CN111593662A - A smart cable with built-in sensor and sensor packaging method - Google Patents

Abstract

The invention discloses an intelligent cable with a built-in sensor and a sensor packaging method. The end portion of the cable is stripped of the outer shell to reveal the steel wires within the cable. The basement welded fastening is on the steel wire, and sensor welded fastening is on the basement, and the measuring direction of sensor is the same with the axial direction of cable. After the surface of the sensor is metalized, the metalized sensor is welded on the substrate, and the substrate is welded on the steel wire, so that the sensor can be packaged in the cable, and finally, the exposed part of the sensor, the substrate and the steel wire are subjected to corrosion prevention. Compared with the traditional bonding and mechanical connection mode, the intelligent cable with the built-in sensor and the sensor packaging method remarkably prolong the service life of the sensor and realize the full-life monitoring of the cable state. Meanwhile, the structure of the steel wire is not damaged, and the service life of the cable is not reduced.

Description

Translated fromChinese

一种内置传感器的智能缆索及传感器封装方法A smart cable with built-in sensor and sensor packaging method

技术领域technical field

本发明涉及智能缆索技术领域，具体涉及一种内置传感器的智能缆索及传感器封装方法。The invention relates to the technical field of smart cables, in particular to a smart cable with a built-in sensor and a sensor packaging method.

背景技术Background technique

斜拉索、主缆及吊索作为缆索承重桥梁结构主要的受力构件，长期处在高应力循环疲劳荷载作用下，其截面尺寸小，对腐蚀非常敏感。一旦因斜拉索或吊索耐久性和安全性不足出现病害与劣化，桥梁承载能力丧失会导致垮塌的恶性事故，造成恶劣的社会影响和巨大的经济损失。为确保大桥的安全运营，有必要对缆索承重桥梁的斜拉索、主缆及吊索等进行预防性维护和安全性检测。Stay cables, main cables and slings, as the main force-bearing components of cable-bearing bridge structures, are under the action of high-stress cyclic fatigue loads for a long time, and their cross-sectional dimensions are small and very sensitive to corrosion. Once the stay cables or slings are damaged and deteriorated due to insufficient durability and safety, the loss of the bearing capacity of the bridge will lead to a vicious accident of collapse, resulting in bad social impact and huge economic losses. In order to ensure the safe operation of the bridge, it is necessary to carry out preventive maintenance and safety inspection on the stay cables, main cables and slings of the cable-bearing bridge.

智能缆索技术是将应变传感元件(温度、应力或振动等传感器)在缆索制作过程中直接植入缆索结构，赋予缆索自感知能力的一种新技术。目前世界各国的桥梁工程师们都在关注着桥梁智能缆索的研究和应用，如何将精密的传感器和缆索相结合，使传感器经受住缆索的各道制造工序最终成活，并能准确地输出传感信号，从而有效地保证内置传感器的存活率是智能缆索研究的一大难题。Smart cable technology is a new technology in which strain sensing elements (sensors such as temperature, stress or vibration) are directly implanted into the cable structure during the cable manufacturing process to endow the cable with self-sensing capabilities. At present, bridge engineers all over the world are paying attention to the research and application of bridge smart cables, how to combine sophisticated sensors and cables, so that the sensors can withstand the various manufacturing processes of cables and finally survive, and can accurately output sensing signals , so as to effectively ensure the survival rate of built-in sensors is a major problem in smart cable research.

考虑缆索制造的各道工序，传感器埋入拉索可有两种形式：整体敷设法和局部埋植法。整体敷设法是将传感器以适当结构形式封装，做成线缆结构，与钢丝一起参与缆索制造的各道工序，与钢丝扭绞灌锚成一体，通过传感器的输出获知缆索的整体变形。局部埋植法是将传感器埋植在缆索内的局部位置，如靠近锚端等，以实现对索力和温度等参数的检测。但是，对于传统的局部埋植法，一般是将传感器直接粘接或机械连接到钢丝上，传感器的寿命较低，不能实现缆索状态全寿命监测。Considering the various processes of cable manufacturing, the sensor can be embedded in the cable in two forms: the overall laying method and the partial implanting method. The overall method is to encapsulate the sensor in an appropriate structural form, make it into a cable structure, participate in each process of the cable manufacturing together with the steel wire, and integrate with the steel wire twist and anchor, and obtain the overall deformation of the cable through the output of the sensor. The local implantation method is to implant the sensor in the local position of the cable, such as near the anchor end, etc., to realize the detection of parameters such as cable force and temperature. However, for the traditional local implantation method, the sensor is generally directly bonded or mechanically connected to the steel wire, and the life of the sensor is relatively low, and the full-life monitoring of the cable status cannot be realized.

