CN117664401B - Flexible passive pressure sensor for railway monitoring - Google Patents
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- CN117664401B CN117664401B CN202311677738.7A CN202311677738A CN117664401B CN 117664401 B CN117664401 B CN 117664401B CN 202311677738 A CN202311677738 A CN 202311677738A CN 117664401 B CN117664401 B CN 117664401B
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Abstract
The invention discloses a flexible passive pressure sensor for railway monitoring, which comprises an upper five-mode metamaterial thin film layer, a lower five-mode metamaterial thin film layer, a piezoelectric material thin film layer and a flexible packaging layer, wherein the piezoelectric material thin film layer is packaged in the flexible packaging layer and leads out piezoelectric signals through signal wires; the upper five-mode metamaterial thin film layer and the lower five-mode metamaterial thin film layer are made of five-mode metamaterials and flexible nanowires. The invention is arranged between the elastic strip of the rail fastener and the rail, does not influence the running safety of the railway, monitors the running state of the railway in real time, has stable monitoring signals and long service life.
Description
Technical Field
The invention relates to the technical field of railway monitoring, in particular to a flexible passive pressure sensor for railway monitoring.
Background
At present, a great part of high-speed railway accidents are caused by invasion of foreign matters (debris flow, falling rocks and the like) into running tracks or collapse of railway beds, and a few derailment accidents are caused by technical faults in the high-speed running process, so that trains lose balance and are turned over.
The invention patent (2016111264939) discloses a device and a method for monitoring the aging degree of a rubber pad for a rail structure, wherein a pressure monitoring sensor is paved below the rubber pad, and the method is limited by the thickness and the contact area of the sensor, so that the contact area of the rubber pad 03 (see figure 1) and a sleeper 04 is influenced, the damping effect of the rubber pad is further influenced, the running safety of a railway is influenced, particularly the running safety of a high-speed railway is not easy to popularize and use in the high-speed railway. Meanwhile, because the replacement process of the rubber backing plate of the high-speed railway is complex, the aged backing plate needs to be replaced after the whole rail is lifted, and after the rail is restored, the whole rail is polished and the smoothness of the line is monitored by using an engineering vehicle, the replacement cost is high, and meanwhile, the safe operation is greatly influenced, so that the rail is not easy to popularize and apply in the high-speed railway.
Disclosure of Invention
The invention aims to solve the technical problem of providing the flexible passive pressure sensor for railway monitoring, which is arranged between the elastic strip of the steel rail fastener and the steel rail, can not influence the running safety of the railway, monitors the running state of the railway in real time, has stable monitoring signals and has long service life.
The technical scheme of the invention is as follows:
the flexible passive pressure sensor for railway monitoring comprises an upper five-mode metamaterial thin film layer, a lower five-mode metamaterial thin film layer, a piezoelectric material thin film layer and a flexible packaging layer, wherein the piezoelectric material thin film layer is packaged in the flexible packaging layer and leads out piezoelectric signals through signal wires, and the flexible packaging layer is fixedly adhered between the upper five-mode metamaterial thin film layer and the lower five-mode metamaterial thin film layer; the upper five-mode metamaterial thin film layer and the lower five-mode metamaterial thin film layer are made of five-mode metamaterial and flexible nanowires, the flexible nanowires are embedded into the five-mode metamaterial, unit cells of the five-mode metamaterial are attached to the flexible nanowires, and the overall rigidity of the flexible nanowires embedded into the five-mode metamaterial is larger than that of the five-mode metamaterial.
The upper five-mode metamaterial thin film layer and the lower five-mode metamaterial thin film layer are thin film structures made by adopting a 3D printing technology, the five-mode metamaterial comprises a bottom layer, a top layer and a plurality of microstructure units arranged between the bottom layer and the top layer, each microstructure unit consists of a plurality of cells, the cells of the microstructure units are obliquely upwards extended and arranged, the extended axes are parallel to each other, each flexible nanowire extends to the top layer along the bottom layer of the five-mode metamaterial in the printing process, the bottom of each flexible nanowire is embedded into the bottom layer, the horizontal height of the top end of each flexible nanowire is lower than that of the bottom end of the top layer, each flexible nanowire penetrates through the center of the corresponding microstructure unit cell of the five-mode metamaterial, and each flexible nanowire penetrates through a node between adjacent cells of the microstructure unit.
