horizontal adjustment knob 2021 (which is connected to and drives the horizontal slide rail mechanism through a gear mechanism, worm gear mechanism, and rack and pinion mechanism) for manual drive, fine horizontal position adjustment can be achieved. This allows the operator to accurately align the fiber placement control platform 300 with the fiber array in the horizontal plane, providing accurate alignment for subsequent coating or transfer processes and ensuring the positional accuracy of the fibers in the film. The horizontal clamping module 203 adopts a parallel clamping mechanism, and the movement of the clamping surface is parallel, which can evenly apply clamping force to both sides of the fiber placement control platform 300 or specific clamping parts. This avoids platform warping, stress concentration or damage that may be caused by non-parallel clamping (such as single-point pressure or V-groove clamping). The horizontal clamping knob 2031 can control the clamping force to achieve controllable adjustment and reliable locking, which not only ensures that the platform is firmly fixed in subsequent process steps and will not be displaced, but also avoids damage to the platform due to excessive clamping force.The three key functional modules utilize mature and reliable mechanical mechanisms (scissor lift, slide rail, and parallel clamping) supplemented by manual knobs for precise control. This makes the operation of the entire position control platform 200 intuitive, precise, and highly repeatable, reducing operational difficulty and excessive skill requirements for operators. This facilitates consistent process parameters and preparation quality across different batches, ensuring the stable and reliable performance of the final thin-film sensor. The scissor lift mechanism, horizontal slide rail mechanism, and parallel clamping mechanism, along with corresponding adjustment knobs, not only achieve their basic positioning and fixing functions but also significantly improve adjustment accuracy, operational stability, load-bearing capacity, and operational controllability. Together, they ensure that the fiber placement control platform 300 can be precisely and stably positioned and fixed, providing equipment support for the subsequent preparation of highly consistent and high-quality magnetostrictive fiber array films.

[0028] like Figure 1 and Figure 2As shown, in this embodiment, the support device 100 includes a support leg 101, a crossbeam 102, and a V-groove beam 103. The support leg 101, crossbeam 102, and V-groove beam 103 are detachably connected to form an outer frame. A V-groove support platform 104 is provided on the top of the outer frame. Two sets of V-groove support platforms 104 are arranged relatively at intervals and symmetrically. The corresponding V-shaped grooves on the two sets of V-groove support platforms 104 are arranged coaxially. A magnetostrictive fiber monofilament is placed on the two coaxially arranged V-shaped grooves. The arrangement direction of the two sets of V-groove support platforms 104 is perpendicular to the clamping direction of the position control platform 200. The V-groove structure on the V-groove support 104 has a natural guiding and positioning effect on the magnetostrictive fiber monofilaments placed on it. Due to the geometric characteristics of the V-groove, the magnetostrictive fiber monofilaments will naturally fall into the bottom of the groove under their own weight, thereby achieving automatic centering on the horizontal plane. The corresponding V-grooves on the two sets of V-groove supports 104 are arranged coaxially, ensuring that the axial direction of each magnetostrictive fiber monofilament can be naturally constrained to a precise straight line after placement. This provides a fundamental guarantee for achieving a high degree of parallelism in the fiber array and solves the key technical problems such as misalignment and non-parallelism that easily occur in fiber arrangement. Two sets of V-groove supports 104 are arranged at relative intervals and symmetrically. This symmetrical structure provides completely equal support points for both ends of the fiber. When the magnetostrictive fiber monofilament is tensioned, the mechanical environment at both ends is symmetrical and consistent, which helps to ensure that both ends of each magnetostrictive fiber monofilament are tensioned by the same tension force. The line contact between the V-groove and the magnetostrictive fiber monofilament has low and consistent friction, which further ensures the uniform transmission of tension force and lays the foundation for forming a magnetostrictive fiber array 400 with consistent internal stress. The support legs 101, crossbeam 102, and V-groove beam 103 are detachably connected, making the entire support device 100 easy to transport, assemble, and debug, thus improving the modularity and practicality of the equipment. The arrangement direction of the two sets of V-groove supports 104 is perpendicular to the clamping direction of the position control platform 200. This spatial layout allows the fiber placement control platform 300 to simultaneously and evenly contact and support all parallel fibers at the optimal angle when moving from bottom to top, avoiding fiber displacement or uneven force that may be caused by oblique contact, and optimizing the rationality of the process flow. Through its detachable frame structure and the core, symmetrically and coaxially arranged V-groove supports 104, the support device 100 cleverly utilizes the geometric characteristics of the V-groove to achieve rapid and precise automatic centering and parallel arrangement of multiple magnetostrictive fiber monofilaments, and provides them with a uniform tension environment. This not only ensures the forming quality of the fiber array, but its modular and directional optimization design also improves the operability and process stability of the entire preparation device.

