Shield Segment Self-Diagnosis via Embedded Optical Fiber Sensors
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Solution Overview
Problem
Existing shield segment manufacturing processes are prone to sensor damage, require extensive manpower and time, and are limited by tight installation schedules and poor working environments, making long-term monitoring and accurate deformation diagnosis challenging.
Innovation Solution
An integrated manufacturing system for small-deformation self-diagnosis shield segments, incorporating pre-cast boxes and optical fiber grating sensors with temperature compensation, where sensors are embedded within the reinforcement framework during concrete pouring, allowing for real-time monitoring and reduced exposure to environmental damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sensors are installed on the surface of shield segments, then sensor installation is simplified, but sensors are vulnerable to damage during transportation, assembly, grouting and secondary pouring
Solution Approach 1:
The patent embeds sensors inside pre-cast boxes that are integrated into the reinforcement framework of shield segments. The pre-cast boxes act as protective containers that nest the sensors within the segment structure, protecting them from damage during transportation, assembly, grouting and secondary pouring while maintaining measurement capabilities through designed access points.
Solution Approach 2:
The patent performs sensor installation and protection box integration during the concrete pouring process rather than after segment assembly. By embedding the pre-cast boxes with sensors inside the concrete segments during manufacturing, the sensors are protected from future damage while enabling long-term monitoring without requiring subsequent installation operations.
2Adaptability or versatility
If sensors are installed on shield machine after segments are assembled, then sensor installation flexibility is improved, but installation time is limited and tight
Solution Approach 1:
The patent moves sensor installation to the concrete pouring stage, which occurs before segment assembly. This preliminary action allows sufficient time for sensor installation, calibration and testing without being constrained by the tight schedule of shield machine operations, while the pre-cast box design maintains installation flexibility through standardized interfaces.
3Area of stationary object
If sensors are installed on lifting platform at high altitude, then sensor installation coverage is improved, but working difficulty and personnel risk increase
Solution Approach 1:
The patent performs all sensor installations during concrete pouring operations at ground level or in controlled factory settings, eliminating the need for high-altitude work on lifting platforms. The pre-cast boxes are prepared and sensors installed before segments are lifted and assembled, transferring the work to safer conditions while maintaining comprehensive monitoring coverage.
4Quantity of substance
If traditional resistive or vibrating wire sensors are used, then initial installation cost is reduced, but zero point drift occurs over long term leading to distorted results
Solution Approach 1:
The patent transitions from traditional resistive or vibrating wire sensors to optical fiber grating sensors, representing a parameter change in the sensing mechanism. Optical fiber sensors use light wavelength measurements instead of electrical resistance or vibration frequency, providing superior long-term stability and immunity to environmental factors like humidity and chemical corrosion, thereby eliminating zero point drift while maintaining cost-effectiveness through the pre-cast box integration system.
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
The solution ensures sensor protection, simplifies installation, reduces maintenance risks, and enables efficient long-term monitoring of deformation, displacement, strain, and pressure changes within shield segments, enhancing operational safety and efficiency.
Implementation Method 1
Fiber Bragg Grating (FBG) sensor has the advantages of high precision measurement and distributed detection, which can accurately measure the above-mentioned deformation
Implementation Method 2
optical fiber grating sensor self-provided with temperature compensation
Data Source
AI summary
The invention discloses an integrated manufacturing system and method for a small-deformation self-diagnosis shield segment, wherein the designed installation process saves time and effort, and all the sensing modules are provided inside the segment without disturbing the space outside the segment. Integration of all the deformation self-diagnosis shield segments is achieved by comprehensively monitoring inclination, displacement, strain, pressure and temperature of the shield segments via five monitoring modules. At the same time, the obtained data is uploaded to a database, and various contents are displayed in real time according to indication information input by a user.