IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT, VOL. 69, NO.
5, MAY 2020
FBG Smart Bolts and Their Application
in Power Grids
Chao Duan , Hongying Zhang , Zhuoshu Li , Ye Tian , Quan Chai , Jun Yang , Libo Yuan ,
Jianzhong Zhang , Kai Xie , and Zhongbin Lv
Abstract— Based on the analysis and research of the existing
intelligent bolt technology, this article proposes a smart bolt
based on fiber Bragg grating sensing technology. The bolt design
process was systematically introduced, and the physical model
of the three-point fixed anti-tail fiber sloshing was given, as well
as the corresponding simulation and experimental comparison.
The ability to monitor the looseness of the smart bolts was also
tested and installed as a smart unit in the fiber-optic smart grid
system for monitoring and testing. The wire dancing simulation
test machine was used to simulate various practical application
conditions, and the effective monitoring performance of the
intelligent bolt was verified.
Index Terms— Bolt loose monitoring, fiber Bragg grat-
ing (FBG), smart bolts, tail fiber sway.
I. I NTRODUCTION
B OLTS are the most widely used and important connectors
in industry and daily life, especially those installed in
large-scale structures with high safety requirements. If the
bolts fail, the damage to the connection structure will be
devastating, such as tower collapse, power grid outage, traffic
accidents, equipment failure, and so on, which has a serious
impact on people’s daily life and even life safety [1]–[4].
In different bolt application environments, many factors, such
as high temperature, high pressure, high-frequency vibration,
and load impact will cause bolt failure. Therefore, monitoring
the health status of bolts through structural health monitoring
and timely grasping of the failure status of bolts can greatly
reduce the occurrence of accidents.
Manuscript received August 8, 2019; revised September 23, 2019; accepted
September 28, 2019. Date of publication November 14, 2019; date of
current version April 7, 2020. This work was supported in part by the
National Natural Science Foundation of China under Grant 61775045, Grant
61805054, and Grant 61605030, in part by the State Grid Project under
Grant 52170215000R, in part by the National Key R&D Program of China
under Grant 2016YFF0200700, in part by the Heilongjiang Young Researcher
Support Project under Grant 1253G018, in part by the Fundamental Research
Funds of the Central University, China, and in part by the 111 Project through
Harbin Engineering University under Grant B13015. The Associate Editor
coordinating the review process was Kok-Sing Lim. (Corresponding author:
Jianzhong Zhang.)
C. Duan, H. Zhang, Z. Li, Y. Tian, Q. Chai, J. Yang, L. Yuan, and
J. Zhang are with the Key Lab of In-Fiber Integrated Optics, Ministry of
Education, Harbin Engineering University, Harbin 150001, China (e-mail:
zhangjianzhong@hrbeu.edu.cn).
K. Xie and Z. Lv are with the Laboratory of Transmission Line Galloping
Prevention Technique, State Grid Henan Electric Power Research Institute,
Zhenzhou 450052, China.
Color versions of one or more of the figures in this article are available
online at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TIM.2019.2947995
0018-9456 © 2019 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See https://www.ieee.org/publications/rights/index.html for more information.
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2515
Methods to effectively monitor the bolt failures such as
monitoring the degree of bolt loosening [5]–[11], the pre-
tightening force of bolts [12]–[20], and the structural strain
of bolt installation points [21]–[23] to characterize the failure
status of bolts were proposed. To achieve these goals, they
usually install piezoelectric transducer (PZT), resistance strain
gauges, optical fiber sensors (OFSs) and other sensors on the
structure of bolt installation points, the bolt surface, the bolt
interior, or the bolt washer to monitor the bolts’ working
status [5]–[29]. In addition, some researchers monitored the
bolt loosening through external components, such as reed
switch [7], and measured the strain of the washer by automatic
digital image correlation device to monitor the displacement
of a white light speckle pattern on the washer’s face [16].