[0029] like Figure 1 and Figure 2As shown, in this embodiment, the support device 100 further includes an adhesive weight 105 located outside the V-groove support 104. The adhesive weight 105 is used to bond the ends of the magnetostrictive fiber array 400 arranged in an array. Both ends of the magnetostrictive fiber array 400 are tensioned by the suspended adhesive weight 105 and arranged in an array on the support device 100. Unlike mechanical tensioning schemes that use complex clamping knobs or clamps, this invention uses an adhesive weight 105 to fix the fiber ends through the adhesive portion, and then uses the weight of the weight itself to hang naturally, thereby applying a constant and flexible tension force to the fiber. This avoids problems such as stress concentration, fiber damage, or fiber slippage that may occur with mechanical clamps, and achieves non-destructive and uniform tensioning of fragile fiber monofilaments. Since each magnetostrictive fiber monofilament is bonded to two ends with a corresponding adhesive weight 105 of approximately the same weight, according to the principle of gravity, the tension force borne by each magnetostrictive fiber monofilament is theoretically determined only by the mass of the weight. Therefore, as long as the mass of the adhesive weight 105 is consistent, the tension force of all magnetostrictive fiber monofilaments in the entire magnetostrictive fiber array 400 can be ensured to have a high degree of consistency. The structure is simple, yet it effectively solves the core technological problem of ensuring uniform force value when manually tensioning each fiber individually, thus providing a guarantee for the preparation of sensor films with uniform performance. The adhesive weight 105 is in a suspended state, making it a simple gravity balance system. If a fiber undergoes slight elongation due to temperature changes or material creep, its corresponding weight will drop slightly. Through the adjustment of gravity, a constant tension on the fiber can still be automatically maintained, thereby improving the stability of the tensioning process throughout the entire preparation cycle. At the same time, the suspended state avoids friction with surrounding structures, ensuring the purity and accuracy of the tension force. The introduction of the adhesive weight 105 is one of the core innovations of this device in achieving high uniformity of fiber tension. Utilizing the principle of gravity, it ingeniously achieves both flexible and non-destructive tensioning of individual fibers and uniform control of the tension force of the entire fiber array through an extremely simple, non-mechanical passive design. This not only ensures process reliability but also significantly simplifies the device structure and reduces operational difficulty, thereby facilitating the efficient and repeatable fabrication of high-performance magnetostrictive fiber array thin-film sensors.

[0030] like Figure 1 and Figure 4As shown, in this embodiment, the fiber placement control platform 300 adopts a regular smooth plate 301 with a smooth upper surface. Double-sided adhesive 302 is provided at both ends of the regular smooth plate 301. The double-sided adhesive 302 is used to adhere to the magnetostrictive fiber array 400 arranged in an array on the support device 100 when the fiber placement control platform 300 rises with the position control platform 200, thereby realizing the fixed positioning of the magnetostrictive fiber array 400. The smooth surface of the regular smooth plate 301 ensures a low-friction, smooth contact when the position control platform 200 rises and contacts the magnetostrictive fiber array 400. This effectively avoids the possibility of rough surfaces snagging, damaging, or disturbing the precisely arranged fibers. The double-sided adhesive 302 at both ends of the regular smooth plate 301 provides an efficient and reliable bonding and fixing method. Under the precise drive of the position control platform 200, as it rises, the double-sided adhesive 302 instantly and firmly adheres to the tensioned fiber array, thus transferring and fixing the magnetostrictive fiber array 400 completely and in one go from the V-groove of the support device 100 to the regular smooth plate 301. The operation is simple and avoids the damage or contamination that complex mechanical clamping or chemical coating fixing methods may cause to the fibers. Using a regular smooth plate 301 (such as a flat glass plate, acrylic plate, or polished metal plate) as a substrate provides an ideal smooth reference plane for the magnetostrictive fiber array 400 adhered thereon. Double-sided adhesive 302 is used to bond the two ends of the regular smooth plate 301, reliably fixing the two ends of the magnetostrictive fiber array 400. The large smooth area in the middle provides sufficient support for the magnetostrictive fiber array 400, ensuring that the entire array maintains its initial parallelism, spacing, and straightness throughout the entire process from adhesion to subsequent processing steps. This prevents array distortion caused by sagging or deformation in the middle, laying a structural foundation for forming a high-quality thin-film sensor. The carrier platform of the magnetostrictive fiber array 400 is integrated with the substrate for subsequent magnetostrictive fiber array thin film forming. After successfully fixing the magnetostrictive fiber array 400, the smooth surface of the regular smooth plate 301 becomes an ideal working surface for thin film preparation. Epoxy resin and other matrix materials can be directly coated and cured on it, eliminating the complex step of transferring the magnetostrictive fiber array 400 from the temporary carrier to the final substrate. This simplifies the process, reduces the risk of introducing defects in intermediate steps, and improves preparation efficiency and yield.

