FBG Sensor Fiber Mounting With Carrier Element Preload Control
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Solution Overview
Problem
The existing methods for fixing fiber Bragg grating (FBG) sensor segments onto components like bearing rings face challenges in precision positioning and maintaining consistent preload during bonding, especially under varying temperatures, leading to limited measurement accuracy and increased manufacturing complexity.
Innovation Solution
A method involving stretching a fiber with an FBG sensor segment into a defined preload condition, fixing it onto a carrier element, and then securing the carrier element onto the component, allowing for precise positioning and controlled preload, which can be achieved through gluing, mechanical interlocking, or fitting, and subsequently fixing the carrier element to the component using methods like welding or gluing, ensuring accurate and reliable measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If FBG sensor segments are bonded directly onto the bearing ring using adhesive under preload, then the measurement function is achieved, but positioning precision deteriorates and measurement accuracy is limited
Solution Approach 1:
The patent introduces a carrier element as an intermediary component between the FBG sensor segment and the bearing ring. The carrier element enables precise positioning of the sensor segment through a groove structure, while maintaining the required preload through dedicated fixation elements. This mediator resolves the contradiction by separating the positioning function (carried out by the groove) from the preload application function (carried out by fixation elements), allowing both high positioning precision and accurate measurement to be achieved simultaneously.
Solution Approach 2:
The patent divides the fixation system into separate functional components: the carrier element with its groove structure for positioning, and separate fixation elements for applying preload. This segmentation allows each component to optimize its specific function - the groove ensures precise lateral positioning while the fixation elements maintain constant preload, thereby resolving the contradiction between positioning precision and measurement accuracy.
2Reliability
If FBG sensor segments are bonded directly onto the bearing ring, then the measurement function is achieved, but service life deteriorates due to undefined preloads and temperature variations
Solution Approach 1:
The carrier element acts as a stable intermediary that maintains consistent preload conditions on the FBG sensor segment throughout temperature variations and operational life. By providing a dedicated fixation structure with proper thermal and mechanical properties, the carrier element ensures preload stability that direct bonding cannot achieve, thereby improving service life and reliability.
Solution Approach 2:
The patent addresses preload stability by carefully selecting the carrier element material and fixation method to compensate for temperature variations. The carrier element is designed with appropriate thermal expansion characteristics and bonding properties that maintain constant preload on the sensor segment across the operating temperature range, thus improving reliability and service life.
3Ease of manufacture
If FBG sensor segments are bonded directly onto the bearing ring, then the measurement function is achieved, but manufacturing complexity increases due to laborious processes
Solution Approach 1:
The patent segments the manufacturing process into standardized steps: placing the sensor segment in the groove, applying adhesive, and securing with fixation elements. This segmentation transforms a complex direct bonding process into a series of simple, repeatable operations, thereby improving ease of manufacture despite adding a carrier element.
Solution Approach 2:
While the carrier element adds a component, it simplifies the overall manufacturing process by providing a pre-fabricated positioning structure. The groove and fixation elements are designed to guide the assembly process, reducing the skill level and time required for bonding operations compared to direct sensor-to-bearing-ring attachment.
Data Source
AI summary
A method for fixing a fiber having a fiber Bragg grating sensor segment onto a component configured to undergo changes in strain and/or temperature. The method providing the steps of stretching at least a section of the fiber including the fiber Bragg grating sensor segment by a defined and calibrated preload into a preloaded condition, fixing the section of the fiber including the fiber Bragg grating sensor segment being in the preloaded condition on a carrier element, and fixing the carrier element onto the component, as well as a bearing device with such a fiber.