GB2619560A - Rapidly deployable strain gauge based monitoring system - Google Patents
Rapidly deployable strain gauge based monitoring system Download PDFInfo
- Publication number
- GB2619560A GB2619560A GB2208537.7A GB202208537A GB2619560A GB 2619560 A GB2619560 A GB 2619560A GB 202208537 A GB202208537 A GB 202208537A GB 2619560 A GB2619560 A GB 2619560A
- Authority
- GB
- United Kingdom
- Prior art keywords
- strain gauge
- monitoring system
- based monitoring
- rapidly deployable
- electronics
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000012544 monitoring process Methods 0.000 title claims abstract description 55
- 239000000463 material Substances 0.000 claims abstract description 19
- 238000012546 transfer Methods 0.000 claims abstract description 7
- 230000003321 amplification Effects 0.000 claims abstract description 4
- 238000003199 nucleic acid amplification method Methods 0.000 claims abstract description 4
- 238000005259 measurement Methods 0.000 claims description 9
- 230000036316 preload Effects 0.000 claims description 7
- 239000000853 adhesive Substances 0.000 claims description 6
- 230000001070 adhesive effect Effects 0.000 claims description 6
- 230000006854 communication Effects 0.000 claims description 4
- 238000004891 communication Methods 0.000 claims description 4
- 230000005355 Hall effect Effects 0.000 claims description 3
- 239000011152 fibreglass Substances 0.000 claims description 3
- 239000006260 foam Substances 0.000 claims description 3
- 230000002618 waking effect Effects 0.000 claims description 3
- 210000004128 D cell Anatomy 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical group [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- 239000004411 aluminium Substances 0.000 claims description 2
- 238000001514 detection method Methods 0.000 claims description 2
- 238000012800 visualization Methods 0.000 claims 1
- 238000009434 installation Methods 0.000 abstract description 6
- 230000007175 bidirectional communication Effects 0.000 abstract description 3
- 238000006243 chemical reaction Methods 0.000 abstract description 3
- 238000012545 processing Methods 0.000 abstract description 3
- 238000005516 engineering process Methods 0.000 abstract description 2
- 239000011159 matrix material Substances 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 238000004026 adhesive bonding Methods 0.000 description 1
- 239000012790 adhesive layer Substances 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000005538 encapsulation Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 238000003306 harvesting Methods 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- 238000011900 installation process Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 239000008259 solid foam Substances 0.000 description 1
- 238000010561 standard procedure Methods 0.000 description 1
- 239000013077 target material Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
Classifications
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
- G01B7/16—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring the deformation in a solid, e.g. by resistance strain gauge
- G01B7/18—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring the deformation in a solid, e.g. by resistance strain gauge using change in resistance
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
- G01B7/16—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring the deformation in a solid, e.g. by resistance strain gauge
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B2210/00—Aspects not specifically covered by any group under G01B, e.g. of wheel alignment, caliper-like sensors
- G01B2210/58—Wireless transmission of information between a sensor or probe and a control or evaluation unit
Landscapes
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Measurement Of Length, Angles, Or The Like Using Electric Or Magnetic Means (AREA)
- Arrangements For Transmission Of Measured Signals (AREA)
Abstract
The strain gauge is pre-wired, preloaded by a flexible material 1c and interfaced with electronics 1i for monitoring of strain. The apparatus enables rapid installation of strain-gauge technology, by both skilled and non-skilled personnel, due to the interconnection and pre-loading arrangement. The electronics contained within the apparatus are used for signal amplification, conversion to of the signal from analogue to digital, and wireless data transfer. The apparatus features a microprocessor for on-device processing of signals (to minimise the size of data files being stored and/or wirelessly transmitted) as well as bi-directional communication to facilitate adjustment of configuration parameters.
Description
Rapidly Deployable Strain Gauge Based Monitoring System
Technical Field
The present invention relates to a strain gauge which is pre-wired and interfaced with electronics for monitoring of strain on industrial assets. The invention enables rapid installation of strain-gauge technology, by both skilled and non-skilled personnel, due to a novel interconnection and pre-loading arrangement.