[0031] like Figure 5As shown, the fabrication method of the magnetostrictive fiber array thin film sensor in this embodiment uses the aforementioned fabrication apparatus and includes the following steps: S100, fabrication of the magnetostrictive fiber array 400; S200, fabrication of the magnetostrictive fiber array thin film; S300, fabrication of the magnetostrictive fiber array thin film sensor. The complex thin film sensor fabrication process is clearly defined into three logically rigorous stages: "fiber array fabrication (S100) → thin film forming (S200) → sensor fabrication (S300)". This modular division makes the objectives of each stage clear and the process focused, facilitating independent process optimization and quality control. The entire fabrication process is built on a dedicated and precise hardware platform, thereby ensuring the standardization and repeatability of the process flow from a methodological perspective, effectively avoiding product performance fluctuations caused by the use of different or temporary tooling. The preparation of the magnetostrictive fiber array 400 in step S100 is accomplished by the V-groove support 104 of the aforementioned device ensuring parallel alignment and the adhesive counterweight 105 ensuring uniform tension. The aim is to first obtain a high-quality fiber array with parallel arrangement, consistent tension, and uniform internal stress. The quality of this initial array is one of the decisive factors for the overall sensor performance. This method, through the binding of the device and the process, fundamentally guarantees the excellent quality of the intermediate product. The preparation of the magnetostrictive fiber array film in step S200 is performed by the position control platform 200 providing precise and stable vertical and horizontal adjustment, and the fiber placement control platform 300 using a smooth flat plate and double-sided adhesive 302 for fixed transfer. Under controlled conditions, the ideal magnetostrictive fiber array 400 formed in S100 is completely and accurately transferred and fixed onto a flat substrate for resin impregnation, coating or encapsulation. This ensures that the transition of the fiber array from a tensioned state to a fixed state is smooth, controlled and undamaged, maximizing the preservation of the geometric integrity of the magnetostrictive fiber array 400. The fabrication of the magnetostrictive fiber array thin-film sensor in step S300 is based on the successful completion of the first two steps, followed by subsequent processes such as electrode fabrication, wire bonding, and final packaging. Since the high quality of the sensitive core magnetostrictive fiber array thin film was ensured in stages S100 and S200 using specialized equipment and methods, a solid foundation is laid for the performance of the final sensor (such as sensitivity and consistency). The entire process forms a tightly linked, progressively advanced precision manufacturing chain, systematically guaranteeing the performance and reliability of the final product. The precise mechanical functions of the equipment are systematically transformed into repeatable process actions, ensuring that the entire fabrication process from a single fiber to the final sensor remains controllable and precise, thereby enabling the efficient and reliable fabrication of magnetostrictive fiber array thin-film sensors with uniform structure and consistent performance.

[0032] like Figure 5As shown, in this embodiment, the preparation of the magnetostrictive fiber array 400 in step S100 specifically includes: S101, taking magnetostrictive fiber monofilaments with a length of 150mm to 200mm for later use; S102, adjusting the horizontal positioning knob 2031 to fix the regular smooth plate 301 on the horizontal adjustment module 202; S103, adjusting the vertical adjustment knob 2011 to make the horizontal position of the regular smooth plate 301 3mm-8mm lower than the V-groove of the V-groove support 104; S104, taking the prepared magnetostrictive fiber monofilaments and aligning them with the V-groove of the V-groove support 104. Arrange the magnetostrictive fiber monofilaments by attaching both ends to the adhesive weights 105 and placing them in the corresponding V-grooves; S105, adjust the vertical adjustment knob 2011 so that the horizontal position of the regular smooth plate 301 is 3mm-8mm higher than the V-groove of the V-groove support 104; S106, cut the two ends of the magnetostrictive fiber monofilaments outside the regular smooth plate 301 and remove the adhesive weights 105; S107, adjust the horizontal adjustment knob 2021, move it a certain distance, and repeat steps S103-S106 until the magnetostrictive fiber array 400 reaches the preset width. In step S103, before arranging the fibers, the regular smooth plate 301 is actively lowered to a position 3mm-8mm below the V-groove of the V-groove support 104 by adjusting the vertical adjustment knob 2011. This reserved space operation ensures that the regular smooth plate 301 will not cause any obstruction to the operation when arranging the magnetostrictive fiber monofilaments, effectively avoiding the disruption of the already arranged fibers or damage to the smoothness of the plate surface due to accidental contact, and preparing a clean and undisturbed working environment for subsequent steps. In step S105, after the magnetostrictive fiber monofilament array is tensioned and arranged in the V-groove, the vertical adjustment knob 2011 is adjusted to smoothly raise the regular smooth plate 301 to a position 3mm-8mm above the V-groove. This raising process is completed under the precise and stable drive of the position control platform 200. When the regular smooth plate 301 rises, the double-sided adhesive 302 pre-set at both ends will reliably adhere to all the parallel tensioned magnetostrictive fiber arrays 400, thereby lifting the entire magnetostrictive fiber array 400 from the V-groove and fixing it to the surface of the regular smooth plate 301 in one go. This process is smooth and controllable, minimizing the disturbance to the fiber array. In step S107, by adjusting the horizontal adjustment knob 2021, the fiber placement control platform 300 is moved a certain distance in the horizontal direction. Then, steps S103 to S106 are repeated. Next to the fixed first row of magnetostrictive fiber array 400, the second row of magnetostrictive fiber array 400 can be arranged and fixed again. This breaks through the array width limitation caused by the number of V-grooves or the operating space in a single arrangement. It allows the magnetostrictive fiber array 400 to be spliced ​​to a preset larger width through repeated operations, which improves the flexibility and applicability of the device and enables the fabrication of sensors with different sensitive unit densities.The entire S100 process is designed with a highly logical sequence. First, the support platform is fixed and positioned (S102-S103), then the fibers are arranged (S104), then transferred and fixed (S105), and finally cut and cleaned (S106). This sequence ensures that each step is performed under optimal conditions, resulting in smooth operation and avoiding repeated adjustments. In particular, the sequence of fixing before cutting ensures that the fibers are always under controlled tension during the transfer process and will not shift due to slack during cutting, thus guaranteeing the parallelism and straightness of the fiber array finally fixed on the plate.