The thicknesses of the upper five-die metamaterial thin film layer and the lower five-die metamaterial thin film layer are not more than 0.341mm.
The flexible nanowires are silver nanowires, and the length of the part of each flexible nanowire embedded into the bottom layer of the five-mode metamaterial is 10-15% of the total length of each flexible nanowire.
The piezoelectric material film layer is a polarized polyvinylidene fluoride film layer, and the thickness of the piezoelectric material film layer is not more than 0.03mm.
The flexible packaging layer comprises an upper flexible packaging layer and a lower flexible packaging layer, wherein the upper flexible packaging layer and the lower flexible packaging layer are packaging film structures which are made by adding short carbon fibers and carbon fiber particles into high molecular polymers, and the piezoelectric material film layer is completely adhered between the central parts of the upper flexible packaging layer and the lower flexible packaging layer, and the annular edge parts of the upper flexible packaging layer and the annular edge parts of the lower flexible packaging layer are mutually adhered, so that the piezoelectric material film layer is completely packaged in the flexible packaging layer.
The high molecular polymer is made of polydimethylsiloxane material or polyimide.
The mass ratio of the total mass of the short carbon fibers and the carbon fiber particles to the mass of the high polymer is 0.003:1, a step of; the mass ratio of the short carbon fibers to the carbon fiber particles is 1.125-1.356:1.
The short carbon fibers are short carbon fibers with the length not more than 20 micrometers, and the carbon fiber particles are carbon fiber particles with the particle size controlled between 1 and 5 micrometers.
The flexible passive pressure sensor is arranged between the elastic strip of the fastener and the steel rail, the contact part of the elastic strip of the fastener and the steel rail is completely adhered to the flexible passive pressure sensor, the bottom end of the flexible passive pressure sensor is arranged on the steel rail, and the horizontal projection axis of each microstructure unit in the upper five-mode metamaterial film layer and the lower five-mode metamaterial film layer is parallel to the horizontal axis of the steel rail.
The invention has the advantages that:
(1) The top and the bottom of the invention are five-mode metamaterial film layers, the five-mode metamaterial only bears axial load in the vertical direction after being installed, when a train runs at high speed, the five-mode metamaterial film layer bears shearing force in the horizontal direction and axial load in the vertical direction, when the train only bears axial load in the vertical direction, the microstructure units of the five-mode metamaterial cannot deform, when the train bears shearing force in the horizontal direction, the microstructure units of the five-mode metamaterial deform, the deformation at the moment becomes buckling of the integral structure of the five-mode metamaterial, the five-mode metamaterial is of a porous structure, and when buckling of the integral structure occurs, namely the aspect ratio of the five-mode metamaterial is suddenly reduced, a damping effect cannot be generated, and the purpose of buckling of the five-mode metamaterial is to ensure that the piezoelectric material film layer and a steel rail are in a relatively parallel state, so that the accuracy of measurement data of the piezoelectric material film layer is ensured.
(2) The upper five-mode metamaterial thin film layer and the lower five-mode metamaterial thin film layer are made of the five-mode metamaterial and the flexible nanowire, the overall rigidity of the flexible nanowire embedded into the five-mode metamaterial is larger than that of the five-mode metamaterial, the flexible nanowire cannot influence the deformation process of the five-mode metamaterial, the upper five-mode metamaterial thin film layer and the lower five-mode metamaterial thin film layer can be accelerated to recover through the flexible nanowire, the recovery reaction time of the five-mode metamaterial after deformation under the shearing stress state is reduced, and the accuracy of the measured data of the piezoelectric material thin film layer is further improved.
