光纤传感器在深海采矿柔性管中的集成方案研究

崔新雨; 徐万海; 王莹莹; 沈飞; 柯燎亮

doi:10.21656/1000-0887.460110

光纤传感器在深海采矿柔性管中的集成方案研究

doi: 10.21656/1000-0887.460110

崔新雨^1,,
徐万海²,
王莹莹³,
沈飞^{1, 2},
柯燎亮^{1, 2, ,}

1.
天津大学机械工程学院，天津 300350
2.
天津大学水利工程智能建设与运维全国重点实验室，天津 300072
3.
中国石油大学(北京) 安全与海洋工程学院，北京 102249

(本刊编委柯燎亮来稿)

基金项目:

国家重点研发计划项目 2022YFC2803703

详细信息

作者简介:
崔新雨(1998—)，男，博士生(E-mail: cxy0411@tju.edu.cn)

通讯作者:
柯燎亮(1979—)，男，教授，博士，博士生导师(通信作者. E-mail: llke@tju.edu.cn)

中图分类号: TH166
计量
- 文章访问数: 108
- HTML全文浏览量: 36
- PDF下载量: 24
- 被引次数: 0
出版历程
- 收稿日期: 2025-06-03
- 修回日期: 2025-08-22
- 刊出日期: 2026-06-01

Research on the Integration Methods for Fiber Optic Sensors in Deep Sea Mining Flexible Pipes

CUI Xinyu^1
,,
XU Wanhai²,
WANG Yingying³,
SHEN Fei^{1, 2},
KE Liaoliang^{1, 2
, ,}

1.
School of Mechanical Engineering, Tianjin University, Tianjin 300350, P.R. China
2.
National Key Laboratory of Intelligent Construction and Operation of Water Conservancy Engineering, Tianjin University, Tianjin 300072, P.R. China
3.
School of Safety and Ocean Engineering, China University of Petroleum (Beijing), Beijing 102249, P.R. China

(Contributed by KE Liaoliang, Member of the Editorial Board of AMM)

摘要

摘要: 针对非粘结柔性管在深海采矿服役中的健康监测需求，研究了光纤传感器与柔性管的集成工艺方案. 通过设计三种集成工艺(芳纶绳及传感器缠绕、预浸带内置传感器、内衬层开槽置入传感器)，结合有限元模拟分析了不同工艺参数对传感器及柔性管力学性能的影响. 仿真结果表明：在芳纶绳缠绕工艺中，张紧力与缠绕角度对传感器伸长率和内衬层应力影响较小，均低于材料极限；预浸带内置方案中，张紧力及缠绕角度的变化未显著影响传感器性能；而内衬层开槽方案，在60 MPa爆破内压载荷下，传感器伸长率超过其极限值，存在失效风险. 结合集成工艺难易程度综合评估表明，芳纶绳缠绕工艺兼具低应力、高可靠性及工艺简便性，为最优选择. 研究结果为深海采矿非粘结柔性管内传感器集成提供了理论依据与工艺优化策略.
- 深海采矿 /
- 非粘结柔性管 /
- 传感器 /
- 集成加工 /
- 有限元模拟
Abstract: Based on the health monitoring requirements for unbonded flexible pipes in deep-sea mining operations, the integration process schemes for optical fiber sensors with flexible pipes were investigated. Three integration processes (the aramid fiber rope and sensor winding, the pre-impregnated tape with embedded sensors, and the lining grooving for sensor placement) were designed, and the effects of different process parameters on mechanical performances of sensors and flexible pipe structures werw analyzed through finite element simulations. Simulation results indicate that, in the aramid fiber rope winding process, variations of the tension force and the winding angle minimally affect sensor elongation rates and inner liner layer stresses, both below material limits. For the pre-impregnated tape embedding scheme, changes of the tension force and the winding angle do not significantly compromise the sensor performances. For the lining grooving solution, under an internal burst pressure load of 60 MPa, the sensor elongation rate exceeds its limit, posing a risk of failure. A comprehensive evaluation demonstrates that, the aramid fiber rope winding process offers low stress, high reliability, and process simplicity, making it the optimal choice. This research provides a theoretical foundation and a process optimization strategy for sensor integration of deep-sea flexible pipes.
- deep-sea mining /
- unbonded flexible pipe /
- sensor /
- integration process /
- finite element simulation
edited-by

edited-by
注释:

1) (本刊编委柯燎亮来稿)

HTML全文

图 1 传感器缠绕工艺几何模型

注为了解释图中的颜色，读者可以参考本文的电子网页版本，后同.