[0033] like Figure 5As shown, in this embodiment, the preparation of the magnetostrictive fiber array film in step S200 is specifically as follows: S201, a layer of PI film is tightly adhered to the surface of a regular smooth plate 301, and a layer of double-sided adhesive is attached to both ends of the smooth plate; S202, the prepared magnetostrictive fiber array 400 along with the regular smooth plate 301 is removed by operating the horizontal locking knob 2031; S203, double-sided adhesive of the same size is simultaneously attached to the same positions as the double-sided adhesive in step S201; S204, epoxy resin is poured; S205, a second regular smooth plate 301 with a layer of PI film also adhered to its surface is taken, and the side with the PI film is pressed onto the epoxy resin; S206, after the epoxy resin has cured, the two regular smooth plates 301 are peeled off from the adhered PI film, and the effective part is cut to obtain the magnetostrictive fiber array 400 film. In steps S201 and S205, a PI film is tightly bonded to the surface of the regular smooth plate 301 as a release layer or demolding layer. Because the PI film has the characteristics of smoothness, good chemical stability and good flexibility, it can be easily peeled off from the regular smooth plate 301 after the epoxy resin is cured. At the same time, its smooth surface can ensure the surface smoothness of the cured epoxy resin film, effectively solving the problem that the epoxy resin may adhere too tightly, be difficult to demold or damage the film surface after being directly cured with the plate, thus ensuring the integrity and surface quality of the finished film. After pouring epoxy resin in step S204, step S205 immediately follows by taking a second regular smooth plate 301 with a PI film also adhered to its surface, and pressing the side with the PI film onto the epoxy resin. This double-plate pressing method uses two parallel, smooth plates to naturally constrain the flow space of the epoxy resin, thereby directly defining and controlling the final film thickness. Under the gravity or slight pressure of the regular smooth plate 301 serving as the upper plate, the epoxy resin will be spread into a uniform thin layer, completely impregnating and covering the magnetostrictive fiber array 400, ensuring the consistency of film thickness and the uniformity of resin wrapping the fibers, avoiding the problems of thick edges, thin middle, or uncontrollable thickness that may be caused by free leveling. In steps S201 and S203, double-sided adhesive is repeatedly applied to both ends of the regular smooth plate 301. The first application is used to fix the magnetostrictive fiber array 400 in S100. After the regular smooth plate 301 is removed from the device and before the resin is poured, double-sided adhesive of the same size is applied synchronously at the same position. This is equivalent to a secondary reinforcement of the ends of the magnetostrictive fiber array 400, ensuring that the ends of the magnetostrictive fiber array 400 can be firmly fixed in the predetermined position during subsequent pouring, covering the upper plate, and resin flow. This effectively prevents fiber drift or twisting caused by resin flow impact or operational vibration, and maintains the geometric accuracy of the fiber array.In step S202, the smooth, regular flat plate 301 carrying the magnetostrictive fiber array 400 can be removed from the position control platform 200 by operating the horizontal locking knob 2031. This allows subsequent steps such as casting, covering, and curing to be performed on an operating table outside the dedicated device, realizing the separation and parallel operation of processes, improving the utilization rate of the preparation device and the efficiency of the entire process. Finally, cutting the effective part removes areas with potentially irregular edges and areas with double-sided adhesive, ensuring the quality of the effective sensing area of ​​the final thin-film sensor 3.