The electronics contained within the devices are used for signal amplification, conversion of the signal from analogue to digital, and wireless data transfer. The device features a microprocessor for on-device processing of signals (to minimise the size of data files being stored and/or wirelessly transmitted) as well as bi-directional communication to facilitate the adjustment of configuration parameters.
Background
Strain gauge sensors are one of the most commonly used sensors to measure the strain due to an applied load. The electrical properties of the strain gauge are such that its electrical resistance varies in proportion to the amount of strain induced in the body. This change in the electrical resistance can be directly equated to the amount of stress induced in a body and perform structural health monitoring and experimental stress analysis.
The most common type of strain gauge sensor consists of a thin metallic track which is laminated onto an insulating backing material or carrier matrix. The carrier matrix ads as the bonding surface between the metallic track and the test specimen. The carrier matrix and the bonding adhesive must work together to transmit strain from the specimen to the foil.
Strain gauges can be set up in various configurations to measure strain in a specimen. Most common configurations include the full Wheatstone bridge, half-bridge, and quarter-bridge.
These configurations can be used to measure axial strain, shear strain, bending strain, and torsional strain.
Despite their effectiveness in many applications, strain gauges require a very specific installation process which can be a drawback. Typical strain gauge installation requires a trained technician to follow intricate and time-consuming procedures. Most installations generally follow standard procedures which include: 1. Surface preparation 2. Gauge position marking 3. Preparing gauge for bonding 4. Gauge gluing 5. Preload and adhesive curing 6. Soldering lead wires 7. Gauge protection 8. Mounting data logging or telemetry instrumentation 9. Wring gauge to data logging instrumentation 10. Wire protection and encapsulation 11. Bridge balancing Whilst with proper care and attention, strain gauges can be installed to a high standard, these installations are usually done by trained technicians and can be an expensive and time-consuming task.
It is the aim of embodiments of the invention to address these drawbacks.
Summary of Invention
In accordance with a first aspect of the invention, there is provided a rapidly deployable strain gauge-based monitoring system for monitoring of strain on industrial assets. The rapidly deployable strain gauge-based monitoring system comprises of a pre-wired strain gauge system which is mounted on a compressible material to provide the necessary preload for the strain gauge adhesive to set. The device may utilise magnets to pre-load compressive material and strain gauge.
The said strain gauge system is connected to a self-contained electronics system which is powered by an integrated battery. The electronics contained within the devices are used for signal amplification, filtering, conversion to of the signal from analogue to digital, and wireless data transfer to a transceiver. The device features a microprocessor for on-device processing of signals (to minimise the size of data files being stored and/or wirelessly transmitted) as well as bi-directional communication to facilitate both data transfer and adjustment of configuration parameters. Additionally, the electronics contain sleep mode functionality which can be manually or autonomously adjusted using programmed intelligence for conservation of battery life.
The said electronics system comprises a temperature sensor mounted in proximity to the parent material to which the gauge is adhered, to monitor the operating temperature of the asset. The said electronics system also comprises of one or more tri-axial accelerometers and a tri-axial gyroscope to measure the vibrations and rate of rotation of the system.
Where the device is to be fitted onto a curved surface, such as a shaft, adaptor feet may be changed to suit a particular surface profile.
Optionally, the physical geometry of the strain gauge may vary depending on the type of measurement output required.
Optionally, the said strain gauge is a full-bridge rosette strain gauge for measuring torque.
Optionally, the instrumentation electronics may be configured in full-bridge, half-bridge, or quarter-bridge configurations depending on the type of measurement output required.
Optionally, the method of interconnecting the strain gauge to the instrumentation electronics is through a flexible Printed Circuit Board (PCB).
Optionally, the said instrumentation electronics PCB and strain-gauge interconnection flexible PCB may instead be a single, combined flex-rigid PCB.
Optionally, the said instrumentation electronics PCB is powered by an internal battery.
Optionally, the said instrumentation electronics is powered by energy harvesting or an inductive power supply.
Optionally, the said internal battery is a 1/6 D cell battery.
Optionally, the said main instrumentation electronics PCB is powered by an external source.
Optionally, the compressible preloading material is a type of flexible foam.
