A smart support of a button spot welding grating sensor

Abstract

The application discloses a button type spot welding grating sensor intelligent support, and belongs to the technical field of bridge engineering health monitoring and support. The button type spot welding grating sensor intelligent support comprises an upper connecting steel plate, a rubber support, a sensor steel plate seat, a lower connecting steel plate and a button type spot welding grating sensor. The sensor steel plate seat is fixedly connected with the rubber support and the upper and lower connecting steel plates through a flexible connection mode, and a sensor mounting groove and a lead groove in communication are arranged on the surface of the sensor steel plate seat; and the button type spot welding grating sensor is correspondingly embedded and fixed in the mounting groove. The application adopts a split type structure, the sensing unit can be independently disassembled and replaced, the support does not need to be replaced as a whole, and the operation and maintenance cost is greatly reduced. The spot welding integrated grating sensor has high stress transmission efficiency, and can realize high-precision monitoring of the stress state of the support in cooperation with a groove type fitting installation structure, is convenient to install and maintain, and has high long-term operation reliability.

Description

Technical Field

[0001] This invention belongs to the field of bridge engineering health monitoring and bearing technology, and particularly relates to a smart bearing with a button-type spot-welded grating sensor. Background Technology

[0002] Bridge bearings are core load-bearing components in bridge structures, connecting the superstructure and the piers. They are responsible for transmitting loads and accommodating the rotation and horizontal displacement of the bridge structure. Their working condition directly affects the overall safety and service life of the bridge. As bridge operation and maintenance move towards intelligence and digitalization, smart bearings with integrated sensing units are gradually being applied. These bearings can achieve long-term real-time monitoring of bearing stress and deformation, providing data support for bridge health assessment.

[0003] In existing technologies, bridge bearings with monitoring functions mostly adopt a structure in which the sensor and the bearing body are integrally formed, which has the following significant drawbacks in practical engineering applications: Firstly, the maintenance and replacement costs of sensors are high. The integrated support embeds the sensing unit inside the rubber or steel plate. When the sensor fails, is damaged, or its accuracy degrades, the sensing element cannot be replaced individually. The entire support must be replaced, which not only makes construction difficult and causes long downtime, but also results in a huge waste of support material, leading to high maintenance costs throughout the entire life cycle.

[0004] Secondly, the sensor measurement accuracy and long-term reliability are insufficient. Most built-in sensors adopt a surface-mount mounting process, which results in low stress transmission efficiency between the sensing element and the support substrate. They are susceptible to detachment and drift due to environmental temperature and humidity and adhesive aging, making it difficult to meet the measurement accuracy requirements for long-term monitoring. At the same time, conventional arrangement methods cannot achieve synchronous and accurate acquisition of multi-dimensional forces, and cannot fully reflect the true working state of the support.

[0005] To address this, a smart support for a button-type spot-welded grating sensor is proposed. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention proposes a smart support for a button-type spot-welded grating sensor.

[0007] To achieve the above objectives, the present invention provides a smart support for a button-type spot-welded grating sensor, comprising an upper connecting steel plate, a rubber support, and a lower connecting steel plate arranged sequentially from top to bottom. Both the upper and lower connecting steel plates are square steel plates, and the rubber support is composed of multiple layers of rubber plates. The support also includes a sensor steel plate base and a button-type spot-welded grating sensor. The sensor steel plate base is flexibly connected to the rubber support, the upper connecting steel plate, and the lower connecting steel plate. A sensor mounting groove is formed on the surface of the sensor steel plate base, and the button-type spot-welded grating sensor is correspondingly installed within the sensor mounting groove. A lead wire groove communicating with the sensor mounting groove is also formed on the sensor steel plate base.

[0008] Optionally, four sets of sensor mounting slots and four sets of button-type spot welding grating sensors are provided, and the outer diameter and number of the four sets of sensor mounting slots and the four sets of button-type spot welding grating sensors are matched one-to-one; the four sets of button-type spot welding grating sensors are symmetrically distributed in a circle with four equal parts on the surface of the sensor steel plate base.

[0009] Optionally, the four sets of button-type spot-welded grating sensors are connected in series by a wire, which is laid inside the lead groove and leads out from one side wall of the sensor steel plate seat.