[0034] like Figure 5 and Figure 6As shown, in this embodiment, the fabrication of the magnetostrictive fiber array thin film sensor in step S300 is specifically as follows: S301, attaching the magnetostrictive fiber array 400 thin film to the surface of the sample to be tested; S302, placing a magnetic field generator 2 along the fiber axial direction of the magnetostrictive fiber array 400 thin film, the magnetic field generator 2 being generated by a permanent magnet or an AC coil; S303, installing a magnetic flux sensing probe 1 near the magnetostrictive fiber array 400 thin film; S304, recording the data from the magnetic flux sensing probe 1 when the force on the sample to be tested changes; S305, comparing the data from the magnetic flux sensing probe 1 obtained from the test with the normal value, and then analyzing whether the sample to be tested is damaged or the degree of damage. Step S301 involves attaching the thin film to the surface of the sample under test. Utilizing the ultra-thin and flexible core features of the sensor prepared in steps S100 and S200, the sensor can be tightly and firmly attached to the sample under test, especially to the surface of structures with complex curves. When the sample is subjected to force and deforms, the strain on its surface can be directly transmitted to the thin film sensor 3 attached thereto without loss or hysteresis, ensuring the authenticity and accuracy of the sensing response and solving the signal attenuation problem caused by the difficulty of conformal bonding of rigid or thick film sensors. Steps S302 and S303 together construct the sensing working loop. First, a bias magnetic field is provided to the magnetostrictive fiber through the magnetic field generator 2 (permanent magnet or AC coil) to put it at the sensitive operating point. When the deformation of the sample is transmitted to the fiber (magnetostrictive effect), the magnetization state inside the fiber will change. Then, this change in magnetic flux is detected non-contactly through the magnetic flux sensing probe 1. Throughout the process, the sensor film itself is completely passive and does not require a power supply from the connecting wires. It can work by simply being excited and detected by the external magnetic field, truly realizing non-contact and passive sensing. It is particularly suitable for long-term monitoring scenarios such as rotating parts, enclosed environments, or where wiring is difficult. Steps S304 and S305 clarify the data analysis method. By recording the magnetic flux signal of the sample under stress and comparing it with known normal values ​​(usually the baseline data under undamaged conditions), the magnetic flux signal characteristics of the sensor area above the sample will change due to the alteration of the local strain field caused by damage (such as cracks or yielding). This comparative analysis method based on signal differences is logically clear and does not require complex model calculations. It can effectively determine whether the sample is damaged and assess its degree of damage, making the sensing system very suitable for structural health monitoring and non-destructive testing applications.The preparation method described in step S300 clearly demonstrates how to apply the high-quality magnetostrictive fiber array film prepared by the aforementioned process to actual detection. It makes full use of the flexibility of the film to achieve conformal bonding, and through an external magnetic field generation and detection unit, a complete and efficient passive wireless sensing system is constructed. Finally, the scheme of damage diagnosis by comparing changes in magnetic flux signal is highly operable and reliable. Ultimately, the sensor prepared by this invention can be effectively applied to non-destructive testing and health monitoring of actual engineering structures, realizing a closed loop from core material preparation to final functional application.

[0035] In practice, a magnetostrictive fiber array thin-film sensor and its fabrication apparatus and process are provided. The apparatus of this invention allows for precise control of the fiber filaments, forming a uniform fiber array. The method of this invention enables the fabrication of magnetostrictive fiber epoxy resin films.

[0036] The preparation apparatus of the present invention arranges magnetostrictive fibers in a uniform array, pours epoxy resin into the neatly arranged fiber array, and completely coats the outer surface of the fiber array with epoxy resin (such as PI film), and waits for the epoxy resin to cure to form an epoxy resin film containing the magnetostrictive fiber array 400.

[0037] Example 1: like Figure 1 As shown, the preparation apparatus includes a support device 100, a position control platform 200, and a fiber placement control platform 300. Figure 2 As shown, the support device 100 includes a leg 101, a crossbeam 102, a V-groove support 104, and a V-groove beam 103; Figure 3 As shown, the position control platform 200 includes a vertical adjustment module 201, a horizontal adjustment module 202, and a horizontal positioning module 203. The vertical adjustment module 201 is adjusted via a vertical adjustment knob 2011, the horizontal adjustment module 202 is adjusted via a horizontal adjustment knob 2021, and the horizontal positioning module 203 is adjusted via a horizontal positioning knob 2031. Figure 4 As shown, the fiber placement control platform 300 is a regular smooth flat plate 301.

[0038] The vertical adjustment module 201 and the horizontal adjustment module 202 in the position control platform 200 are connected by bolts, and the horizontal locking module 203 is installed on the horizontal adjustment module 202.

[0039] The support device 100 consists of bolted connections between the legs 101, crossbeam 102, and V-groove beam 103, and is assembled according to required modules. The V-groove support 104 is connected to the V-groove beam 103 using strong adhesive or bolts. A set of V-groove support 104 comprises two units for joint use. During installation, the V-groove support 104 is installed parallel to the V-groove beam 103, meaning that each V-groove on the V-groove support 104 is a straight line in space.

[0040] like Figure 4 As shown, the fiber placement control platform 300 is fixed to the horizontal adjustment module 202 via the horizontal locking module 203. The vertical adjustment knob 2011 enables vertical movement of the regular smooth plate 301. The horizontal adjustment knob 2021 enables horizontal movement of the regular smooth plate 301. The horizontal locking knob 2031 enables fixing and loosening of the regular smooth plate 301.