PZT, resistance strain gauge, reed switch, and other sensors
are sensitive to the external electric and magnetic field and
vulnerable to the external environment, easily being felled off
or damaged from the pasting point of the bolt. As the bolt
failure is a long-term and continuous process, sensors installed
externally are more likely to be damaged compared to the
internal installation. Therefore, we need a monitoring tool with
anti-electromagnetic interference, long life, high sensitivity,
and simple structure.
Fiber Bragg Grating (FBG) is a type of OFS with the
characteristics of small size, anti-electromagnetic interfer-
ence, wavelength multiplexing capability, and resistance in
harsh environments. So it is widely used as the strain and
temperature sensors [30]–[36]. FBG smart bolt is the bolt
integrated with the FBG inside, which can monitor strain,
temperature, load, and other information at the same time.
Khomenko et al. [8] embedded the FBG into the bolt by
adhesives and made a reusable smart bolt, which verified the
feasibility of using it to monitor the preload of the initial instal-
lation of the bolt. Ren et al. installed four angular FBGs in
bolts to measure the axial and shear forces acting on bolts [36].
Biao [24] tried to make temperature self-compensating smart
bolts. At a recent conference, we introduced a smart bolt with
temperature compensation to achieve bolt failure monitoring
and to monitor the bolt operating conditions under simulated
actual conditions. We introduced a smart bolt with temperature
compensation to achieve the monitoring of bolt loosening, and
to monitor the bolt operating conditions under simulated actual
conditions [37].
Smart bolts are new forms of bolts that have been developed
over the past two decades. For the moment, smart bolts
2516
Fig. 1. (a) Response of FBG encapsulated with full adhesive under ununiform
force. (b) Response of two-point packaging FBG under ununiform force.
have two main functions. The first is the ability to sense
environmental factors, such as temperature, load, pressure,
etc., [8], [24], [37], which can be applied to the metrology
or structural health monitoring. The second is data storage
and identification capabilities, which can be applied to areas
such as product assembly and maintenance [38].
A kind of smart bolt with an embedded FBG probe is stud-
ied and manufactured in this article. The first part introduces
the application of smart bolts, the monitoring method of bolt
failure, and the research status of FBG smart bolts. The second
part introduces the design process of smart bolts, focusing
on the physical model of three-point fixed suppression of tail
fiber sloshing, and the corresponding simulation and experi-
ment. The third part tests the bolt temperature compensation
characteristics and the ability to monitor the looseness of the
bolts. The fourth part uses the wire galloping simulation test
machine to simulate the monitoring of the state of the bolt
loosening and the ability to monitor the dancing frequency
under various practical application conditions.
II. D ESIGN OF S MART B OLT
At present, the package of FBG in the smart bolt is often
directly used in the full-glue package [39]. The FBG is buried
directly in the bolt mounting hole by an adhesive. Limited
by the characteristics of FBG, under the uneven force, FBG
is prone to enthalpy, which causes the grating spectrum to
broaden and even be distorted, and the center wavelength can-
not be accurately obtained, as shown in Fig. 1(a). Therefore,
using a two-point package structure, the external nonuniform
force is transmitted to the two ends of the FBG through
the metal tube, so that the FBG is uniformly strained, and
an accurate central wavelength value is obtained, as shown
in Fig. 1(b).
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IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT, VOL. 69, NO. 5, MAY 2020
Fig. 2. Structural diagram of the smart bolt. (a) Bolt body. (b) FBG probe.
(c) Internal structure diagram of the FBG probe.
Fig. 3. Photograph of the smart bolt.
Fig. 4. Impact of tail fiber sway on FBG1. (a) Before the tail fiber is fixed by
the heat-shrinkable tube. (b) After thetail fiber is fixed by the heat-shrinkable
tube.