[0010] Optionally, the button-type spot-welded grating sensor includes an optical fiber conductor, a metal substrate, adhesive, a stainless steel tube, an optical fiber heat-shrink tubing, a drop cable, and a femtosecond pulse fiber grating; the stainless steel tube is spot-welded to the surface of the metal substrate; the optical fiber conductor is sequentially inserted into the drop cable, the optical fiber heat-shrink tubing, the femtosecond pulse fiber grating, and the stainless steel tube; the drop cable, the optical fiber conductor, and the femtosecond pulse fiber grating are integrally formed; the adhesive fills the inner cavity of the stainless steel tube to encapsulate and fix the optical fiber conductor and the femtosecond pulse fiber grating.

[0011] Optionally, the stainless steel tube is spot-welded to the metal substrate using a portable lithium battery spot welding machine; the spot-welded grating sensing unit encapsulated with optical fiber wires is spot-welded into the button-type substrate using a 3V to 5V portable lithium battery spot welding machine to form the button-type spot-welded grating sensor; the button-type spot-welded grating sensor is fixed in the sensor mounting slot by adhesive.

[0012] Optionally, the sensor steel plate seat is disposed between the rubber support and the lower connecting steel plate, with the upper end face of the sensor steel plate seat being in contact with the lower end face of the rubber support, and the lower end face of the sensor steel plate seat being in contact with the upper end face of the lower connecting steel plate.

[0013] Optionally, the sensor mounting slot is a circular recessed slot with a flat bottom, and the bottom surface of the button-type spot-welded grating sensor is completely fitted with the bottom of the sensor mounting slot.

[0014] Optionally, the lead wire groove extends radially along the sensor steel plate base and corresponds one-to-one with the sensor mounting groove.

[0015] Compared with the prior art, the present invention has the following advantages and technical effects: By setting up an independent sensor steel plate base and flexibly connecting it to the rubber support and upper and lower connecting steel plates, a separate architecture for the sensing unit and the main body of the support is achieved while ensuring that the original load-bearing capacity and deformation coordination performance of the support are not affected by the sensing structure. With the sensor mounting groove and the connected lead wire groove opened on the surface of the sensor steel plate base, the button-type spot-welded grating sensor can be stably embedded and positioned. When the sensing element fails or its accuracy degrades, there is no need to replace the entire support; only the sensor needs to be disassembled and replaced. This significantly reduces the maintenance cost and construction difficulty throughout the entire life cycle. At the same time, the groove-type fitting installation structure can ensure efficient stress transmission, and the lead wire groove can provide mechanical protection for the fiber optic line, thereby improving the accuracy of stress monitoring and the long-term operational reliability of the sensing system. Attached Figure Description

[0016] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The 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 smart support structure for the button-type spot-welded grating sensor of the present invention; Figure 2 This is a top view of the sensor steel plate base in this invention; Figure 3 This is a schematic diagram of the front structure of the button-type spot-welded grating sensor in this invention; Figure 4 This is a schematic diagram of the back structure of the button-type spot-welded grating sensor in this invention; Figure 5 For the present invention Figure 4 Top view of the button-type spot-welded grating sensor at point A.

[0017] In the diagram: 1. Upper connecting steel plate; 2. Rubber support; 3. Sensor steel plate base; 4. Lower connecting steel plate; 5. Button-type spot-welded grating sensor; 501. Fiber optic cable; 502. Metal substrate; 503. Adhesive; 504. Stainless steel tube; 505. Fiber optic heat shrink tubing; 506. Cordless cable; 507. Femtosecond pulse fiber optic grating; 6. Lead groove. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0020] Reference Figures 1 to 5 As shown, this embodiment provides a smart support for a button-type spot-welded grating sensor, which is mainly used for intelligent stress monitoring of bridge plate rubber bearings. Its overall structure includes, from top to bottom, an upper connecting steel plate 1, a rubber bearing 2, a sensor steel plate seat 3, and a lower connecting steel plate 4. A button-type spot-welded grating sensor 5 and a lead wire groove 6 are integrated and installed on the sensor steel plate seat 3.

[0021] In this embodiment, both the upper connecting steel plate 1 and the lower connecting steel plate 4 are square structural steel plates with rust-proof and corrosion-proof treatment on the surface. They are used for anchoring connections with the upper beam and lower pier of the bridge, respectively, providing a stable installation interface for the bearing. The rubber bearing 2 is composed of multiple layers of rubber plates and stiffening steel plates stacked alternately, possessing vertical bearing capacity, horizontal displacement, and rotational deformation capabilities. It is the main load-bearing unit of the bearing and can effectively buffer the impact of bridge loads.

