Perforated Metal Fiber Sensor Tubes Without Drilling Damage
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Solution Overview
Problem
Existing methods for producing optical fiber sensors with metal casings face challenges such as damage to fibers during hole drilling, limitations in tube diameter and wall thickness, and deformation of holes during diameter reduction, leading to mechanical stress and weight issues.
Innovation Solution
A continuous process involving laser welding and controlled drilling methods to form and perforate metal hollow profiles with fiber conductors, allowing for precise control of energy input and hole formation without deformation, enabling smaller diameters and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If holes are made in the metal jacket before fiber insertion, then fiber damage during drilling is avoided, but the production process requires additional steps and time
Solution Approach 1:
The patent applies preliminary action by making holes in the metal strip before forming it into a tube and inserting the fiber. This ensures that the holes are already positioned and sized correctly before the fiber is vulnerable to drilling damage, thereby protecting fiber integrity while maintaining production efficiency through a streamlined process sequence.
2Ease of manufacture
If arc welding process is used, then welding can be performed, but wall thicknesses smaller than 0.15 mm cannot be welded reliably and weld beads protrude into the pipe interior
Solution Approach 1:
The patent replaces the mechanical arc welding process with laser welding technology. This substitution enables reliable welding of thin-walled tubes (smaller than 0.15 mm) with precise control over the welding parameters, producing smooth welds that do not protrude into the pipe interior, thereby resolving both the welding capability and weld quality issues.
3Length of moving object
If pipe diameter is reduced using drawing dies or rollers, then smaller diameters can be achieved, but the previously made perforation closes due to compressive stress
Solution Approach 1:
The patent performs the hole-making operation after the pipe diameter reduction process. By reversing the sequence of operations—first reducing the pipe to its final small diameter, then creating the holes—the compressive stress that causes hole deformation is eliminated. This allows precise hole geometry to be achieved in the final, reduced-diameter pipe.
4Strength
If larger diameter metal tubes are used, then fiber protection is adequate, but minimum bending radius increases and weight increases
Solution Approach 1:
The patent changes the material parameter by using laser welding technology, which enables the fabrication of thin-walled, small-diameter tubes that maintain sufficient structural strength. This parameter change allows the use of smaller diameter tubes (reducing weight and bending radius) while still providing adequate fiber protection through optimized wall thickness and laser-welded joints.
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 the production of high-quality, perforated metal hollow profiles with diameters down to 1 mm, reducing material usage, weight, and allowing for longer lengths, while minimizing fiber damage and mechanical stress.
Implementation Method 1
The edges which abut flush against one another are welded together using a laser or another welding device
Implementation Method 2
a wall of the metal hollow profile is perforated by a drilling device, in particular by a laser
Data Source
Figure 1~5b
Figure 2
Figure 3
AI summary
A method (100) for the continuous production of a thin-walled, perforated metal hollow profile with one or more fiber conductors embedded therein comprises feeding (102) a flat metal strip at a first feeding speed to a forming device that continuously forms the metal strip into a metal hollow profile with a longitudinally extending slot. Two opposing edges of the metal strip formed into the metal hollow profile, which lie flush against each other in a contact area extending longitudinally along the metal hollow profile, are continuously welded together (110), withdrawn from the welded area, and perforated.The method according to the invention further comprises positioning a protective tube extending into the welded hollow metal profile on the pull-out side up to behind the perforation point and feeding (111) one or more fiber conductors from one or more fiber unwinders via the protective tube, so that the fiber conductor(s) are inserted from the guide or protective tube into the perforated hollow metal profile behind the perforation point in the pull-out direction. The perforated hollow metal profile with the fiber conductor(s) stored therein is received in a receiving device (124).