[0041] like Figure 5 (a) and Figure 5 As shown in (b), the specific steps of the magnetostrictive fiber array fabrication process of the present invention include: A1. Preparation of magnetostrictive fiber monofilament: Take magnetostrictive fiber monofilaments with a length of 150mm-200mm for later use; A2. Adjust the horizontal locking knob 2031 to fix the regular smooth plate 301 onto the horizontal adjustment module 202; A3. Adjust the vertical adjustment knob 2011 so that the horizontal position of the regular smooth plate 301 is about 5mm lower than the V-groove of the V-groove support 104. A4. Take the fiber monofilaments prepared in step A1 and arrange them according to the corresponding V-groove. Attach the weights at both ends of the fiber to the V-groove beam 103. A5. Adjust the vertical adjustment knob 2011 so that the horizontal position of the regular smooth plate 301 is about 5mm higher than the V-groove of the V-groove support 104. A6. Cut off the fiber monofilaments on both sides outside the regular smooth plate 301, and remove the adhesive material adhering to the V-groove beam 103. A7. Adjust the horizontal adjustment knob 2021, move it a certain distance, and repeat steps A3-A6 until the magnetostrictive fiber array 400 reaches the required width.

[0042] like Figure 5 (c) and Figure 5 As shown in (d), the specific steps of the magnetostrictive fiber array thin film preparation process of the present invention include: B1. A layer of PI film is tightly bonded to the surface of the regular smooth plate 301, and a layer of double-sided adhesive is attached to both sides of the smooth plate 301. B2. The regular smooth plate 301 obtained in step B1 is prepared according to the magnetostrictive fiber array preparation process of the present invention. B3. By operating the horizontal locking knob 2031, remove the prepared magnetostrictive fiber array 400 along with the regular smooth plate 301.

[0043] B4. In step B1, double-sided adhesive tape of the same size is simultaneously pasted at the same positions. B5. Cast epoxy resin onto the sample completed in B4; B6. Press another regular smooth plate 301 with a PI film also adhered to its surface onto the sample completed in B5. B7. After the epoxy resin has cured, peel the two regular smooth flat plates 301 from the adhered PI film and cut the effective part (including the magnetostrictive fiber array 400 but excluding the double-sided adhesive part) to obtain the magnetostrictive fiber array film.

[0044] like Figure 6 As shown, the sensing performance principle of the magnetostrictive fiber array thin film sensor of the present invention is as follows: C1. The prepared magnetostrictive fiber array film 4 is attached to the surface of the test sample 5; C2. A magnetic field generator 2 is placed on the magnetostrictive fiber array film 4 along the fiber axial direction. The magnetic field generator 2 can be generated by a permanent magnet or an AC coil, etc. C3. Install a magnetic flux sensing probe 1 near the magnetostrictive fiber array film 4; C4. When the force on the experimental sample changes, such as tension, compression, bending, delamination, etc., record the data of magnetic flux induction probe 1. C5. By comparing the data obtained from the magnetic flux induction probe 1 with the normal value, it can be analyzed whether the tested sample is damaged or the degree of damage. In addition, the thin-film sensor 3 can be attached to the surface of the product being tested as needed to achieve health monitoring of the product being tested.

[0045] The beneficial effects of this invention are as follows: 1. It can achieve precise control and parallel arrangement of magnetostrictive fiber monofilaments; 2. The mechanical structure of this invention is simple and easy to operate; 3. The preparation device of this invention is modularly assembled and can be directly replaced; 4. The thin film prepared by this invention has magnetostrictive properties and can be used for performance testing of materials and structures; 5. This invention can control the fiber array spacing and film thickness; 6. The size and quantity of the magnetostrictive fiber array thin film sensor can be adjusted according to requirements, and modular operation is possible; 7. This invention enables contactless sensing and detection, reducing damage to the tested component.

[0046] In this embodiment, the thin-film sensor can be fabricated in different sizes as needed, and can be attached to the surface of the sample under test in modules.

[0047] Example 2: In this embodiment, compared to Embodiment 1, it is not necessary to install a magnetic field generator 2 when testing the sample to be tested; the other procedures are exactly the same as in Embodiment 1.

[0048] Example 1 involves adding a magnetic field generator. In actual operation, the magnetic field generator can generate a magnetic field along the fiber length, which increases the signal (magnetic field strength) detected by the detection device, thus facilitating the acquisition of the feedback signal. However, in actual measurements, due to site constraints, the equipment does not allow the installation of a magnetic field generator 2, resulting in a slightly smaller signal acquisition value under the same conditions, although it is still measurable.