[0022] The sensor steel plate base 3 is positioned between the rubber support 2 and the lower connecting steel plate 4. Its upper end face is bonded to the lower end face of the rubber support 2 and integrally bonded to form a flexible connection interface. The lower end face of the sensor steel plate base 3 is bonded to the upper end face of the lower connecting steel plate 4, together forming a continuous overall force-bearing system. The flexible connection formed by vulcanization bonding can work together with the rubber support 2 to generate compression and shear deformation, avoiding stress concentration caused by rigid connection and ensuring that the original mechanical properties of the support are not affected by the sensing structure.

[0023] The upper surface of the sensor steel plate base 3 has four sets of sensor mounting slots. The sensor mounting slots are circular recessed structures, and the bottom of the slots is precision machined to form a flat end face, with the flatness meeting the sensor force requirements. The four sets of sensor mounting slots are symmetrically distributed in a circle with the geometric center of the sensor steel plate base 3 as the center. The inner diameter of each set of sensor mounting slots is adapted to the outer diameter of the button-type spot-welded grating sensor 5, and the depth is matched with the thickness of the button-type spot-welded grating sensor 5, ensuring that the top surface of the sensor does not protrude from the surface of the sensor steel plate base 3 after installation, and avoiding additional compression of the sensor when the support is under pressure.

[0024] Corresponding to the four sets of sensor mounting slots, the sensor steel plate base 3 also has four lead wire slots 6, each corresponding to a sensor mounting slot and extending radially along the sensor steel plate base 3. The inner end of each lead wire slot 6 is connected to the side wall of the corresponding sensor mounting slot, and the outer ends converge and exit from one side wall of the sensor steel plate base 3 to the outside of the support. The depth and width of the lead wire slots 6 are adapted to the layout requirements of the drop cable 506, providing mechanical protection for the optical fiber and preventing it from being squeezed or sheared and damaged when the support is deformed under pressure, thus ensuring the integrity of the signal transmission link.

[0025] The button-type spot-welded grating sensors 5 are embedded one-to-one in the sensor mounting slots. Their specific structure includes an optical fiber conductor 501, a metal substrate 502, adhesive 503, a stainless steel tube 504, an optical fiber heat-shrink tubing 505, a drop cable 506, and a femtosecond pulse fiber grating 507. The metal substrate 502 is a circular metal sheet, serving as the sensor's stress-bearing base and stress-transfer surface. The stainless steel tube 504 is spot-welded to the center of the upper surface of the metal substrate 502, forming a rigidly connected sensing base. The optical fiber conductor 501, femtosecond pulse fiber grating 507, and drop cable 506 are integrated. The drop cable 506 is sequentially sleeved within the optical fiber heat-shrink tubing 505 and the inner cavity of the stainless steel tube 504, forming a multi-layered protective structure. Adhesive 503 is injected into the stainless steel tube 504, and after the adhesive has completely cured, the optical fiber conductor 501, stainless steel tube 504, and metal substrate 502 are integrated into a single package, forming the core spot-welded grating sensing unit. Subsequently, the spot-welded grating sensing unit was spot-welded into the button-shaped metal substrate using a portable lithium battery spot welder with a voltage of 3V to 5V, thus obtaining a modular button-shaped spot-welded grating sensor 5.

[0026] During on-site installation, the bottom of the sensor mounting slot is first cleaned. After applying adhesive 503, the metal substrate 502 of the button-type spot-welded grating sensor 5 is inserted into the mounting slot with one side facing down. The sensor is pressed evenly to ensure complete adhesion between the bottom surface and the slot bottom, removing any air bubbles. Once the adhesive has cured, the sensor is fixed in place. The fiber optic cables 506 of the four sets of button-type spot-welded grating sensors 5 are laid along the corresponding lead-in slots 6. After series connection, they are all led out from the side wall outlet of the sensor steel plate base 3 and connected to an external fiber optic grating demodulation device.

[0027] The working principle of this invention is as follows: When the load from the bridge superstructure is transferred to the smart bearing, the rubber bearing 2 undergoes vertical compression and horizontal shear deformation, which is simultaneously transferred to the sensor steel plate seat 3. The strain of the sensor steel plate seat 3 is evenly transferred to the metal substrate 502 of the button-type spot-welded grating sensor 5 through the bottom surface of the mounting groove, thereby causing the internal fiber optic grating to generate axial strain and causing the grating wavelength to shift. The external demodulation equipment collects the grating wavelength change data through the fiber optic cable 501, and after calibration and conversion, the magnitude of the force, the amount of deformation and the off-center load state of the bearing can be obtained, realizing real-time online monitoring and health assessment of the bearing's working performance.