The intelligent bolt consists of a bolt body and an FBG
probe. As shown in Fig. 2(a) and (b), a length of the mounting
hole is drilled down the axis of the bolt head. The length of
the mounting hole is determined by the length of the bolt and
nut at the mounting position so that the FBG strain sensor is
placed within this length; the mounting hole diameter is the
same as the outer diameter of the FBG sensor. The internal
structure of the FBG sensor is shown in Fig. 2(c). FBG1 is
a strain sensor that is fixed at two points and is sensitive to
temperature and strain. FBG2 is a temperature sensor that only
fixes one end of the grating. It is only sensitive to temperature.
The FBG’s tail fiber is protected by a metal-rubber composite
sleeve that passes through the Gulen fixed casing and bolts.
A photograph of the smart bolt is shown in Fig. 3.
When testing the smart bolts made in the above manner,
it was found that FBG1 was sensitive to the sway of the tail
casing, and the result is shown in Fig. 4(a). When we made
the smart bolts, we fixed the fiber-optic and metal-rubber com-
posite sleeves with heat-shrink tubing, as shown in Fig. 2(c),
DUAN et al.: FBG SMART BOLTS AND THEIR APPLICATION IN POWER GRIDS
TABLE I
M ATERIAL PARAMETERS
Fig. 5. Simulation model (a) Fixed at two points. (b) Fixed 1 section.
Fig. 6. Simulation model fixed at three points.
and the sleeves were tightly connected with the bolts to
achieve a three-point fixing method. The tail fiber sloshing test
was performed on the bolts made according to the improved
scheme, and the experimental results are shown in Fig. 4(b).
It can be seen that the tail fiber sway affects the FBG1 below
the measurement limit of the sensor.
In response to this problem, the force transfer situation
here was analyzed by the finite element simulation software
COMSOL Multiphysics. The modules used are solid mechan-
ics and a stationary study. The required material parameters
are Young’s modulus, Poisson’s ratio, and density, as shown
in Table I.
The simulation model is shown in Fig. 5. Between the
fixed 1 and 2 is an FBG. The right side of the fixed 2 is
the tail fiber. The right end of the tail fiber is the point of
force, applying a force along the axial direction of the fiber.
Because the strain distribution is uniform in the FBG and the
tail fiber, the strain at points A and B represents the strain of
this area.
When F = 1 N, we can find that ε B = 1100 με, and
ε A = 20 με. Consider a 3-point fixed approach, adding a
fixed point to the tail fiber to create the model shown in Fig. 6.
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2517
Fig. 7. Effect of l1 , l2 on ε A.
l1 is the distance between the fixed 2 and the fixed 3, l2 is
the length of the fixed 3, and ε P is the pre-strain applied
between the fixed 2 and the fixed 3. When l1 = 10 mm,
l2 = 3 mm, ε P = 0, F = 1 N, we can find that ε B = 1100 με,
ε A = 0.35 με. The third fixed point greatly reduces the impact
of the tail fiber force on the FBG.
Next, we analyze the effect of the fixed 3 position l1 ,
the length l2 , and the prestrain ε P on the force transmission
of the tail fiber.
The effect of the l1 and l2 on the force transmission of
the tail fiber is shown in Fig. 7. The shorter l1 , l2 , the worse
the ability of fixed 3 to weaken the force transmission of the
tail fiber. First, we analyze the impact of l1 . Let the left end
of the l1 area be C, and the right end be D, as shown in
Fig. 6. If point C is the free end, the displacement of point
D is a fixed value n at a given force F. Now that point C is
constrained, the displacement change at point D increases as l1
increases and tends to n. The displacement at point D can be
approximated as the length change l1 of the l1 . If l1 increases
linearly, the increase of l1 will gradually slow down, and
l1 is much smaller than l1. Therefore, the strain here (ε23 =
l1 /l1 ) is a process in which the decrease gradually slows
down and tends to 0. ε23 is transmitted to the FBG, and ε A
also has a changing trend as shown in Fig. 7. Analysis of the
effect of l2 , at a given F, the longer l2 , the more difficult the
force is transmitted to the FBG, the smaller ε A .