发明内容SUMMARY OF THE INVENTION

基于此，有必要针对传统的局部埋植法，传感器的寿命较低，不能实现缆索状态全寿命监测的问题，提供一种内置传感器的智能缆索及传感器封装方法。Based on this, it is necessary to provide a smart cable with built-in sensor and a sensor packaging method to solve the problem that the traditional local implantation method has a low sensor life and cannot realize the full-life monitoring of the cable state.

一种内置传感器的智能缆索，包括：A smart cable with built-in sensors that includes:

缆索，所述缆索的端部部分剥除外壳，以显露所述缆索内的钢丝；a cable, the ends of which are partially stripped of the sheath to reveal the wires within the cable;

金属材料制作的基底，焊接固定在所述钢丝上；及A base made of metallic material, welded and fixed to the steel wire; and

表面金属化的传感器，焊接固定在所述基底上，所述传感器的测量方向与所述缆索的轴向方向相同。The surface metallized sensor is welded and fixed on the base, and the measurement direction of the sensor is the same as the axial direction of the cable.

在其中一个实施例中，所述基底为矩形，所述基底沿其短边弯曲成弧形，且该弧形的半径与所述钢丝的半径相同。In one embodiment, the base is rectangular, the base is curved along its short side into an arc, and the radius of the arc is the same as the radius of the steel wire.

在其中一个实施例中，所述基底的端面设有向内凸出的插块，所述插块插入到钢丝束之间的间隙内。In one of the embodiments, the end surface of the base is provided with an inwardly protruding insert block, and the insert block is inserted into the gap between the wire bundles.

在其中一个实施例中，还包括柔性的金属插条，所述金属插条设置于钢丝束的间隙内，并沿着钢丝束的间隙变形延伸，所述金属插条位于基底两端的插块之间。In one of the embodiments, it also includes flexible metal inserts, the metal inserts are arranged in the gaps of the steel wire bundles and extend along the gaps of the steel wire bundles, the metal inserts are located between the insert blocks at both ends of the base between.

在其中一个实施例中，所述基底上开设有多排焊接孔，且每排的所述焊接孔沿所述缆索的轴向方向间隔设置，所述传感器的两侧均布置有至少一排所述焊接孔。In one embodiment, the base is provided with a plurality of rows of welding holes, and the welding holes of each row are arranged at intervals along the axial direction of the cable, and at least one row of the welding holes is arranged on both sides of the sensor. the welding hole.

在其中一个实施例中，所述基底的外表面设有定位凸块，所述定位凸块沿所述缆索的轴向方向延伸，所述传感器的表面设有与所述定位凸块配合的定位槽。In one embodiment, the outer surface of the base is provided with positioning bumps, the positioning bumps extend along the axial direction of the cable, and the surface of the sensor is provided with positioning bumps that cooperate with the positioning bumps groove.

一种传感器封装方法，利用上述任意一项所述的内置传感器的智能缆索，其特征在于，包括以下步骤：A sensor packaging method, using any of the above-mentioned smart cables with built-in sensors, characterized in that it includes the following steps:

对传感器进行表面金属化处理；Surface metallization of the sensor;

将传感器焊接到金属材料制成的基底上；Weld the sensor to the base made of metal material;

使传感器的测量方向与缆索的轴向方向相同，然后将基底焊接固定在缆索外露的钢丝上；Make the measurement direction of the sensor the same as the axial direction of the cable, and then weld the base to the exposed steel wire of the cable;

对传感器的外露部分、基底和钢丝进行防腐。Protect the exposed parts of the sensor, substrate and wires from corrosion.

在其中一个实施例中，所述对传感器进行表面金属化处理的步骤具体为：In one of the embodiments, the step of performing surface metallization on the sensor is specifically:

对传感器的表面进行预处理，然后在传感器的表面化学镀镍。The surface of the sensor is pretreated, and then electroless nickel is plated on the surface of the sensor.