[0028] When a sensor malfunctions or its accuracy degrades and needs to be replaced, it is only necessary to clean the adhesive in the corresponding mounting slot, remove the failed button-type spot-welded grating sensor 5, re-spot weld a new sensing unit and fix it in place. There is no need to disassemble the entire support structure. The operation and maintenance are convenient and inexpensive, which can effectively extend the entire life cycle of the support.

[0029] All aspects not detailed in this invention are conventional technical means known to those skilled in the art.

[0030] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0031] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A smart support for a button-type spot-welded grating sensor, characterized in that, The system includes an upper connecting steel plate (1), a rubber support (2), and a lower connecting steel plate (4) arranged sequentially from top to bottom. Both the upper connecting steel plate (1) and the lower connecting steel plate (4) are square steel plates. The rubber support (2) is composed of multiple layers of rubber plates. The system also includes a sensor steel plate seat (3) and a button-type spot-welded grating sensor (5). The sensor steel plate seat (3) is fixedly connected to the rubber support (2), the upper connecting steel plate (1), and the lower connecting steel plate (4) through a flexible connection. The surface of the sensor steel plate seat (3) is provided with a sensor mounting groove, and the button-type spot-welded grating sensor (5) is installed in the corresponding sensor mounting groove. The sensor steel plate seat (3) is also provided with a lead wire groove (6) that communicates with the sensor mounting groove.

2. The smart support for the button-type spot-welded grating sensor according to claim 1, characterized in that, The sensor mounting slots and the button-type spot welding grating sensors (5) are each provided with four sets. The outer diameter and number of the four sets of sensor mounting slots and the four sets of button-type spot welding grating sensors (5) are matched one by one. The four sets of button-type spot welding grating sensors (5) are symmetrically distributed in a circle with four equal parts on the surface of the sensor steel plate base (3).

3. The smart support for the button-type spot-welded grating sensor according to claim 2, characterized in that, The four sets of button-type spot-welded grating sensors (5) are connected in series by a wire (506). The wire (506) is laid inside the lead groove (6) and extends out from one side wall of the sensor steel plate seat (3).

4. The smart support for the button-type spot-welded grating sensor according to claim 1, characterized in that, The button-type spot-welded grating sensor (5) includes an optical fiber conductor (501), a metal substrate (502), adhesive (503), a stainless steel tube (504), an optical fiber heat shrink tubing (505), a drop cable (506), and a femtosecond pulse fiber grating (507). The stainless steel tube (504) is spot-welded to the surface of the metal substrate (502). The optical fiber conductor (501) is sequentially inserted into the drop cable (506), the optical fiber heat shrink tubing (505), the femtosecond pulse fiber grating (507), and the stainless steel tube (504). The drop cable (506), the optical fiber conductor (501), and the femtosecond pulse fiber grating (507) are integrally formed. The adhesive (503) fills the inner cavity of the stainless steel tube (504) to encapsulate and fix the optical fiber conductor (501) and the femtosecond pulse fiber grating (507).

5. The button-type spot-welded grating sensor smart support according to claim 4, characterized in that, The stainless steel tube (504) is spot-welded to the metal substrate (502) using a portable lithium battery spot welder with a voltage of 3V to 5V; the spot-welded grating sensing unit encapsulated with an optical fiber wire (501) is spot-welded into the button-type substrate using a portable lithium battery spot welder to form the button-type spot-welded grating sensor (5); the button-type spot-welded grating sensor (5) is glued and fixed in the sensor mounting slot using adhesive (503).

6. The smart support for the button-type spot-welded grating sensor according to claim 1, characterized in that, The sensor steel plate seat (3) is disposed between the rubber support (2) and the lower connecting steel plate (4). The upper end face of the sensor steel plate seat (3) is in contact with the lower end face of the rubber support (2), and the lower end face of the sensor steel plate seat (3) is in contact with the upper end face of the lower connecting steel plate (4).

7. The smart support for the button-type spot-welded grating sensor according to claim 1, characterized in that, The sensor mounting slot is a circular recessed slot with a flat bottom. The bottom surface of the button-type spot-welded grating sensor (5) is completely in contact with the bottom of the sensor mounting slot.

8. The smart support for the button-type spot-welded grating sensor according to claim 1, characterized in that, The lead groove (6) extends radially along the sensor steel plate base (3) and corresponds one-to-one with the sensor mounting groove.

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