(3) The flexible packaging layer is prepared by adding short carbon fibers and carbon fiber particles into a high polymer, and reasonably proportioning the short carbon fibers and the carbon fiber particles and proportioning the high polymer and the carbon fiber, so that the strength of the flexible packaging layer is improved, the problem that sensing failure is caused by rainwater invading the piezoelectric material film layer due to cracks in the use process of the flexible packaging layer is avoided, the use reliability of the flexible packaging layer in a severe environment is further improved, the piezoelectric material film layer is prevented from being wrinkled and buckled, the use reliability of the piezoelectric material film layer is further ensured, the service life of the flexible packaging layer is greatly prolonged, and the accuracy of measured values is ensured;
(4) When in use, the invention is adhered and fixed with the elastic strip of the fastener to form an integrated structure, and then pressed on the steel rail, thereby ensuring the stability of the installation structure of the invention, ensuring that the installation structure is not easy to shift from the elastic strip to the steel rail, facilitating the installation of the elastic strip at different detection positions of the steel rail, and having simple installation mode and accurate monitoring data.
Drawings
Fig. 1 is a schematic view of a structure in which a spring strip of a fastener fixes a rail.
Fig. 2 is a cross-sectional view of the invention in an unstressed condition attached to a spring strip.
Fig. 3 is a cross-sectional view of the invention in a deformed state of being attached to a spring strip under shear stress.
FIG. 4 is a cross-sectional view of an upper or lower five-die metamaterial film layer of the present invention in an unstressed state.
FIG. 5 is a cross-sectional view of the upper or lower five-mode metamaterial film layer of the present invention in a state of being subjected to shear stress.
Fig. 6 is a block diagram of a railway monitoring system according to an embodiment of the present invention.
Reference numerals: 01-steel rail, 02-elastic strip, 03-rubber backing plate, 04-sleeper, 1-upper five-mode metamaterial film layer, 2-lower five-mode metamaterial film layer, 3-piezoelectric material film layer, 4-upper flexible packaging layer, 5-lower flexible packaging layer, 6-signal wire, 101-bottom layer of five-mode metamaterial, 102-top layer of five-mode metamaterial, 103-unit cell, 104-flexible nanowire, node between 105-unit cells, 7-signal filter, 8-signal amplifier, 9-AD converter, 10-wireless transmitter, 11-wireless receiver 11, 12-analysis early warning controller, 13-disaster early warning digital twin platform and 14-monitoring terminal.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 2 and 3, the flexible passive pressure sensor for railway monitoring includes an upper five-mode metamaterial thin film layer 1, a lower five-mode metamaterial thin film layer 2, a piezoelectric material thin film layer 3, an upper flexible packaging layer 4 and a lower flexible packaging layer 5, wherein the upper flexible packaging layer 4 and the lower flexible packaging layer 5 are packaging film structures made by adding short carbon fibers and carbon fiber particles into high molecular polymers, the piezoelectric material thin film layer 3 is completely adhered between the central parts of the upper flexible packaging layer 4 and the lower flexible packaging layer 5, and the annular edge parts of the upper flexible packaging layer 4 and the annular edge parts of the lower flexible packaging layer 5 are mutually adhered, so that the piezoelectric material thin film layer 3 is completely packaged between the upper flexible packaging layer 4 and the lower flexible packaging layer 5, piezoelectric signals are led out by the piezoelectric material thin film layer 3 through signal wires 6, and the upper flexible packaging layer 4 and the lower flexible packaging layer 5 are adhered and fixed between the upper five-mode metamaterial thin film layer 1 and the lower five-mode metamaterial thin film layer 2.
