Copper Belt Sensor Cables for Offshore Wind Pile Stress Testing
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Solution Overview
Problem
Existing stress-strain testing systems for large-diameter steel pipe piles in offshore wind turbines face challenges with small load capacity and inadequate corrosion protection, which are critical for ensuring safe operation under harsh marine conditions.
Innovation Solution
The system employs copper belt type sensor cables welded to the steel pipe pile, covered with epoxy adhesive and gold foil paper, and integrated with a high-strength armored optical cable connected to a Brillouin optical fiber demodulator, allowing for accurate stress and strain measurement and enhanced corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional testing systems are used for large-diameter steel pipe piles, then the structure is simple and manufacturing is easy, but the load capacity is insufficient and corrosion protection is inadequate for offshore conditions
Solution Approach 1:
The patent implements nested protection by placing the copper belt sensor cable inside the epoxy adhesive layer, which is in turn protected by the gold foil paper and angle steel structure. This multi-layer nested configuration provides progressive protection while maintaining measurement functionality, resolving the contradiction between strength enhancement and system complexity.
Solution Approach 2:
The patent uses composite materials including copper belt for sensing, epoxy adhesive for bonding and protection, gold foil for corrosion resistance, and angle steel for structural support. This composite approach enhances both load capacity and corrosion protection while distributing the functional requirements across different material layers.
2Object-affected harmful factors
If traditional sensor protection methods are used, then the manufacturing process is simple, but corrosion protection is insufficient for seawater and submarine formations
Solution Approach 1:
The patent applies preliminary protection by pre-coating the copper belt sensor cable with epoxy adhesive before installation, and then adding gold foil paper and angle steel protection layers. This preliminary action ensures corrosion protection is built-in from the start, addressing the harsh marine environment requirements while maintaining a systematic manufacturing approach.
Solution Approach 2:
The patent uses thin film materials including epoxy adhesive coating and gold foil paper to provide corrosion protection. These flexible thin layers conform to the sensor cable geometry and provide effective barrier protection against seawater and submarine formation corrosion without adding excessive bulk or complexity.
3Reliability
If comprehensive corrosion protection is applied to the pipe pile and testing system, then corrosion resistance is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent achieves multi-functionality where the angle steel structure serves both as mechanical support for the sensor cable and as part of the corrosion protection system. The epoxy adhesive simultaneously bonds the cable to the pipe pile and provides a protective layer. This multi-functional design reduces overall system complexity while maintaining reliable corrosion protection.
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
This solution effectively measures deformation and stress while providing robust protection against seawater corrosion and large environmental loads, ensuring reliable operation under wind, wave, and storm conditions.
Implementation Method 1
copper belt type sensor cables are correspondingly welded on both sides of the steel pipe pile along an axis direction
Implementation Method 2
the fiber core of each copper belt type sensor cable is transferred into a high-strength armored optical cable by a special fixture and then is led out; and the high-strength armored optical cable is connected with a Brillouin optical fiber demodulator
Implementation Method 3
each sensor cable is sequentially covered with an epoxy adhesive
Implementation Method 4
each sensor cable is sequentially covered with an epoxy adhesive, gold foil paper and angle steel welded on the steel pipe pile
Data Source
AI summary
The present invention relates to a stress-strain testing system for a large-diameter steel pipe pile of an offshore wind turbine and a construction method, comprising a steel pipe pile, wherein copper belt type sensor cables are correspondingly welded on both sides of the steel pipe pile along an axis direction; each sensor cable is sequentially covered with an epoxy adhesive, gold foil paper and an angle steel welded on the steel pipe pile centering on the copper belt type sensor cable; a fiber core of each copper belt type sensor cable is transferred into a high-strength armored optical cable by a special fixture and then is led out; and the high-strength armored optical cable is connected with a Brillouin optical fiber demodulator. The present invention is applicable to the field of foundation engineering testing and detection technology.