Figure 1. The simulation model of integrated processing technology for sensors and flexible pipes

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图 2 预浸带缠绕模型

Figure 2. The pre-impregnated tape winding model

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图 3 柔性管整体结构模型及内衬层开槽模型

Figure 3. The overall structural model of the flexible pipe and the model of the lining slotting

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图 4 边界条件设置

Figure 4. Boundary condition settings

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图 5 缠绕角54°和张紧力50 N时缠绕工艺仿真结果

Figure 5. Integrated process simulation results with a winding angle of 54° and a tension of 50 N

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图 6 传感器直径2 mm缠绕角54°张紧力200 N时缠绕工艺仿真结果

Figure 6. Simulation results of the winding process with a sensor diameter of 2 mm, a winding angle of 54 ° and a tension of 200 N

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图 7 拉伸载荷下的仿真结果

Figure 7. The simulation results under tensile load

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图 8 内压20 MPa下的Mises应力分布

Figure 8. The Mises stress distribution under an internal pressure of 20 MPa

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图 9 内压60 MPa下的Mises应力分布

Figure 9. The Mises stress distribution under an internal pressure of 60 MPa

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表 1 传感器与柔性管复合集成加工成型方案

Table 1. Integrated processing and forming methods for the sensor and flexible tube composite

integrated processing solution	sensor placement location	processing and molding method	processing diagram
method Ⅰ: integrated winding process of aramid ropes and sensor ropes	the sensor is located in the compensation reinforcement layer	the compensation reinforcement layer is fabricated by winding aramid ropes and sensor ropes together
method Ⅱ: pre-impregnated tape winding process with built-in sensor	the sensor is located in the compensation enhancement layer	the aramid fibers and sensors are impregnated with glue to form a pre-impregnated tape and wrapped around the lining to form the compensation reinforcement layer
method Ⅲ: lining slotted with built-in sensor	the sensor is located inside the groove of lining	groove the outer surface of the lining and place sensors

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表 2 传感器缠绕工艺仿真模型各结构尺寸

Table 2. Structural dimensions of the sensor and flexible tube integrated processing process simulation model

structure name	component	material	size	value/mm	number	helix angle/(°)
lining	-	-	inside diameter	200	1	-
lining	-	-	outside diameter	224	1	-
compensation reinforcement layer 1	sensor cable bundle	optical fiber	diameter	2.5	2，4，6	35，45，54
		outer sheath	outside diameter	0.125
		aramid fiber	thickness	0.25
	aramid rope	aramid fiber	diameter	3	168, 166, 164	35，45，54
compensation reinforcement layer 2	sensor cable bundle	optical fiber	diameter	2.5	0	-35，-45，-54
		outer sheath	outside diameter	0.125
		aramid fiber	thickness	0.25
	aramid rope	aramid fiber	diameter	3	170	-35，-45，-54

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表 3 内衬层和补偿增强层材料参数

Table 3. Material parameters of the inner lining layer and compressive reinforcement layer of the prepreg

structure	material	elastic modulus/MPa	Poisson’s ratio	limiting performance
lining	modified ultra-high molecular weight polyethylene	536.2	0.41	ultimate strength 20 MPa
aramid rope	aramid fiber^[27]	17 100(axial)	0.3	ultimate strength 960 MPa
sensor bundle rope	SiO₂^[27] high molecular weight polyethylene aramid fiber	9 867(axial)	0.3	ultimate elongation 2.8%

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表 4 工艺参数设置

Table 4. The process parameter setting

process parameter	value
tension force/N	20，30，50
winding angle/(°)	35，45，54

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表 5 预浸带缠绕模型各结构尺寸

Table 5. Dimensions of each structure in the pre impregnated tape winding model

structure	material	inside diameter/mm	outside diameter/mm	thickness/mm	helix angle/(°)
lining	ultra high molecular weight polyethylene	200	224	12	-
pressure armor layer	continuous long fiber composite material	224	230	3	80
compensation enhancement layer 1	continuous long fiber reinforced composite material	230	242	6	35, 45, 54
compensation enhancement layer 2	continuous long fiber reinforced composite material	242	254	6	-35, -45, -54

