Embedded Bolt Strain Sensing for Remote Tension Monitoring
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Solution Overview
Problem
Existing techniques for monitoring the tension in threaded fixings, such as bolts and studs, are complex and require time-consuming calibration, making them inefficient for accurately tracking the securing force in structurally critical components.
Innovation Solution
A tension monitoring apparatus with a strain sensor embedded in the shank of a fixing, such as a bolt, that generates a strain sensor signal processed by data processing means and transmitted wirelessly to a remote receiver, incorporating a module at the fixing's end with a wireless transmitter and data processing unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic transducer or mechanical load monitoring arrangements are used to monitor bolt tension, then tension monitoring capability is achieved, but the implementation becomes complicated and requires careful time-consuming calibration
Solution Approach 1:
The patent replaces complex mechanical monitoring arrangements (ultrasonic transducers, mechanical load cells) with a simplified strain sensor system. The strain sensor directly measures deformation in the bolt shank, converting mechanical strain into an electrical signal that can be processed and transmitted wirelessly, eliminating the need for complex calibration procedures.
Solution Approach 2:
The patent extracts the essential measurement function from complex monitoring systems by using a dedicated strain sensor embedded in the bolt shank. This separates the sensing function from the processing and transmission functions, allowing each component to be optimized independently and reducing overall system complexity.
2Ease of operation
If strain sensor is embedded in the shank with data processing and wireless transmission, then remote monitoring capability is achieved, but device complexity increases
Solution Approach 1:
The patent merges the strain sensor, data processing unit, and wireless transmitter into an integrated monitoring apparatus that is directly mounted on the bolt shank. This consolidation eliminates the need for separate external equipment and complex wiring, simplifying installation and operation while enabling remote monitoring capability.
Solution Approach 2:
The monitoring apparatus performs multiple functions within a single integrated unit: strain measurement, signal processing, data storage, and wireless transmission. This multi-functionality reduces the number of separate components needed and simplifies the overall system architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and accurate remote monitoring of securing force, reducing the risk of loose fixings by providing real-time data on tension levels and alerting when thresholds are breached, thus ensuring secure connections.
Implementation Method 1
a strain sensor embedded in the shank of the fixing and configured to generate a strain sensor signal corresponding to tension in the shank
Implementation Method 2
a wireless transmitter for communicating the strain sensor data to a remote receiver
Data Source
AI summary
Disclosed herein is a tension monitoring apparatus. The apparatus comprises a fixing with a shank which in use is under tension, a strain sensor embedded in the shank of the fixing and configured to generate a strain sensor signal corresponding to tension in the shank. The apparatus further comprises a data processing means configured to receive the strain sensor signal, process the strain sensor signal in accordance with one or more characterising parameters associated with the strain sensor and thereby generate corresponding strain sensor data indicative of a strain to which the shank is subject. Additionally, the apparatus comprises a wireless transmitter for communicating the strain sensor data to a remote receiver, wherein the data processing means and the wireless transmitter are mounted in a module fixed to an end of the fixing.