在其中一个实施例中，将基底焊接固定在缆索外露的钢丝上的步骤具体为：In one of the embodiments, the step of welding and fixing the base on the exposed steel wire of the cable is as follows:

将柔性的金属插条插入到钢丝束的间隙内，且使金属插条沿着钢丝束的间隙变形延伸；Insert the flexible metal insert into the gap of the wire bundle, and deform and extend the metal insert along the gap of the wire bundle;

将基底的插块对准钢丝束的间隙，然后将基底贴合到钢丝上，并将金属插条固定在基底两端的插块之间；Align the inserts of the base with the gap between the wire bundles, then fit the base to the steel wire, and fix the metal inserts between the inserts at both ends of the base;

将基底的周缘与钢丝焊接，然后通过焊接孔点焊固定基底。Weld the perimeter of the base with the steel wire, and then spot-weld the base through the welding hole.

在其中一个实施例中，所述将基底焊接固定在钢丝上的步骤具体为：In one of the embodiments, the step of welding and fixing the base on the steel wire is specifically:

采用低温钎料焊接或者焊机，将所述基底焊接固定在所述钢丝上。The base is welded and fixed on the steel wire by using low temperature brazing filler metal or welding machine.

上述内置传感器的智能缆索及传感器封装方法至少具有以下优点：The above-mentioned smart cable with built-in sensor and the sensor packaging method have at least the following advantages:

将传感器表面金属化后，金属化的传感器焊接在基底上，基底焊接在钢丝上，从而可以将传感器封装在缆索内，较传统的粘接和机械连接方式，传感器不直接固定到钢丝上，且传感器采用无胶封装，焊接固定稳定，可以大幅度提高传感器的耐疲劳性能和耐腐蚀性能，显著增加传感器的使用寿命，实现对缆索状态的全寿命监测。同时，仅剥除缆索的部分外壳，而不破坏钢丝本身的结构，不会降低缆索的寿命。After metallizing the surface of the sensor, the metallized sensor is welded to the substrate, and the substrate is welded to the steel wire, so that the sensor can be encapsulated in the cable. Compared with the traditional bonding and mechanical connection methods, the sensor is not directly fixed to the steel wire, and The sensor is packaged without glue, and the welding is stable, which can greatly improve the fatigue resistance and corrosion resistance of the sensor, significantly increase the service life of the sensor, and realize the full-life monitoring of the cable status. At the same time, only part of the outer casing of the cable is stripped, without destroying the structure of the wire itself, and without reducing the life of the cable.

附图说明Description of drawings

图1为一实施方式中内置传感器的智能缆索的结构示意图；FIG. 1 is a schematic structural diagram of a smart cable with built-in sensors in one embodiment;

图2为图1中基底的左视图；Fig. 2 is the left side view of the base in Fig. 1;

图3为一实施方式中金属插条的结构示意图；3 is a schematic structural diagram of a metal insert in an embodiment;

图4为图3中的金属插条填充于基底和钢丝束之间的结构示意图；Fig. 4 is the structural representation that the metal insert in Fig. 3 is filled between the base and the steel wire bundle;

图5为图1中基底的表面开设焊接孔的结构示意图；Fig. 5 is the structural representation that the surface of the base in Fig. 1 is provided with welding holes;

图6为一实施方式中传感器封装方法的流程图。FIG. 6 is a flowchart of a sensor packaging method in one embodiment.

具体实施方式Detailed ways

为使本发明的上述目的、特征和优点能够更加明显易懂，下面结合附图对本发明的具体实施方式做详细的说明。在下面的描述中阐述了很多具体细节以便于充分理解本发明。但是本发明能够以很多不同于在此描述的其它方式来实施，本领域技术人员可以在不违背本发明内涵的情况下做类似改进，因此发明不受下面公开的具体实施的限制。In order to make the above objects, features and advantages of the present invention more clearly understood, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, the present invention can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without departing from the connotation of the present invention, so the invention is not limited by the specific implementation disclosed below.

需要说明的是，当元件被称为“固定于”另一个元件，它可以直接在另一个元件上或者也可以存在居中的元件。当一个元件被认为是“连接”另一个元件，它可以是直接连接到另一个元件或者可能同时存在居中元件。本文所使用的术语“垂直的”、“水平的”、“左”、“右”以及类似的表述只是为了说明的目的，并不表示是唯一的实施方式。It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for the purpose of illustration only and do not represent the only embodiment.

