Search Results (7)

The combine harvester, as a multi-component machine comprising a cutting table, a conveyor, a threshing cylinder, and other components, experiences significant stress and bolt failures in cutting table-conveyor structures due to inherent excitation and the cutting table’s cantilevered design. To address bolt loosening monitoring in the critical joint, this paper designed a Wheatstone bridge circuit-based wireless monitoring system and a multi-channel Wheatstone bridge sensor, enabling multi-bolt monitoring on combine harvesters. Utilizing LoRa wireless communication, the system effectively overcomes the wiring complexity and deployment difficulties of traditional agricultural machinery bolt monitoring systems. The Wheatstone bridge sensor can precisely monitor pre-tightening forces up to 150 kN for M12–M24 bolts. A calibration test based on dynamic time warping (DTW) accurately fitted the sensor’s response to pressure and displacement with determination coefficients of 0.9780 and 0.9753. Then, a validation test focusing on connection bolts revealed a 95.12% overlap between the simulated measurement range and the calibration range under pre-tightening conditions. Furthermore, fitting curves for simulated measurements against tightening torque and angle yielded coefficients of determination of 0.9945 and 0.9939, which demonstrated accurate fitting of pre-tightening conditions and defined the monitoring range of 3.02 × 10¹² to 3.49 × 10¹². Finally, combined with simulation results, a field performance test confirmed the sensor’s ability to detect minute 5% pre-load reductions, achieve 200 ms data transmission to a host computer, and maintain lossless data transmission over 1.2 km. This sensor and system design provided a valuable reference for bolt loosening monitoring in combine harvesters and other agricultural machinery. Full article

Bolt loosening is a common mechanical failure in large-scale generator sets, especially the top cover bolts, which can lead to unstable operation, affecting the safety and efficiency of the unit. Real-time monitoring of bolt pre-tightening force and the early diagnosis of loosening are crucial for ensuring the long-term safe operation of the generator set. This study proposes a novel method for diagnosing faults in large-scale hydraulic units, with a particular focus on thread loosening failures. The proposed approach utilizes stress feature analysis and intelligent algorithms to enhance the diagnostic process. The study involves a detailed analysis of the stress transfer mechanism during bolt loosening, aiming to elucidate the relationship between changes in pre-tightening force and stress distribution in the surrounding bolts. A combined approach of monitoring the pre-tightening force and signal analysis is employed to facilitate the real-time tracking of dynamic changes. Experimental results show that loosening a single bolt causes stress distribution changes in the entire bolt group, particularly in the adjacent bolts. The study also introduces a diagnosis method combining pre-tightening force changes and VMD (Variational Mode Decomposition), which proves to be highly accurate in locating loosened bolts. Engineering applications validate that VMD analysis combined with the Spearman method effectively identifies changes in stress and has high accuracy and potential for diagnosing bolt loosening failures, providing valuable guidance for generator set maintenance. Full article

Electrical accidents caused by bolt looseness in transformers have been frequently reported in recent years. The monitoring, and warning of, axial force as an indicator of looseness is one of the key issues affecting the operation and maintenance of transformers. Traditional ultrasonic testing and a patch-type ultrasonic method, using piezoelectric probes and coupling agents, showed poor repeatability and accuracy in detecting the bolt pre-tightening force, because of the uncertainty of the contact interface produced via manual operation. A permanent thin-film pressure sensor (PMTS), which provides accurate and in-situ stress detection, is more suitable for bolts, to reveal the pretightening force. The key is depositing a nano-zinc oxide (ZnO) piezoelectric film with an excellent measurement performance, which could be tuned using deposition parameters. This paper investigates the effects of the current and bias voltage on the crystal structure and performance of ZnO piezoelectric films. The results show that the crystallinity degree and resistance decrease with the increase in bias voltage, while the target current could increase the crystallinity. However, a high current also brings large particles in the coating surface, which greatly decrease the resistance. The cause is expected to be related to the ion energy, which could be affected by the bias voltage and current. The PMTS deposited with an optimized bias voltage and current revealed excellent measurement performance, and is expected to be applied to the bolt, to detect the pretightening force. Full article

