An ultra-thin bolt tension sensor and online monitoring system: For application in hydropower plant unit

The condition of bolted connections significantly affects the structural safety. However, conventional bolt tension sensors fail to provide precise measurements due to their bulky size or inadequate stability. This study employs the piezoresistive effect of crystalline silicon material to fabricate an ultrathin sensor. The sensor exhibits a linear relationship between pressure and voltage, an exceptional stability at varying temperatures, and a superior resistance to corrosion, making it adaptable and user-friendly for applications of high-strength bolt tension monitoring. A monitoring system, incorporating the proposed sensor, has also been developed. This system provides real-time display of bolt tension and enables the assessment of sensor and structural conditions, including bolt loosening or component failure. The efficacy of the proposed sensor and monitoring system was validated through a project carried out at the Xiluodu Hydropower Plant. According to the results, the sensor and online monitoring system effectively gauged and proficiently conveyed and stored bolt tension data. In addition, correlations were created between bolt tensions and essential unit parameters, such as water head, active power, and pressures at vital points, facilitating anomaly detection and early warning.