基于柔性多功能传感的轮轴力-热-振动监测
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华东交通大学电气与自动化工程学院南昌330013

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TH8

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国家自然科学基金(52565063)、江西省自然科学基金(20252BAC240344)、江西省研究生创新基金(YC2025-S499)项目资助


Wheel axle force-thermal-vibration monitoring based on flexible multifunctional sensors
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School of Electrical and Automation Engineering, East China Jiaotong University, Nanchang 330013, China

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    摘要:

    针对高速列车轮轴在复杂服役中持续承受交变载荷,现有监测器件面临几何失配、多维信号交叉串扰等瓶颈。设计了一种双侧空间隔离拓扑多模态柔性传感器,通过硬件架构创新有效抑制串扰,实现轮轴应变-温度-振动实时监测。该器件以十字形聚酰亚胺为绝缘隔热屏障,顶层旋涂集成掺杂氮化硼纳米片与钛酸钡颗粒的聚偏氟乙烯压电复合薄膜,用于宽频振动参数实时采集;底层基于图案化丝网印刷等工艺,共面异构集成液态金属与聚乙烯醇交联网络的应变单元,及具面内拉伸顺应性的蛇形银浆温度单元。整体以聚酰亚胺封装,并在底层测温区局部集成高面外热导率的热塑性聚氨酯与氮化硼复合薄膜,从而在物理拓扑层面构建力、热、振动信号的正交解耦机制与高效热传导路径。性能评估表明:在10~50 Hz频带内振动灵敏度达0.404 V/N;应变敏感层最高规范系数达32.11,响应延迟低至26 ms,具备二维交变应力场矢量解算能力;温度单元在0~120℃宽温域内分辨率达0.5℃,且8%机械拉伸下应变交叉干扰率低于0.3%。该双侧空间隔离拓扑结构能够有效抑制多模态监测中的物理参量交叉干扰,无需复杂后端补偿算法,经模拟台架实验证实,实现了强耦合工况下多物理量的高保真同步独立提取,为高速列车旋转部件原位状态评估提供数据支撑。

    Abstract:

    Aiming at the problem that high-speed train axles are continuously subjected to alternating loads under complex service conditions, and existing monitoring devices suffer from bottlenecks such as geometric mismatch and cross-crosstalk of multidimensional signals, this article proposes a dual-side isolated topological multimode flexible sensor. The innovative hardware architecture effectively suppresses signal crosstalk and realizes real-time monitoring of strain, temperature, and vibration of train axles. With cross-shaped polyimide serving as the electrical and thermal insulation barrier, the top layer is spin-coated with a polyvinylidene fluoride piezoelectric composite film doped with boron nitride nanosheets and barium titanate particles, enabling broadband real-time acquisition of vibration parameters. Based on patterned screen printing and other fabrication processes, the bottom layer coplanarly integrates strain units with liquid metal and polyvinyl alcohol crosslinked networks, as well as serpentine silver paste temperature units with excellent in-plane tensile compliance. The entire device is encapsulated with polyimide, and a thermoplastic polyurethane/boron nitride composite film with high out-of-plane thermal conductivity is locally integrated in the bottom temperature measurement area. This structural design establishes an orthogonal decoupling mechanism for force, thermal, and vibration signals as well as efficient heat transfer pathways at the physical topological level. Performance evaluations demonstrate that the sensor achieves a vibration sensitivity of 0.404 V/N within the frequency band of 10~50 Hz. The strain-sensitive layer delivers a maximum gauge factor of 32.11 and a low response delay of 26 ms, enabling vector decoupling capability for two-dimensional alternating stress fields. The temperature unit achieves a resolution of 0.5℃ within a wide temperature range of 0~120℃, while the strain crosstalk interference rate remains lower than 0.3% under 8% mechanical stretching. The proposed dual-side isolated topological structure can effectively suppress physical parameter crosstalk in multimode monitoring without relying on complex back-end compensation algorithms. Verified by bench simulation experiments, the sensor realizes high-fidelity, synchronous, and independent extraction of multiple physical quantities under strongly coupled operating conditions, providing reliable data support for in-situ condition assessment of rotating components of high-speed trains.

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董文涛,朱磊.基于柔性多功能传感的轮轴力-热-振动监测[J].仪器仪表学报,2026,47(8):361-373

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  • 在线发布日期: 2026-10-29
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