The effect of prestrain ε P on the force transmission of
the tail fiber is shown in Fig. 8. When F = 0 N, it means
there is only prestrain; when F = 1 N, it means that there is
both prestrain and tail fiber stress. The two lines are parallel,
indicating that the strain at point A is the sum of the influences
of ε P and F. Prestrain has no effect on the force transmission
of the tail fiber.
If the l1 area can be bent, the sloshing of the tail fiber will
be more difficult to transfer to the FBG. However, in actual
production, the length of l1 is relatively short, and bending
tends to cause large optical loss and even damage the optical
fiber. So when we make the smart bolt, keep the area in a
relaxed state.
We chose l1 = 10 mm and l2 = 3 mm to make smart
bolts. In the simulation, the strain transmitted at the FBG was
reduced by 56.9 times, and the strain transmitted during the
experiment was reduced by more than 20 times, as shown
in Fig. 4.
We also analyzed the influence of drilling on bolt
strength by finite element simulation. The strength has not
2518 IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT, VOL. 69, NO. 5, MAY 2020
Fig. 8. Effect of ε P on ε A.
decreased much. However, the drilling actually brings a lot of
unpredictable defects, which will greatly reduce the strength
of the bolt. It is necessary to appropriately increase the size of
the bolt when using, and making a finer FBG probe to reduce
the size of the hole is also our follow-up work.
III. P ERFORMANCE T ESTING OF S MART B OLT
The performance of smart bolts is the key to determining
the value of their monitoring. The temperature compensation
is performed by means of double FBG; the strain monitoring
performance of the intelligent bolt is tested, and the calibration
curve of the intelligent bolt is obtained to characterize the
loose state of the bolt.
FBG1 is sensitive to both temperature and strain; tem-
perature and strain sensitivity are K T 1 = 12.331 pm/◦ C,
K ε1 = 0.77 pm/με, respectively. The strain sensitiv-
ity curve of FBG1 is shown in Fig. 9. FBG2 is only
temperature sensitive and has a temperature sensitivity of
K T 2 = 11.683 pm/◦C.
Because the two FBGs are close together, they can be
considered to have the same temperature. The wavelength
change λ1 of FBG1 and the wavelength change λ2 of
FBG2 can be shown as (1) due to temperature and strain [40].
Then we can get the strain ε, as shown in the following
equation:

λ1 = K T 1 · T + K ε1 · ε
(1)
λ2 = K T 1 · T
  
λ2 1 IV. A PPLICATION OF S MART B OLTS IN P OWER G RID
ε = λ1 − K T 1 · . (2)
KT 2 K ε1
We installed a smart bolt on the test fastener and charac-
terized the looseness of the bolt by the angle of rotation of
the nut (denoted as θ ). θ = 0 indicates that the nut is in a
tightened state. The strain data of the bolt after temperature
compensation under different θ is recorded, and the calibration
curve is obtained, as shown in Fig. 10. The curve can be fit
to ε = 144.8e−0.0212θ .
It can be found that when the rotation angle of the nut
reaches 180◦ , the monitoring strain value has approached zero,
which means the smart bolt is invalid. On the other hand,
the bolt still has the condition of accidental damage and failure
under the influence of sudden change. In order to deal with
this situation, we made an alternative scheme for auxiliary
judgment. When the strain value monitored by the smart bolt
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Fig. 9. FBG1 strain sensitivity.
Fig. 10. Calibration curve of smart bolt loosening state.
is less than 5% of the initial strain value, the bolt is considered
to be invalid at this time. The smart bolt is connected with
the demodulation system. The demodulation system judges
whether the bolt is invalid according to the above scheme.
If the bolt is considered to be invalid, the system will issue
a whistle warning, and the staff should carry out on-site
maintenance of the corresponding bolt.