Referring to fig. 4 and 5, the thicknesses of the upper five-mode metamaterial thin film layer 1 and the lower five-mode metamaterial thin film layer 2 are not greater than 0.341mm, the thicknesses of the upper five-mode metamaterial thin film layer 1 and the lower five-mode metamaterial thin film layer 2 are all of thin film structures made of five-mode metamaterial and flexible nanowires by adopting a 3D printing technology, the flexible nanowires are silver nanowires, the five-mode metamaterial comprises a bottom layer 101 and a top layer 102, and a plurality of microstructure units arranged between the bottom layer 101 and the top layer 102, each microstructure unit consists of a plurality of cells 103, the cells 103 of the microstructure units extend obliquely upwards and are parallel to each other, in the printing process, each flexible nanowire 104 extends towards the top layer 102 along the bottom layer 101 of the five-mode metamaterial, the bottom of each flexible nanowire 104 is embedded into the bottom layer 101, the top end of each flexible nanowire 104 is lower than the bottom end of the top layer 102, namely, each flexible nanowire 104 is not embedded into the top layer 102, the whole length of each flexible nanowire 104 is not embedded into the top layer 102, and the whole length of each flexible nanowire 103 is greater than the whole length of the adjacent cells 103 and passes through the five-mode nanowire 104 (the flexible nanowire is preferably greater than 15%) and passes through the flexible nanowire 104 in the whole length of the five-mode cell structure and passes through the flexible nanowire 104) and passes through the five-10% of the flexible nanowire.
The piezoelectric material film layer 3 is a polarized polyvinylidene fluoride film layer, and the thickness of the piezoelectric material film layer 3 is not more than 0.03mm.
The high molecular polymer in the upper flexible packaging layer 4 and the lower flexible packaging layer 5 is made of polydimethylsiloxane material or polyimide; the mass ratio of the total mass of the short carbon fibers and the carbon fiber particles in the upper flexible packaging layer 4 and the lower flexible packaging layer 5 to the mass of the high polymer is 0.003:1, a step of; the mass ratio of the short carbon fiber to the carbon fiber particles is 1.125-1.356:1, a step of; the short carbon fibers are short carbon fibers with the length not more than 20 micrometers, and the carbon fiber particles are carbon fiber particles with the particle size controlled between 1 and 5 micrometers.
Referring to fig. 1, the flexible passive pressure sensor is arranged between the elastic strip 02 of the fastener and the steel rail 01, the contact part of the elastic strip 02 of the fastener and the steel rail 01 is completely adhered to the flexible passive pressure sensor, the bottom end of the flexible passive pressure sensor is arranged on the steel rail 01, and the horizontal projection axis of each microstructure unit in the upper five-mode metamaterial film layer 1 and the lower five-mode metamaterial film layer 2 is parallel to the horizontal axis of the steel rail 01.
The manufacturing process of the invention comprises the following steps:
(1) Dispersing short carbon fibers and carbon fiber particles into a high polymer in a centrifugal way, and preparing a film structure to obtain a flexible packaging material, then cutting the flexible packaging material to obtain an upper flexible packaging layer 4 and a lower flexible packaging layer 5 with the same size, finally completely bonding a piezoelectric material film layer 3 between the central parts of the upper flexible packaging layer 4 and the lower flexible packaging layer 5, and mutually bonding the annular edge part of the upper flexible packaging layer 4 and the annular edge part of the lower flexible packaging layer 5, so that the piezoelectric material film layer 3 is completely packaged between the upper flexible packaging layer 4 and the lower flexible packaging layer 5, and leading out piezoelectric signals through a signal wire 6 by the piezoelectric material film layer 3 to obtain the piezoelectric packaging structure;