除非另有定义，本文所使用的所有的技术和科学术语与属于本发明的技术领域的技术人员通常理解的含义相同。本文中在本发明的说明书中所使用的术语只是为了描述具体的实施例的目的，不是旨在于限制本发明。Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terms used herein in the description of the present invention are for the purpose of describing specific embodiments only, and are not intended to limit the present invention.

请参阅图1，一实施方式中的内置传感器的智能缆索，包括缆索12、金属材料制成的基底14及表面金属化的传感器16。Referring to FIG. 1 , a smart cable with a built-in sensor in an embodiment includes acable 12 , asubstrate 14 made of a metal material, and asensor 16 with a metallized surface.

缆索12包括钢丝绳和外壳，外壳套设在钢丝绳外，外壳用于保护钢丝绳。缆索12的端部部分剥除外壳，可以显露缆索12内的钢丝。一实施方式中，外壳为PE(Polyethylenepipe，聚乙烯塑料)制成。Thecable 12 includes a wire rope and a casing, the casing is sleeved on the wire rope, and the casing is used to protect the wire rope. The end portion of thecable 12 is partially stripped of the sheath to reveal the wires within thecable 12 . In one embodiment, the outer shell is made of PE (Polyethylenepipe, polyethylene plastic).

基底14由金属材料制成，基底14焊接固定在缆索12外露的钢丝上。一实施方式中，基底14为不锈钢板或镍基合金板。基底14为矩形，且基底14的长边与缆索12的轴向方向一致。基底14沿其短边弯曲成弧形，且基底14弯曲弧形的半径与钢丝的半径相同，以保证基底14与钢丝相贴合，保证基底14焊接后的稳固。Thebase 14 is made of metal material, and thebase 14 is welded and fixed on the exposed steel wire of thecable 12 . In one embodiment, thebase 14 is a stainless steel plate or a nickel-based alloy plate. Thebase 14 is rectangular, and the long sides of thebase 14 are aligned with the axial direction of thecable 12 . Thebase 14 is bent into an arc along its short side, and the radius of the curved arc of thebase 14 is the same as the radius of the steel wire, so as to ensure that thebase 14 is attached to the steel wire and thebase 14 is stable after welding.

请参阅图2至图4，一实施方式中，基底14的端面设有向内凸出的插块142，插块142与基底14的端面平齐，插块142沿基底14的径向方向延伸突出基底14的内壁，基底14的两端均设有插块142，插块142的形状与钢丝束122之间的间隙适配。基底14贴合到钢丝上时，插块142插入到钢丝束122之间的间隙内，基底14与钢丝之间相互咬合，基底14的周缘和钢丝束122之间的间隙较小，能够避免焊接过程中过多的熔融钢丝，破坏钢丝本身的结构，同时能够保证基底14焊接固定在钢丝上的稳定。Referring to FIGS. 2 to 4 , in one embodiment, the end surface of thebase 14 is provided with an inwardly protrudinginsert block 142 , theinsert block 142 is flush with the end surface of thebase 14 , and theinsert block 142 extends along the radial direction of thebase 14 . Protruding from the inner wall of thebase 14 , both ends of the base 14 are provided with insert blocks 142 , and the shape of the insert blocks 142 is adapted to the gap between the wire bundles 122 . When thebase 14 is attached to the steel wire, theinsert block 142 is inserted into the gap between the steel wire bundles 122, thebase 14 and the steel wire are engaged with each other, and the gap between the periphery of thebase 14 and thesteel wire bundle 122 is small, which can avoid welding Excessive molten steel wire in the process will destroy the structure of the steel wire itself, and at the same time, the stability of the welding and fixing of the base 14 on the steel wire can be ensured.

在上述实施方式的基础上，进一步地，内置传感器16的智能缆索12还包括柔性的金属插条18，金属插条18设置于钢丝束122之间的间隙内。柔性的金属插条18能够变形，因此可以沿着钢丝束122之间的间隙变形延伸。金属插条18设置于钢丝束122之间的间隙内后，金属插条18的表面与钢丝表面相切同圆。金属插条18位于基底14的覆盖区域内，且金属插条18固定在基底14两端的插块142之间。一实施方式中，金属插条18可以为铁金属制成，细长的铁制插条能够在外力的作用下变形沿着钢丝束122的间隙延伸。On the basis of the above embodiment, further, thesmart cable 12 with the built-insensor 16 further includes aflexible metal insert 18 , and themetal insert 18 is arranged in the gap between the wire bundles 122 . The flexible metal inserts 18 are deformable and thus extend along the gaps between the wire bundles 122. After the metal inserts 18 are arranged in the gaps between the wire bundles 122, the surface of the metal inserts 18 is tangent to the surface of the steel wires and is in the same circle. The metal inserts 18 are located in the coverage area of thebase 14 , and the metal inserts 18 are fixed between the insert blocks 142 at both ends of thebase 14 . In one embodiment, the metal inserts 18 may be made of iron metal, and the elongated iron inserts can be deformed under the action of external force and extend along the gaps of the steel wire bundles 122 .