Optionally, the device enclosure may contain one or more preloading magnets to compress the said solid foam, which in turn preloads the said strain gauge against the parent material.
Optionally, the said device enclosure may be metallic.
Optionally, the said device enclosure may be made from aluminium.
Optionally, the said device enclosure may contain a Radio-Frequency (RF) transparent window to enable wireless data transfer.
Optionally, the said RF transparent window may be located on the top of the device.
Optionally, the said RF transparent window may be made from Glass Reinforced Plastic (GRP) Optionally, the instrumentation electronics has a temperature sensor.
Optionally, the said temperature sensor is mounted on the flexible PCB near the strain gauge.
Optionally, the instrumentation electronics has bridge auto-balancing functionality for adjusting the zero-load level of the signal.
Optionally, the instrumentation electronics has an adjustable gain setting.
Optionally, the said instrumentation electronics has bridge shunt calibration.
Optionally, the main instrumentation electronics PCB has an accelerometer for monitoring vibrations.
Optionally, the said accelerometer is a tri-axial accelerometer.
Optionally, the main instrumentation electronics PCB has a gyroscope for monitoring the rate of rotation of a rotating body.
Optionally, the said gyroscope is a tri-axial gyroscope.
Optionally, the said instrumentation electronics PCB has a 6-axis Inertial Measurement Unit (IMU) with an integrated tri-axial accelerometer and tri-axial gyroscope.
Optionally, the said adaptor feet may vary depending on the curvature of the surface of the specimen being monitored.
Optionally, the said adaptor feet may be glued to the base of the strain gauge-based monitoring system.
Optionally, the said instrumentation electronics may contain a hall-effect sensor for waking the device using a magnet, or for detection of the speed of rotation.
Optionally, the said instrumentation electronics may contain one or more LEDs.
Optionally, the said instrumentation electronics may contain an RF antenna.
Optionally, the said RF antenna may be a trace embedded on the PCB as a track.
Optionally, the said RF antenna may be an RF chip antenna.
Optionally, the said RF antenna may be Bluetooth or Bluetooth Low Energy (BLE). Brief Description of the Drawings Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings where like parts are provided with corresponding reference numerals and in which: Figure 1 provides a cross-sectional view of a rapidly deployable strain gauge based monitoring system in accordance with certain embodiments of the invention; Figure 2 provides a simplified schematic diagram depicting the lower isometric view of a rapidly deployable strain gauge based monitoring system in accordance with certain embodiments of the invention;
Detailed Description of the Drawings
Figure 1 provides a cross-sectional view of a rapidly deployable strain gauge monitoring system in accordance with certain embodiments of the invention.
Figure 1 shows the rapidly deployable strain gauge based monitoring system comprising of a device enclosure 1a, adaptor feet lb, a compressible preloading material in an uncompressed state lc (i), a compressible preloading material in a compressed state lc (ii), a strain gauge id, a temperature sensor le, a flexible PCB if, an internal battery 1g, a radio-frequency (RF) transparent window lh, and an instrumentation electronics PCB li.
The strain gauge id is glued to the specimen using an adhesive and the preload required for the strain gauge adhesive to set is provided by the compressible preloading material lc. The strain gauge id is mounted on the compressible preloading material lc with the help of an adhesive layer on the compressible preloading material lc.
To provide a fully operational, ready-to-use monitoring system, the strain gauge id is pre-wired directly to the main instrumentation electronics PCB li through a flexible PCB if. The flexible PCB if also comprises of a temperature sensor le which is placed in proximity to the strain gauge to provide temperature compensation if/where required, and to monitor the operating temperature of the target material.
The main instrumentation electronics PCB 1i contains tri-axial accelerometer and tri-axial gyroscope sensors to also monitor the vibrations and rate of rotation of the specimen. The main instrumentation electronics PCB ii contains a hall-effect sensor for waking the electronics from power-saving sleep mode, and an LED which can be used to show the operational state of the device. The main instrumentation electronics PCB li can wirelessly transfer the collected data from strain gauge, accelerometer, and gyroscope sensors to a nearby telemetry device. To allow for wireless communication an RF transparent window 1 h is attached at the top of the enclosure la. The main instrumentation electronics PCB 1i is powered by an internal battery 1g, however, the main instrumentation electronics PCB li can also be powered from an external source.