(2) The method comprises the steps that a 3D printing technology is adopted to manufacture a five-mode metamaterial film from a five-mode metamaterial and flexible nanowires, in the printing process, each flexible nanowire 104 extends towards a top layer 102 along a bottom layer 101 of the five-mode metamaterial, the bottom of each flexible nanowire 104 is embedded into the bottom layer 101, the length of the part of each flexible nanowire 104 embedded into the bottom layer 101 of the five-mode metamaterial is 15% of the total length of each flexible nanowire 104, each flexible nanowire 104 penetrates through the center of a corresponding microstructure unit cell of the five-mode metamaterial, and each flexible nanowire 104 penetrates through a node 105 between adjacent unit cells 103 of the microstructure unit; then cutting the five-die metamaterial thin film to obtain an upper five-die metamaterial thin film layer 1 and a lower five-die metamaterial thin film layer 2 which are consistent with the upper flexible packaging layer 4 and the lower flexible packaging layer 5 in size;
(3) Firstly, coating a certain amount of glue on the top surface of a lower five-die metamaterial film layer 2, then placing the lower five-die metamaterial film layer 2 into a spin coater or a high-speed centrifuge for uniform spin coating treatment, placing a piezoelectric packaging structure on the top surface of the lower five-die metamaterial film layer 2, and then applying axial load to the piezoelectric packaging structure, and curing the glue between the lower five-die metamaterial film layer 2 and a lower flexible packaging layer 5 by using ultraviolet light to bond and fix the lower five-die metamaterial film layer 2 and the piezoelectric packaging structure;
(4) The bottom surface of the contact area between the elastic strip 02 and the steel rail 01 is subjected to roughening treatment by using high-power laser, then the roughened area is subjected to glue filling treatment, the roughened area is covered and bonded by the upper five-mode metamaterial film layer 1 after the treatment, and the glue is cured by using ultraviolet light after the pasting;
(5) Firstly, coating a certain amount of glue on the top surface of a flexible packaging layer 4 on a piezoelectric packaging structure, performing spin coating treatment, placing an upper five-mold metamaterial film layer 1 and a spring strip 02 which are adhered and fixed on the top surface of the upper flexible packaging layer 4, then applying axial load to the upper five-mold metamaterial film layer and performing curing treatment on the glue by using ultraviolet light;
(6) After the glue is solidified, the flexible passive pressure sensor is formed, calibration treatment is carried out on the flexible passive pressure sensor, and the state of impact load and electric signals under the action of dynamic load is tested.
The inner end of the signal wire 6 is directly encapsulated between the upper flexible encapsulation layer 4 and the lower flexible encapsulation layer 5, the outer end is led out from the space between the upper flexible encapsulation layer 4 and the lower flexible encapsulation layer 5, and a corresponding signal interface can be arranged at the outer end of the signal wire 6, so that the signal wire is convenient to be connected with an external railway monitoring system.
Referring to fig. 6, the railway monitoring system includes a signal collector disposed at a side of a steel rail 01 and an analysis and early warning terminal disposed at a far end, the signal collector includes a signal filter 7, a signal amplifier 8, an AD converter 9 and a wireless transmitter 10 sequentially connected with a signal line 6, the analysis and early warning terminal includes a wireless receiver 11 and an analysis and early warning controller 12 sequentially connected, the wireless transmitter 10 and the wireless receiver 11 are in wireless communication connection, the analysis and early warning controller 12 stores, processes and analyzes the collected signals, analyzes disaster assessment and the like, the analysis and early warning controller 12 is also connected with a disaster early warning digital twin platform 13 through a wireless network, the disaster early warning digital twin platform 13 pre-determines a possible disaster, and a plurality of monitoring terminals 14 (wired terminals (railway office command center), wireless terminals and handheld terminals) are all in communication connection with the disaster early warning digital twin platform 13, so as to realize the purpose of remote monitoring.