请参阅图5，基底14的表面开设有多排焊接孔144，且每排的焊接孔144沿缆索12的轴向方向间隔布置。将基底14焊接到固定到钢丝上时，可以先将基底14的周缘与钢丝焊接，初步固定基底14，然后通过焊接孔144进行点焊，点焊的过程中能够熔融金属插条18，熔融的金属插条18填充满基底14内壁和钢丝束122之间的间隙，实现将基底14的内壁与钢丝焊接。基底14通过多个焊接点与钢丝焊接，基底14表面均匀受力，能够使钢丝的应力应变均匀传递到基底14上，保证传感器16监测数据的准确。Referring to FIG. 5 , a plurality of rows ofwelding holes 144 are formed on the surface of thebase 14 , and the welding holes 144 of each row are arranged at intervals along the axial direction of thecable 12 . When thebase 14 is welded to the steel wire, the periphery of the base 14 can be welded to the steel wire to initially fix thebase 14, and then spot welding is performed through thewelding hole 144. During the spot welding process, themetal insert 18 can be melted, and the molten Themetal insert 18 fills the gap between the inner wall of thebase 14 and thesteel wire bundle 122, so as to realize the welding of the inner wall of thebase 14 and the steel wire. Thebase 14 is welded to the steel wire through a plurality of welding points, and the surface of thebase 14 is uniformly stressed, so that the stress and strain of the steel wire can be uniformly transmitted to thebase 14, so as to ensure the accuracy of the monitoring data of thesensor 16.

传感器16的表面金属化后，传感器16焊接于基底14上，传感器16的测量方向与缆索12的轴向方向相同，以使传感器16能够监测缆索12的状态。传感器16的表面金属化处理，可以通过在传感器16的表面镀设金属材料，如采用化学镀的方式镀设一层金属。After the surface of thesensor 16 is metallized, thesensor 16 is welded to thesubstrate 14, and the measurement direction of thesensor 16 is the same as the axial direction of thecable 12, so that thesensor 16 can monitor the state of thecable 12. The surface metallization of thesensor 16 can be performed by plating a metal material on the surface of thesensor 16, such as plating a layer of metal by means of electroless plating.

一实施方式中，基底14的外表面设有定位凸块(图未示)，定位凸块沿缆索12的轴向方向方向延伸，传感器16的表面设有定位槽，定位槽与定位凸块插接配合，能够保证传感器16的测量方向与缆索12的轴向方向相同，保证传感器16测量的准确。一实施方式中，传感器16为光纤光栅应变传感器。传感器16表面的定位槽可以在传感器16表面金属化时形成。In one embodiment, the outer surface of thebase 14 is provided with positioning protrusions (not shown), the positioning protrusions extend along the axial direction of thecable 12 , the surface of thesensor 16 is provided with positioning grooves, and the positioning grooves are inserted into the positioning protrusions. The connection and cooperation can ensure that the measurement direction of thesensor 16 is the same as the axial direction of thecable 12 , thereby ensuring the accuracy of the measurement of thesensor 16 . In one embodiment, thesensor 16 is a fiber grating strain sensor. The locating grooves on the surface of thesensor 16 may be formed when the surface of thesensor 16 is metallized.

请参阅图6，本发明还提供一种传感器封装方法，为实现该封装方法，其采用上述内置传感器的智能缆索。具体地，该封装方法包括如下步骤：Referring to FIG. 6 , the present invention further provides a sensor packaging method. To implement the packaging method, the above-mentioned smart cable with built-in sensor is used. Specifically, the packaging method includes the following steps:

步骤S110：对传感器16进行表面金属化处理。Step S110 : performing surface metallization treatment on thesensor 16 .