The adaptor feet lb are designed such that the step can be adjusted to accommodate for various surface curvatures. The adaptor feet lb may be glued to the metallic enclosure la to provide ease of installation.
Figure 2 provides a simplified schematic diagram depicting the lower isometric view of a rapidly deployable strain gauge monitoring system in accordance with certain embodiments of the invention.
Figure 2 shows the rapidly deployable strain gauge-based monitoring system comprising a preloading magnets 2a, adaptor feet 2b, an adjustable step on the adaptor feet 2c, a strain gauge 2d, a compressible preloading material 2e, a flexible PCB 2f, and a device enclosure 2g.
The compressible preloading material 2e provides the preload for the strain gauge to be glued onto the specimen. This preloading force from the compressible preloading material 2e is reacted against by the preloading magnet 2a, which pulls the metallic enclosure 2g towards the specimen and compresses the compressible preloading material, as can be seen in Figure 1 The adjustable feet 2b have an adjustable step 2c, the height of which can be increased or decreased to accommodate for various surface curvatures. This allows the rapidly deployable strain gauge monitoring system to monitor rotating shafts as well as flat surfaces.
Claims (35)
- CLAIMS1. A rapidly deployable strain gauge-based monitoring system for measurement of strain in industrial assets, comprising of a pre-wired strain gauge wherein said strain gauge is mounted on a compressible preloading material which is used to preload the strain gauge during curing of the adhesive, a self-contained instrumentation electronics which is powered by an internal battery which enables measurement of strain, and an in-built wireless communication system which can transmit and receive data from a receiver or transceiver.
- 2. A rapidly deployable strain gauge-based monitoring system according to claim 1, which contains adaptor feet to suit the curvature of the surface of the specimen being monitored.
- 3. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the physical geometry of the strain gauge varies depending on the type of measurement output required.
- 4. A rapidly deployable strain gauge monitoring system according to claim 3, wherein the said strain gauge is set up for measuring torque.
- 5. A rapidly deployable strain gauge monitoring system according to claim 1, wherein the instrumentation electronics configuration varies depending on the type of measurement output required.
- 6. A rapidly deployable strain gauge monitoring system according to claim 5, wherein the instrumentation electronics configuration can be full-bridge, half-bridge or quarter-bridge configurations depending on the type of measurement output required.
- 7. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said strain gauge is pre-soldered on a flexible PCB which is attached to the main electronics PCB.
- 8. A rapidly deployable strain gauge-based monitoring system according to claim 7, wherein the said main electronics PCB is a flex-rigid PCB.
- 9. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the instrumentation electronics is powered by an internal battery.
- 10. A rapidly deployable strain gauge-based monitoring system according to claim 9, wherein the said battery is a 1/6 D cell battery.
- 11. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said instrumentation electronics is powered from an external power source.
- 12. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said compressible preloading material is a type of flexible foam.
- 13. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the device enclosure contains one or more magnets for pre-loading of the foam and/or holding the device to a metallic surface to which the device is fitted.
- 14. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said instrumentation electronics has a temperature sensor mounted on the flexible PCB in proximity to the strain gauge.
- 15. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said instrumentation electronics has bridge auto-balancing functionality for adjusting the zero-load level of the signal.
- 16. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said instrumentation electronics has bridge shunt calibration.
- 17. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said instrumentation electronics has an accelerometer sensor to detect vibrations of the specimen.
- 18. A rapidly deployable strain gauge-based monitoring system according to claim 17, wherein the said accelerometer is a 3-axis combined accelerometer.
- 19. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said instrumentation electronics has a gyroscope sensor to detect the rate of rotation of a shaft or a rotating body.
- 20. A rapidly deployable strain gauge-based monitoring system according to claim 19, wherein the said gyroscope is a 3-axis combined gyroscope.
- 21. A rapidly deployable strain gauge-based monitoring system according to claims 17, 18, 19, and 20, wherein the said instrumentation electronics has a 6-axis Inertial Measurement Unit (IMU) with an integrated 3-axis accelerometer and 3-axis gyroscope.