The flexible passive pressure sensor is arranged at a corresponding detection position on the steel rail 01, acquires an electric signal through the piezoelectric material film layer 3, can be used for line invasion monitoring, and can change the value of the electric signal when debris flow or personnel invade the steel rail track, and the electric signal is transmitted to a railway monitoring system, so that the disaster monitoring and early warning function is realized.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (9)
1. A flexible passive pressure sensor for railway monitoring, characterized in that: the piezoelectric material film layer is encapsulated in the flexible encapsulation layer and leads out piezoelectric signals through signal wires, and the flexible encapsulation layer is fixedly adhered between the upper five-mode metamaterial film layer and the lower five-mode metamaterial film layer; the upper five-mode metamaterial thin film layer and the lower five-mode metamaterial thin film layer are made of five-mode metamaterial and flexible nanowires, the flexible nanowires are embedded into the five-mode metamaterial, unit cells of the five-mode metamaterial are attached to the flexible nanowires, and the overall rigidity of the flexible nanowires embedded into the five-mode metamaterial is larger than that of the five-mode metamaterial;
The upper five-mode metamaterial thin film layer and the lower five-mode metamaterial thin film layer are thin film structures made by adopting a 3D printing technology, the five-mode metamaterial comprises a bottom layer, a top layer and a plurality of microstructure units arranged between the bottom layer and the top layer, each microstructure unit consists of a plurality of cells, the cells of the microstructure units are obliquely upwards extended and arranged, the extended axes are parallel to each other, each flexible nanowire extends to the top layer along the bottom layer of the five-mode metamaterial in the printing process, the bottom of each flexible nanowire is embedded into the bottom layer, the horizontal height of the top end of each flexible nanowire is lower than that of the bottom end of the top layer, each flexible nanowire penetrates through the center of the corresponding microstructure unit cell of the five-mode metamaterial, and each flexible nanowire penetrates through a node between adjacent cells of the microstructure unit.
2. A flexible passive pressure sensor for railway monitoring as claimed in claim 1, wherein: the thicknesses of the upper five-die metamaterial thin film layer and the lower five-die metamaterial thin film layer are not more than 0.341mm.
3. A flexible passive pressure sensor for railway monitoring as claimed in claim 1, wherein: the flexible nanowires are silver nanowires, and the length of the part of each flexible nanowire embedded into the bottom layer of the five-mode metamaterial is 10-15% of the total length of each flexible nanowire.
4. A flexible passive pressure sensor for railway monitoring as claimed in claim 1, wherein: the piezoelectric material film layer is a polarized polyvinylidene fluoride film layer, and the thickness of the piezoelectric material film layer is not more than 0.03mm.
5. A flexible passive pressure sensor for railway monitoring as claimed in claim 1, wherein: the flexible packaging layer comprises an upper flexible packaging layer and a lower flexible packaging layer, wherein the upper flexible packaging layer and the lower flexible packaging layer are packaging film structures which are made by adding short carbon fibers and carbon fiber particles into high molecular polymers, and the piezoelectric material film layer is completely adhered between the central parts of the upper flexible packaging layer and the lower flexible packaging layer, and the annular edge parts of the upper flexible packaging layer and the annular edge parts of the lower flexible packaging layer are mutually adhered, so that the piezoelectric material film layer is completely packaged in the flexible packaging layer.
6. A flexible passive pressure sensor for railway monitoring as claimed in claim 5, wherein: the high molecular polymer is made of polydimethylsiloxane material or polyimide.
7. A flexible passive pressure sensor for railway monitoring as claimed in claim 5, wherein: the mass ratio of the total mass of the short carbon fibers and the carbon fiber particles to the mass of the high polymer is 0.003:1, a step of; the mass ratio of the short carbon fibers to the carbon fiber particles is 1.125-1.356:1.
8. A flexible passive pressure sensor for railway monitoring as claimed in claim 5, wherein: the short carbon fibers are short carbon fibers with the length not more than 20 micrometers, and the carbon fiber particles are carbon fiber particles with the particle size controlled between 1 and 5 micrometers.
9. A flexible passive pressure sensor for railway monitoring as claimed in claim 1, wherein: the flexible passive pressure sensor is arranged between the elastic strip of the fastener and the steel rail, the contact part of the elastic strip of the fastener and the steel rail is completely adhered to the flexible passive pressure sensor, the bottom end of the flexible passive pressure sensor is arranged on the steel rail, and the horizontal projection axis of each microstructure unit in the upper five-mode metamaterial film layer and the lower five-mode metamaterial film layer is parallel to the horizontal axis of the steel rail.
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