By optimizing the FBG probe, we solved the problems of
grating chirp and transmission loss in the smart bolt, realized
temperature self-compensation, and obtained the calibration
curve of the loose state of the smart bolt through an experi-
mental test, which laid a foundation for the application of the
smart bolt in the real environment.
We want to install the smart bolt on the transmission tower
as an intelligent unit in FBG smart grid system, but the
real situation on the transmission tower is more complex
than the laboratory. Therefore, we first install the smart bolt
on the transmission line galloping simulation test machine
(hereinafter referred to as Galloping Tester) to simulate the
real working conditions and study the stability and reliability
of the smart bolt.
The Galloping Tester simulates the large frequency variation
of tension caused by transmission lines galloping under natural
wind excitation by applying small force regularly in the shear
direction of a single line. The structural diagram of the
Galloping Tester is shown in Fig. 11(a). We applied 0–1-Hz
excitation frequency to the transmission line stepped by 0.2 Hz
by the Galloping Tester and studied the monitoring response of
DUAN et al.: FBG SMART BOLTS AND THEIR APPLICATION IN POWER GRIDS
Fig. 11. (a) Structural diagram of Galloping Tester. (b) Smart bolt installation
point.
Fig. 12. Monitoring data of smart bolts with different looseness under
external frequency excitation in the time domain.
smart bolts under different excitation frequencies in different
loosening states. Fig. 12 shows the time domain results of
smart bolt monitoring. Each curve in Fig. 12 is a monitoring
signal at a certain excitation frequency. Lines with different
colors in Fig. 12 represent the different rotation angles of
nuts. It can be seen that the monitoring signals of the smart
bolt are not affected by the stable state, and are related only
to the degree of bolt loosening. Therefore, the degree of bolt
loosening can be judged by the monitoring strain data of the
smart bolt.
The monitoring data cannot be distinguished in the time
domain when the excitation frequency is 1 Hz. It is because
1 Hz is the natural frequency of the transmission line. The
bolt and the transmission line resonate, and the signal cannot
be distinguished accurately.
The galloping of the transmission line is one of the factors
that cause bolt loosening, tower structure damage, and tower
collapse, and it needs to be understood. Smart bolts installed
at the hanging point of the transmission line on the tower can
not only monitor the loosening status of itself but also monitor
the galloping frequency of the transmission line. Fig. 13 is the
low-frequency region of the monitoring frequency domain of
the smart bolt under the external excitation frequency under
different loose states. It can be seen that the smart bolt can
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2519
Fig. 13. Low-frequency region of the monitoring data of the smart bolt under
the external-frequency excitation under different loose states.
accurately monitor the external excitation frequency in the
low-frequency region, and the monitoring results have nothing
to do with the bolt’s loose state. Therefore, we can obtain
the galloping frequency of the transmission line through the
frequency of the low-frequency zone monitored by the smart
bolt.
V. C ONCLUSION
We designed and tested an FBG-based smart bolt that
resists tail fiber sloshing to monitor bolt looseness. By using
a three-point fixed method, the strain transmission from the
tail fiber to the FBG was reduced by nearly 57 times in
the simulation, and the tail fiber sloshing was also reduced
by more than 20 times in the experiment. Through testing,
the relationship between the strain of the smart bolt and
the loose angle is ε = 144.8e−0.0212θ , which is the core to
achieve bolt loosening monitoring. Finally, a Galloping Tester
was used to simulate a variety of different actual working
conditions, indicating that the smart bolt can also monitor its
own looseness under the condition of cable dancing.
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Jun. 2000.
Chao Duan received the B.S. degree in photoelectric
information science and engineering from Harbin
Engineering University, Harbin, China, in 2017,
where he is currently pursuing the Ph.D. degree in
optic engineering.
His current research interests include optical fiber
sensors and measurement and systems.
Hongying Zhang received the B.S. degree from the
University of Jinan, Jinan, China, in 2016, where she
is currently pursuing the Ph.D. degree in optic engi-
neering, and the M.S. degree in optic engineering
from Harbin Engineering University, Harbin, China,
in 2019.
