Bolt Monitoring System_Shenzhen Qianhai IntelliUnion Technology Development Co., Lt

Bolt Monitoring System

Wind turbines are costly and operate in harsh, complex conditions. Prolonged vibration, torsion, shear and other loads damage components and connecting fasteners. Bolt preload loss and fracture are common; if undetected, they can cause major equipment accidents, financial losses and even injuries. IntelliUnion's ISys100-BOL bolt monitoring system includes the IMon-U108 acquisition unit and blade-root/tower probes. High-precision ultrasonic technology provides real-time monitoring and warnings, with strong interference immunity, high accuracy and fast response to minute connection changes.

Monitoring Challenges

Hidden Failures Are Difficult to Detect

Bolt loosening, microcracks and fatigue damage occur internally and cannot be detected by surface inspections. Gradual preload loss is difficult to quantify during routine checks.

Reliance on Manual Work and Experience

Torque-wrench rechecks are inefficient and subject to torque errors and experience-based judgment, while work at height poses significant risks.

High Losses from Sudden Failure

A single bolt fracture can cause cascading structural damage and expensive repairs. Unplanned downtime reduces generation and site revenue.

Lack of Full-Lifecycle Data

Missing preload history and accumulated fatigue data leave life assessment dependent on theoretical estimates.

Product Advantages

High-Precision Sensing

Measures ultrasonic travel-time differences within bolts to calculate minute preload and axial-force changes, accurately locating early loosening, cracks and fracture risks for preventive action.

Real-Time Preload Monitoring

Dynamically displays each bolt's preload as a percentage of its design value and generates preload distribution maps to locate weak bolt groups quickly.

Non-Destructive Installation Preserves Structural Strength

Probes are adhesively bonded to bolt end faces without drilling or damaging the base material. Installation does not affect structural safety or operating stability and suits all turbine models.

Strong Interference Immunity and Reliable Operation

Withstands strong vibration, electromagnetic interference and extreme temperature/humidity. Built-in temperature compensation offsets thermal expansion and contraction, ensuring stable data for bolts in towers, blade roots, nacelles and other locations.