[0049] This invention relates to a magnetostrictive fiber array thin-film sensor and its fabrication apparatus and process. Through precise horizontal and vertical movement of a position control platform 200, a magnetostrictive fiber array 400 fixed in a V-groove is bonded to a regular smooth plate 301. The magnetostrictive fiber array 400 remains stationary until it is bonded to the double-sided adhesive 302 on the position control platform 200. This operation ensures that the magnetostrictive fiber array 400 does not move during operation, thus guaranteeing the accuracy of the arrangement. It eliminates the need to control the movement of the V-groove, significantly increasing the fiber arrangement speed. The magnetostrictive fiber array 400 is laid using a simple modular combination, greatly reducing equipment costs.

[0050] This invention is specifically for magnetostrictive fibers. The special characteristics of magnetostrictive fibers (different toughness and strength) mean that they are not used for load-bearing. Their value lies not in their static strength, but in their dynamic deformation ability that can be controlled by a magnetic field and their ability to convert stress into magnetic signals, making them an ideal candidate material for constructing smart structures (such as active deformation of wings, vibration suppression, and self-sensing composite materials).

[0051] The unique characteristic of magnetostrictive fibers lies in their dynamic electromechanical conversion function, rather than their static structural properties. This leads to a shift in the primary goal of magnetostrictive fiber placement applications from "achieving optimal structure" to "successfully integrating and protecting their function within the structure." Magnetostrictive fibers are highly brittle, requiring controlled placement tension to prevent breakage. They are also extremely sensitive to magnetic fields; any magnetic field, or one generated during movement, can cause deformation or performance deviation. The core challenges of magnetostrictive fiber placement technology primarily include brittleness and electromagnetic properties, necessitating the development of specialized, low-stress placement equipment and processes, as well as careful design of insulation and connection schemes. Currently, this remains a cutting-edge research area, largely in the experimental stage. This invention addresses the entire process of fabricating a magnetostrictive fiber array thin-film sensor, encompassing equipment, fabrication, and testing. The magnetostrictive fiber array thin-film sensor fabricated using this invention is already encapsulated with a PI film during fabrication and can be used directly without additional encapsulation.

[0052] Matters not covered in this invention are common knowledge.

[0053] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0054] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

[0055] 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. An apparatus for fabricating a magnetostrictive fiber array thin-film sensor, characterized in that, It includes a support device (100), a position control platform (200), and a fiber placement control platform (300). The support device (100) is used to form an outer frame, and the position control platform (200) is located within the frame space area of ​​the support device (100). The top of the support device (100) is used to arrange magnetostrictive fiber monofilaments in an array and parallel to each other, and to tension both ends of each magnetostrictive fiber monofilament by the same preset tension force, so as to ensure that all magnetostrictive fiber monofilaments are in a consistent preset pre-stretch state during the pre-forming stage, and to keep the arranged magnetostrictive fiber array (400) stationary. The top of the position control platform (200) is used to clamp and fix the fiber placement control platform (300), and the position control platform (200) is used to adjust the height and horizontal position of the fiber placement control platform (300); The fiber placement control platform (300) is used to bond the magnetostrictive fiber array (400) from bottom to top after the magnetostrictive fiber monofilament array is arranged, thereby preparing the magnetostrictive fiber array film; The fiber placement control platform (300) adopts a regular smooth plate (301) with a smooth upper surface. Double-sided adhesive is provided at both ends of the regular smooth plate (301). The double-sided adhesive is used to adhere to the magnetostrictive fiber array (400) arranged in an array on the support device (100) when the fiber placement control platform (300) rises with the position control platform (200), thereby realizing the fixed positioning of the magnetostrictive fiber array (400). The preparation of the magnetostrictive fiber array film is as follows: a PI film is tightly bonded to the surface of a regular smooth plate (301), and a layer of double-sided adhesive is attached to both ends of the smooth plate; the prepared magnetostrictive fiber array (400) is removed along with the regular smooth plate (301) by operating the horizontal locking knob (2031); double-sided adhesive of the same size is simultaneously attached to the same position of the double-sided adhesive; epoxy resin is poured; a second regular smooth plate (301) with a PI film also attached to its surface is taken, and the side with the PI film is pressed onto the epoxy resin; after the epoxy resin is cured, the two regular smooth plates (301) are peeled off from the attached PI film, and the effective part is cut to obtain the magnetostrictive fiber array (400) film.

2. The fabrication apparatus for the magnetostrictive fiber array thin film sensor according to claim 1, characterized in that, The position control platform (200) includes a vertical adjustment module (201), a horizontal adjustment module (202), and a horizontal positioning module (203); A horizontal adjustment module (202) is installed in the movable part of the vertical adjustment module (201), and a horizontal positioning module (203) is installed in the movable part of the horizontal adjustment module (202). The horizontal positioning module (203) is used to clamp and fix the fiber placement control platform (300); or The vertical adjustment module (201) is located in the movable part of the horizontal adjustment module (202), and the horizontal clamping module (203) is located in the movable part of the vertical adjustment module (201). The horizontal clamping module (203) is used to clamp and fix the fiber placement control platform (300).