对传感器16表面进行金属化处理，可以在传感器16的表面镀设金属材料。具体地，对传感器16进行表面金属化处理的步骤具体为：对传感器16的表面进行预处理，然后在传感器16的表面化学镀镍。对传感器16的表面进行预处理，可以提高传感器16表面的镀层质量。一实施方式中，传感器16为光纤光栅应变传感器。对传感器16的表面进行预处理的步骤具体为：对传感器16的表面进行碱洗、水洗、粗化、热处理、活化及解胶。The surface of thesensor 16 is metallized, and a metal material can be plated on the surface of thesensor 16 . Specifically, the step of performing the surface metallization treatment on thesensor 16 is as follows: pretreating the surface of thesensor 16 , and then electroless nickel plating on the surface of thesensor 16 . Preprocessing the surface of thesensor 16 can improve the quality of the coating on the surface of thesensor 16 . In one embodiment, thesensor 16 is a fiber grating strain sensor. The steps of pretreating the surface of thesensor 16 are specifically: performing alkaline washing, water washing, roughening, heat treatment, activation and debonding on the surface of thesensor 16 .

一实施方式中，在上述步骤S110之前，上述方法还包括：缆索12挤塑形成外壳后，安装分丝板，将缆索12的端部插入到锚具的套筒内，然后进行灌锚，最后将缆索12位于套筒内的部分外壳剥除，以显露缆索12内的钢丝，便于后续传感器16的封装。In one embodiment, before the above step S110, the above method further includes: after thecable 12 is extruded to form the shell, installing a wire splitter, inserting the end of thecable 12 into the sleeve of the anchor, then performing anchoring, and finally The part of the outer casing of thecable 12 inside the sleeve is stripped off to expose the steel wire in thecable 12 to facilitate subsequent packaging of thesensor 16 .

步骤S120：将传感器16焊接到金属材料制成的基底14上。Step S120: Weld thesensor 16 to the base 14 made of metal material.

具体地，基底14材料为不锈钢板或镍基合金薄板。将传感器16的定位槽与定位凸起插接，实现将传感器16安装到基底14上，且能够使传感器16的测量方向与基底14的长边方向相同。传感器16安装后，传感器16的两侧均具有至少一排焊接孔144。一实施方式中，传感器16的两侧均具有两排焊接孔144，且传感器16同一侧的两排焊接孔144相互错位设置。最后将传感器16焊接到基底14上，从而将传感器16和基底14固定为一个整体。Specifically, the material of thebase 14 is a stainless steel plate or a nickel-based alloy thin plate. By inserting the positioning groove of thesensor 16 with the positioning protrusion, thesensor 16 is installed on thebase 14 , and the measurement direction of thesensor 16 can be the same as the longitudinal direction of thebase 14 . After thesensor 16 is installed, both sides of thesensor 16 have at least one row of welding holes 144 . In one embodiment, both sides of thesensor 16 are provided with two rows ofwelding holes 144 , and the two rows of welding holes 144 on the same side of thesensor 16 are arranged in a mutually staggered manner. Finally, thesensor 16 is welded to thesubstrate 14, thereby fixing thesensor 16 and thesubstrate 14 as a whole.

步骤S130：使传感器16的测量方向与缆索12的轴向方向相同，然后将基底14焊接固定在缆索12外露的钢丝上。Step S130 : the measurement direction of thesensor 16 is the same as the axial direction of thecable 12 , and then thebase 14 is welded and fixed on the exposed steel wire of thecable 12 .

具体地，基底14为矩形，且基底14的长边与缆索12的轴向方向一致，从而实现将传感器16的测量方向与缆索12的轴向方向相同。基底14沿其短边弯曲成弧形，且基底14弯曲弧形的半径与钢丝的半径相同，以保证基底14与钢丝相贴合，保证基底14焊接后的稳固。基底14焊接在钢丝可以采用低温钎料焊接，或者使用焊机直接焊接。Specifically, thebase 14 is rectangular, and the long side of thebase 14 is consistent with the axial direction of thecable 12 , so that the measurement direction of thesensor 16 is the same as the axial direction of thecable 12 . Thebase 14 is bent into an arc along its short side, and the radius of the curved arc of thebase 14 is the same as the radius of the steel wire, so as to ensure that thebase 14 is attached to the steel wire and thebase 14 is stable after welding. The base 14 can be welded to the steel wire by using low temperature solder, or directly welded by a welding machine.