Her current research interests include optical fiber
sensors and measurement and systems.
Zhuoshu Li received the B.S. degree from the Cen-
tral South University of Forestry and Technology,
Changsha, China, in 2017. He is currently pursuing
the M.S. degree in optical with Harbin Engineering
University, Harbin, China.
His current research interests include optical fiber
sensors and measurement and systems.
DUAN et al.: FBG SMART BOLTS AND THEIR APPLICATION IN POWER GRIDS 2521

Ye Tian received the B.S. degree in nuclear science Jianzhong Zhang received the B.S. degree in con-
and technology and the Ph.D. degree in optic engi- densed matter physics from Lanzhou University,
neering from Harbin Engineering University, Harbin, Lanzhou, China, in 2000, and the M.S. degree and
China, in 2013 and 2019, respectively. the Ph.D. degree in optical engineering from Harbin
His current research interests include optical fiber Engineering University, Harbin, China, in 2004 and
sensors and special fibers. 2007, respectively.
He was a Visiting Research Fellow with the Uni-
versity of New South Wales, Sydney, NSW, Aus-
tralia, in 2006 and 2012. Since 2012, he has been a
Professor with the College of Science, Harbin Engi-
neering University. He has published over 90 articles
in refereed journals and conferences and edited two books. He held over 10
patents. His current research interests include optical fiber devices and optical
fiber sensing technologies and their applications.
Quan Chai received the B.S. and M.S. degrees in
optical information science and technology and opti-
cal engineering from the College of Science, Harbin
Engineering University, Harbin, China, in 2008 and
2011, respectively, and the Ph.D. degree in mecha-
tronic engineering from the College of Mechani-
cal and Electrical, Harbin Engineering University
in 2016.
He is currently a Lecturer with the Key Laboratory
of Fiber Optic Integrated Optics, Ministry of Edu-
cation, Harbin Engineering University. His current
research interests include fiber optic sensors and special fibers.
Kai Xie received the Ph.D. degree from the Harbin
Institute of Technology, Harbin, China.
He is currently a Senior Engineer with the Lab-
oratory of Transmission Line Galloping Preven-
Jun Yang received the B.S., M.S., and Ph.D. degrees tion Technique, State Grid Henan Electric Power
from Harbin Engineering University, Harbin, China, Research Institute, Zhenzhou, China. His current
in 1999, 2002, and 2005, respectively. research interests include fiber optic testing technol-
Since 2007, he has been a Professor with the ogy, transmission line online monitoring technology,
College of Science, Harbin Engineering University. transmission line dance prevention technology, and
He has published over 220 articles in refereed jour- other areas of research and technology applications.
nals and conferences and edited two books. He held
over 121 patents. His current research interests
include optical fiber white light interference test
theory and key technology, laser interferometry prin-
ciple and key technology, integrated fiber devices,
and micro sensor systems.

Libo Yuan received the B.S. degree from Hei-

longjiang University, Harbin, China, in 1984,
the M.S. degree from Harbin Engineering University,
Harbin, in 1990, and the Ph.D. degree from The
Hong Kong Polytechnic University, Hong Kong,
in 2003.
From 1995 to 1997, he was a Visiting Researcher
with the New Jersey Institute of Technology,
Newark, NJ, USA. Since 1990, he has been a Profes-
sor with the College of Science, Harbin Engineering
University. He has published over 300 articles in
refereed journals and conferences and edited two books. He held over
23 patents. His current research interests include optical fiber sensing technol-
ogy, photonic science and technology, and fiber optical tweezers technology.
Zhongbin Lv is currently a Senior Engineer and the
Deputy Director of the Laboratory of Transmission
Line Galloping Prevention Technique, State Grid
Henan Electric Power Research Institute, Zhenzhou,
China. His current research interests include trans-
mission line dancing and prevention technology.
He is a member of the Standard Committee of
Power Industry Safety Equipment.

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