- 22. A rapidly deployable strain gauge-based monitoring system according to claim 2, wherein the said adaptor feet is glued to the base of the strain gauge-based monitoring system.
- 23. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the device enclosure is metallic.
- 24. A rapidly deployable strain gauge-based monitoring system according to claim 23, wherein the device enclosure is aluminium.
- 25. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said instrumentation electronics has a Radio-Frequency (RF) transparent window to enable wireless data transfer.
- 26. A rapidly deployable strain gauge-based monitoring system according to claim 25, wherein the said Radio-Frequency (RF) transparent window is located on the top of the device.
- 27. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said Radio-Frequency (RF) transparent window is made from Glass Reinforced Plastic (GRP or PCB material).
- 28. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said instrumentation electronics has an adjustable gain setting for amplification of the signals.
- 29. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said instrumentation electronics may contain a hall-effect sensor for waking the device using a magnet, or for detection of the speed of rotation.
- 30. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said instrumentation electronics contains one or more LEDs for visualisation of the operational state of the device.
- 31. A rapidly deployable strain gauge-based monitoring system according to claim 1, wherein the said instrumentation electronics is interconnected with, or contains an RF antenna.
- 32. A rapidly deployable strain gauge-based monitoring system according to claim 31, wherein the said RF antenna is a chip antenna.
- 33. A rapidly deployable strain gauge-based monitoring system according to claim 31, wherein the said RF antenna is a PCB trace with its impedance matched to optimise for RF signal strength.
- 34. A rapidly deployable strain gauge-based monitoring system according to claims 1 and 31, wherein the said wireless communication system and the said RF antenna is Bluetooth frequency.
- 35. A rapidly deployable strain gauge-based monitoring system according to claims 1 and 31, wherein the said wireless communication system and the said RF antenna is W-Fi, Bluetooth, Bluetooth Low Energy (BLE) or Zigbee compatible.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2208537.7A GB2619560A (en) | 2022-06-10 | 2022-06-10 | Rapidly deployable strain gauge based monitoring system |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2208537.7A GB2619560A (en) | 2022-06-10 | 2022-06-10 | Rapidly deployable strain gauge based monitoring system |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB202208537D0 GB202208537D0 (en) | 2022-07-27 |
| GB2619560A true GB2619560A (en) | 2023-12-13 |
Family
ID=82496432
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB2208537.7A Pending GB2619560A (en) | 2022-06-10 | 2022-06-10 | Rapidly deployable strain gauge based monitoring system |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2619560A (en) |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1520061A (en) * | 1975-02-22 | 1978-08-02 | Kyowa Electronic Instruments | Device for detecting strain |
| WO2008134877A1 (en) * | 2007-05-02 | 2008-11-13 | Flexco Industries Inc. | Sensor device to monitor deformation in structural members, such as solid structures |
| US20100162824A1 (en) * | 2008-10-27 | 2010-07-01 | The Regents Of The University Of California | Capacitive strain sensor |
| US20100251834A1 (en) * | 2007-12-27 | 2010-10-07 | Alps Electric Co., Ltd. | Load sensor |
| JP2021067664A (en) * | 2019-10-17 | 2021-04-30 | Tdk株式会社 | Measuring device and measuring system |
-
2022
- 2022-06-10 GB GB2208537.7A patent/GB2619560A/en active Pending
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1520061A (en) * | 1975-02-22 | 1978-08-02 | Kyowa Electronic Instruments | Device for detecting strain |
| WO2008134877A1 (en) * | 2007-05-02 | 2008-11-13 | Flexco Industries Inc. | Sensor device to monitor deformation in structural members, such as solid structures |
| US20100251834A1 (en) * | 2007-12-27 | 2010-10-07 | Alps Electric Co., Ltd. | Load sensor |
| US20100162824A1 (en) * | 2008-10-27 | 2010-07-01 | The Regents Of The University Of California | Capacitive strain sensor |
| JP2021067664A (en) * | 2019-10-17 | 2021-04-30 | Tdk株式会社 | Measuring device and measuring system |
Also Published As
| Publication number | Publication date |
|---|---|
| GB202208537D0 (en) | 2022-07-27 |
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