一实施方式中，将基底14焊接固定在缆索12外露的钢丝上的步骤具体为：将柔性的金属插条18插入到钢丝束122的间隙内，且使金属插条18沿着钢丝束122的间隙变形延伸。将基底14一端的插块142对准钢丝束122的间隙，然后将基底14旋转贴合到钢丝上，金属插条18被基底14遮挡覆盖，且金属插条18固定在基底14两端的插块142之间。最后将基底14的周缘与钢丝焊接，初步将基底14固定，然后通过焊接孔144点焊固定基底14。基底14通过多个焊接点与钢丝连接，基底14表面均匀受力，能够使钢丝的应力应变均匀传递到基底14上，进而保证传感器16监测数据的准确。In one embodiment, the step of welding and fixing the base 14 on the exposed wires of thecable 12 is as follows: inserting the flexible metal inserts 18 into the gaps of the steel wire bundles 122 , and making the metal inserts 18 along the wires of the steel wire bundles 122 Gap deformation extension. Align theinsert block 142 at one end of the base 14 with the gap between the wire bundles 122, and then rotate the base 14 to fit the steel wire, themetal insert 18 is covered and covered by thebase 14, and themetal insert 18 is fixed to the insert blocks at both ends of the base 14 between 142. Finally, the peripheral edge of thebase 14 is welded with the steel wire, thebase 14 is initially fixed, and then thebase 14 is fixed by spot welding through thewelding hole 144 . Thebase 14 is connected to the steel wire through a plurality of welding points, and the surface of thebase 14 is uniformly stressed, so that the stress and strain of the steel wire can be uniformly transmitted to thebase 14, thereby ensuring the accuracy of the monitoring data of thesensor 16.

步骤S140：对传感器16的外露部分、基底14和钢丝进行防腐。Step S140: Anticorrosion is performed on the exposed part of thesensor 16, thesubstrate 14 and the steel wire.

具体地，在基底14与缆索12钢丝之间进行焊接后，完成传感器16的封装，然后对传感器16的外露部分、基底14和钢丝进行防腐，可以避免传感器16、基底14和钢丝被腐蚀，提高传感器16的使用寿命。一实施方式中，可以在传感器16外露部分、基底14和钢丝上涂覆黄油等防腐材料进行防腐。Specifically, after welding between the base 14 and the steel wire of thecable 12, the encapsulation of thesensor 16 is completed, and then the exposed part of thesensor 16, thebase 14 and the steel wire are anti-corrosion, which can prevent thesensor 16, thebase 14 and the steel wire from being corroded. Service life ofsensor 16 . In one embodiment, the exposed part of thesensor 16 , thesubstrate 14 and the steel wire can be coated with anti-corrosion materials such as butter for anti-corrosion.

一实施方式中，在上述步骤S140之后，上述方法还包括：在套筒内灌注密封膏。在传感器16固定到钢丝上后，即可进行缆索12生产的后续操作，最后在套筒内灌注密封膏，可以起到对传感器16及引线162进行保护的作用。In one embodiment, after the above step S140, the above method further includes: pouring sealing paste into the sleeve. After thesensor 16 is fixed on the steel wire, the subsequent operations for the production of thecable 12 can be performed, and finally, the sealing paste is poured into the sleeve, which can protect thesensor 16 and thelead 162 .

上述内置传感器的智能缆索及传感器封装方法，将传感器16金属化后，金属化的传感器16焊接在基底14上，基底14焊接在钢丝上，从而可以将传感器16封装在缆索12内，较传统的粘接和机械连接方式，传感器16不直接固定到钢丝上，且传感器16采用无胶封装，焊接固定稳定，可以大幅度提高传感器16的耐疲劳性能和耐腐蚀性能，显著增加传感器16的使用寿命，实现对缆索12状态的全寿命监测。同时，仅剥除缆索12的部分外壳，而不破坏钢丝本身的结构，不会降低缆索12的寿命。基底14通过多个焊接点与钢丝连接，基底14表面均匀受力，能够使钢丝的应力应变均匀传递到基底14上，进而保证传感器16监测数据的准确。In the above-mentioned smart cable with built-in sensor and sensor packaging method, after thesensor 16 is metallized, the metallizedsensor 16 is welded on thebase 14, and thebase 14 is welded on the steel wire, so that thesensor 16 can be packaged in thecable 12. Adhesion and mechanical connection method, thesensor 16 is not directly fixed to the steel wire, and thesensor 16 is packaged without glue, and the welding and fixing are stable, which can greatly improve the fatigue resistance and corrosion resistance of thesensor 16, and significantly increase the service life of thesensor 16 , to realize the full-life monitoring of the state of thecable 12 . At the same time, only part of the outer casing of thecable 12 is stripped off, without destroying the structure of the wire itself, and without reducing the life of thecable 12 . Thebase 14 is connected to the steel wire through a plurality of welding points, and the surface of thebase 14 is uniformly stressed, so that the stress and strain of the steel wire can be uniformly transmitted to thebase 14, thereby ensuring the accuracy of the monitoring data of thesensor 16.