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表 6 预浸带内衬层和抗压增强层材料参数

Table 6. Material parameters of the pre-impregnated lining and compressive reinforcement layer

structure	material	elastic modulus/MPa	Poisson’s ratio	performance limit
lining	modified ultra-high molecular weight polyethylene	536.2	0.41	ultimate strength 20 MPa
pressure armor layer	continuous long fiber composite material	33 700	0.3	-
sensor	silicon dioxide outer cladding	362	0.3	maximum elongation rate 2.8%
pre-impregnated tape	aramid fiber resin	9 476.5(E₁₁), 679(G₁₂)	0.34(ν₁₂)	-
		2 156.5(E₂₂), 711(G₂₃)	0.34(ν₁₃)
		2 167.9(E₃₃), 718(G₃₁)	0.5(ν₂₃)

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表 7 缠绕工艺参数设置

Table 7. Winding process parameter settings

process parameter	process interval
winding tension/N	[50, 300]
winding speed/(r/min)	[0.25, 2]

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表 8 整体结构几何尺寸参数

Table 8. Geometric dimensional parameters of the overall structure

structure	material	inside diameter/mm	outside diameter/mm	thickness/mm	winding angle/(°)
lining	modified ultra-high molecular weight polyethylene	200	224	12	-
pressure armor layer	aramid fiber	224	230	3	80
compensation enhancement layer 1	aramid fiber	230	242	6	54
compensation enhancement layer 2	aramid fiber	242	254	6	-54
skeleton layer	fiberglass reinforced composite	254	274	10	80
tensile reinforcement layer 1	aramid fiber	274	286	6	30
tensile reinforcement layer 2	aramid fiber	286	298	6	-30
outer covering layer	polyurethane	298	306	4	-

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表 9 结构材料参数

Table 9. Structural material parameters

structure	material	longitudinal tensile modulus/GPa	lateral tensile modulus/GPa	in-plane shear modulus/GPa	main Poisson’s ratio
outer covering layer	thermoplastic polyurethane		0.041 4		0.49
tensile reinforcement layer	aramid fiber K29+unsaturated polyester	9.94	2.55	2.37	0.34
skeleton layer	fiberglass Ⅰ	33.70	7.35	2.50	0.3
hot melt adhesive	hot melt adhesive		3.2		0.3

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表 10 不同张紧力下传感器绳束伸长率及内衬层应力结果

Table 10. Sensor rope elongation and inner lining stress results under different tension forces

stress/elongation	tension force 20 N	tension force 30 N	tension force 50 N
sensor rope elongation/%	0.075 6	0.093 7	0.108 0
stress of lining/MPa	0.779	0.876	1.210
stress of aramid rope/MPa	11.0	13.7	18.2

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表 11 不同缠绕角度下传感器绳束伸长率及内衬层应力结果

Table 11. Sensor rope elongation and inner lining stress results at different winding angles

stress/elongation	winding angle 35°	winding angle 45°	winding angle 54°
sensor rope elongation/%	0.034 1	0.038 6	0.093 7
stress of lining/MPa	0.343	0.535	0.876
stress of aramid rope/MPa	6.01	6.07	13.69

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表 12 缠绕仿真计算不同缠绕角度光纤及内衬层应力结果

Table 12. Stress results of optical fibers and inner lining layers with different winding angles calculated by winding simulation

stress/elongation	winding angle 35°	winding angle 45°	winding angle 54°
sensor elongation rate/%	0.891	0.906	0.918
stress of lining/MPa	0.142	0.379	0.264

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表 13 缠绕仿真计算不同张紧力光纤及内衬层应力结果

Table 13. Stress results of fiber optic and lining under different tensions calculated by winding simulation

stress/elongation	tension force 200 N	tension force 250 N	tension force 300 N
sensor elongation rate/%	0.918	0.966	1.200
stress of lining/MPa	0.264	0.277	0.283

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表 14 三种方案的集成加工过程对传感器的综合影响分析

Table 14. Analysis of the comprehensive impact of integrated processing processes of 3 solutions on sensors

methods	advantage and disadvantage of the plan	overall consideration
method Ⅰ: sensor and aramid ropes winding processing	low stress and high safety; mature manufacturing equipment and simple process flow; the sensor is well protected; but the consistency between the aramid rope and the sensor winding needs to be controlled to some extent	considering the difficulty of structural design and processing technology, method Ⅰ is suggested
method Ⅱ: the sensor is embedded in a pre-impregnated tape and wrapped for processing	strong structural integrity and excellent corrosion resistance; high precision requirements for winding; however, the preparation of prepreg is complex and costly; high requirements for process control
method Ⅲ: groove the lining and embed the sensor inside the groove	the sensor is close to the inner wall, with high monitoring sensitivity; however, stress concentration is significant under ultimate load; difficult to control processing accuracy; leakage and structural safety hazards exist

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