3. The fabrication apparatus for the magnetostrictive fiber array thin film sensor according to claim 2, characterized in that, The vertical adjustment module (201) employs a scissor-type upgrade mechanism and is upgraded via a vertical adjustment knob (2011); and / or The horizontal adjustment module (202) employs a horizontal slide rail mechanism and is horizontally adjusted via a horizontal adjustment knob (2021); and / or The horizontal clamping module (203) adopts a parallel clamping mechanism and is clamped by a horizontal clamping knob (2031).

4. The fabrication apparatus for the magnetostrictive fiber array thin film sensor according to claim 1, characterized in that, The support device (100) includes a leg (101), a crossbeam (102) and a V-groove beam (103). The leg (101), the crossbeam (102) and the V-groove beam (103) are detachably connected to form an outer frame. A V-groove support (104) is provided on the top of the outer frame. Two sets of V-groove supports (104) are arranged in a relatively spaced and symmetrical manner. The corresponding V-grooves on the two sets of V-groove foundations (104) are arranged coaxially, and a magnetostrictive fiber monofilament is placed on the two coaxially arranged V-grooves. The two sets of V-groove bearing platforms (104) are arranged perpendicular to each other with the clamping direction of the position control platform (200).

5. The fabrication apparatus for the magnetostrictive fiber array thin film sensor according to claim 4, characterized in that, The support device (100) also includes an adhesive counterweight (105) located outside the V-groove support (104), the adhesive counterweight (105) being used to bond the ends of the array of magnetostrictive fibers (400) arranged in an array. The magnetostrictive fiber array (400) is tensioned at both ends by suspended adhesive counterweights (105) and arranged in an array on the support device (100).

6. A method for fabricating a magnetostrictive fiber array thin-film sensor, characterized in that, The fabrication apparatus of the magnetostrictive fiber array thin film sensor according to any one of claims 1 to 5 includes the following steps: Fabrication of S100 and magnetostrictive fiber array (400); Preparation of S200 magnetostrictive fiber array thin films; Fabrication of S300 magnetostrictive fiber array thin film sensor.

7. The method for fabricating a magnetostrictive fiber array thin-film sensor according to claim 6, characterized in that, The fabrication of the magnetostrictive fiber array (400) in step S100 is specifically as follows: S101. Take magnetostrictive fiber monofilaments with a length of 150mm~200mm for later use; S102. Adjust the horizontal locking knob (2031) to fix the regular smooth plate (301) on the horizontal adjustment module (202); S103. Adjust the vertical adjustment knob (2011) so that the horizontal position of the regular smooth plate (301) is 3mm-8mm lower than the V-groove of the V-groove support (104); S104. Take the prepared magnetostrictive fiber monofilament and arrange it according to the V-groove of the V-groove support (104). Adhere the two ends of the magnetostrictive fiber monofilament to the adhesive counterweight (105) and place them in the corresponding V-groove. S105. Adjust the vertical adjustment knob (2011) so that the horizontal position of the regular smooth plate (301) is 3mm-8mm higher than the V-groove of the V-groove support (104); S106. Cut the two ends of the magnetostrictive fiber monofilament outside the regular smooth plate (301) and remove the adhesive counterweight (105). S107. Adjust the horizontal adjustment knob (2021) and move it a certain distance. Repeat steps S103-S106 until the magnetostrictive fiber array (400) reaches the preset width.

8. The method for fabricating a magnetostrictive fiber array thin-film sensor according to claim 7, characterized in that, The preparation of the magnetostrictive fiber array thin film in step S200 is specifically as follows: S201. A layer of PI film is tightly bonded to the surface of the regular smooth plate (301), and a layer of double-sided adhesive is attached to both ends of the smooth plate. S202. By operating the horizontal locking knob (2031), the prepared magnetostrictive fiber array (400) along with the regular smooth plate (301) is removed. S203. In step S201, double-sided adhesive of the same size is simultaneously pasted at the same position. S204, cast epoxy resin; S205. Take a second regular smooth flat plate (301) with a PI film also adhered to its surface, and press the side with the PI film onto the epoxy resin. S206. After the epoxy resin has cured, peel the two regular smooth flat plates (301) from the adhered PI film and cut the effective part to obtain the magnetostrictive fiber array (400) film.

9. The method for fabricating a magnetostrictive fiber array thin-film sensor according to claim 8, characterized in that, The fabrication of the magnetostrictive fiber array thin-film sensor in step S300 is specifically as follows: S301. The magnetostrictive fiber array (400) film is attached to the surface of the sample to be tested; S302. A magnetic field generator is placed on the magnetostrictive fiber array (400) film along the fiber axial direction. The magnetic field generator is generated by a permanent magnet or an AC coil. S303, Install a flux sensing probe near the magnetostrictive fiber array (400) thin film; S304. When the force on the sample under test changes, record the data from the magnetic flux induction probe. S305. Compare the magnetic flux induction probe data obtained from the test with the normal value, and then analyze whether the tested sample is damaged or the degree of damage.

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