以上所述实施例的各技术特征可以进行任意的组合，为使描述简洁，未对上述实施例中的各个技术特征所有可能的组合都进行描述，然而，只要这些技术特征的组合不存在矛盾，都应当认为是本说明书记载的范围。The technical features of the above-described embodiments can be combined arbitrarily. For the sake of brevity, all possible combinations of the technical features in the above-described embodiments are not described. However, as long as there is no contradiction between the combinations of these technical features, All should be regarded as the scope described in this specification.

以上所述实施例仅表达了本发明的几种实施方式，其描述较为具体和详细，但并不能因此而理解为对发明专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。因此，本发明专利的保护范围应以所附权利要求为准。The above-mentioned embodiments only represent several embodiments of the present invention, and the descriptions thereof are specific and detailed, but should not be construed as a limitation on the scope of the invention patent. It should be pointed out that for those of ordinary skill in the art, without departing from the concept of the present invention, several modifications and improvements can also be made, which all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention should be subject to the appended claims.

Claims (10)

1. A smart cable with built-in sensors, comprising:

a cable having an end portion stripped of a shell to reveal a wire within the cable;

the substrate made of metal materials is welded and fixed on the steel wire; and

and the surface metalized sensor is welded and fixed on the substrate, and the measuring direction of the sensor is the same as the axial direction of the cable.

2. A smart cable with built-in sensor as claimed in claim 1, characterized in that the base is rectangular, the base is curved along its short sides into an arc with the same radius as the steel wire.

3. A smart cable with built-in sensor as claimed in claim 2, wherein the end face of the base is provided with inwardly projecting inserts which are inserted into the gaps between the wire bundles.

4. The smart cable with built-in sensor as claimed in claim 3, further comprising a flexible metal insert disposed in and deformed along the gap of the steel wire bundle, the metal insert being located between the inserts at both ends of the base.

5. The intelligent cable with built-in sensor as claimed in claim 4, wherein a plurality of rows of welding holes are formed in the base, the welding holes in each row are spaced apart along the axial direction of the cable, and at least one row of welding holes is formed on each of two sides of the sensor.

6. A smart cable with built-in sensor as claimed in claim 1, characterized in that the outer surface of the base is provided with a positioning projection extending in the axial direction of the cable, and the surface of the sensor is provided with a positioning groove cooperating with the positioning projection.

7. A method of packaging a sensor using a smart cable with built-in sensor as claimed in any one of claims 1 to 6, comprising the steps of:

carrying out surface metallization treatment on the sensor;

welding the sensor to a substrate made of a metal material;

enabling the measuring direction of the sensor to be the same as the axial direction of the cable, and then welding and fixing the substrate on the exposed steel wire of the cable;

the exposed portion of the sensor, the substrate and the steel wire are protected from corrosion.

8. The method for packaging a sensor according to claim 7, wherein the step of performing surface metallization on the sensor specifically comprises:

the surface of the sensor is pretreated and then chemically plated with nickel on the surface of the sensor.

9. The method for packaging a sensor according to claim 7, wherein the step of solder-fixing the substrate to the exposed steel wire of the cable is embodied as follows:

inserting a flexible metal slip into the gap of the steel wire bundle, and enabling the metal slip to deform and extend along the gap of the steel wire bundle;

aligning the insertion blocks of the substrate to the gaps of the steel wire bundles, then attaching the substrate to the steel wires, and fixing the metal insertion strips between the insertion blocks at the two ends of the substrate;

the periphery of the base is welded to the steel wire, and then the base is fixed by spot welding through the welding hole.

10. The method for packaging a sensor according to claim 7, wherein the step of solder-fixing the substrate to the steel wire is specifically as follows:

and welding and fixing the substrate on the steel wire by adopting low-temperature brazing filler metal welding or a welding machine.

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