The ripeness of tomatoes is crucial to determining their shelf life and quality. Most of the current methods for picking and sorting tomatoes take a long time, so this paper aims to design a device for sorting tomatoes based on force and bioelectrical impedance measurement. A force sensor installed on each of its four fingers may be used as an impedance measurement electrode. When picking tomatoes, the electrical impedance analysis circuit is first connected for pre-grasping. By applying a certain pre-tightening force, the FSR sensor on the end effector finger can be tightly attached to the tomato and establish an electric current pathway. Then, the electrical parameters of the tomato are measured to determine its maturity, and some of the electrical parameters are used for force monitoring compensation. Then, a force analysis is conducted to consider the resistance of the FSR under current stress. According to the principle of complex impedance circuit voltage division, the voltage signal on the tomato is determined. At the same time, the specific value of the grasping force at this time is determined based on the calibration of the pre-experiment and the compensation during the detection process, achieving real-time detection of the grasping force. The bioelectricity parameters of tomatoes can not only judge the ripeness of tomatoes, but also compensate for the force measurement stage to achieve more accurate non-destructive sorting. The experimental results showed that within 0.6 s of stable grasping, this system could complete tomato ripeness detection, improve the overall tomato sorting efficiency, and achieve 95% accuracy in identifying ripeness through impedance. Full article

This paper deals with the coefficient of determination of screw connection friction between the thread and the matrix. The coefficient of friction was measured using a laboratory device with an M20 screw connection without any grease and, subsequently, plastic grease was added (CX80 silicone, lithium, and copper grease). When grease is added, the friction in the threads and screw heads is limited and consistently retained. When tightening by torque, which represents the prevailing assembly method in standard screwing practice, only part of the torque is effectively used to create axial force and pre-stress. The rest of the torque is employed in friction suppression between threads and converted into heat. In general, the coefficient of friction depends on diverse factors such as the roughness of the thread surface, the gradient angle of the helix, and the grease properties. The tightening torque represents a primary parameter in the experimental measurements, monitored using a digital torque spanner, and generates an axial force in the screw. Based on the aforementioned parameters, the objective of this paper was to monitor changes in the coefficient of friction between the thread of the screw and the matrix in the case of different grease types. The actual coefficient of friction was calculated through the exponential equation of the torque balance. First measured was the load of the bolted joint without the use of grease, where the average value of the coefficient of friction was 0.44732; this value served as a benchmark for comparison to the measurements with the use of grease. The measurements showed that the value of the friction coefficient was reduced by 30.57% when using lithium grease, by 40.56% when using silicone grease, and by 47.64% when using copper-based grease, making the latter the most suitable for the application. Without appropriate greasing, friction suppression was accompanied by extremely high torques, which resulted in insufficient screw prolongation. Full article

Pre-stressed bolted joints are widely used in civil structures and industries. The tightening force of a bolt is crucial to the reliability of the joint connection. Loosening or over-tightening of a bolt may lead to connectors slipping or bolt strength failure, which are both harmful to the main structure. In most practical cases it is extremely difficult, even impossible, to install the bolts to ensure there is a precise tension force during the construction phase. Furthermore, it is inevitable that the bolts will loosen due to long-term usage under high stress. The identification of bolt tension is therefore of great significance for monitoring the health of existing structures. This paper reviews state-of-the-art research on bolt tightening force measurement and loosening detection, including fundamental theories, algorithms, experimental set-ups, and practical applications. In general, methods based on the acoustoelastic principle are capable of calculating the value of bolt axial stress if both the time of incident wave and reflected wave can be clearly recognized. The relevant commercial instrument has been developed and its algorithm will be briefly introduced. Methods based on contact dynamic phenomena such as wave energy attenuation, high-order harmonics, sidebands, and impedance, are able to correlate interface stiffness and the clamping force of bolted joints with respective dynamic indicators. Therefore, they are able to detect or quantify bolt tightness. The related technologies will be reviewed in detail. Potential challenges and research trends will also be discussed. Full article

Online and offline monitoring of composite bolted joints under tensile load were investigated using piezoelectric transducers. The relationships between Lamb wave signals, pre-tightening force, the applied tensile load, as well as the failure modes were investigated. Results indicated that S0/A0 wave amplitudes decrease with the increasing of load. Relationships between damage features and S0/A0 mode were built based on the finite element (FE) simulation and experimental results. The possibility of application of Lamb wave-based structure health monitoring in bolted joint-like composite structures was thus achieved. Full article