Early Bolt Loosening Detection Method Based on Digital Image Correlation

Bolt loosening can significantly impact the accuracy, stability, and safety of equipment. The detection of bolt loosening in a timely manner is crucial for ensuring the safety, reliability, performance, and service life of equipment, structures, and systems. Various methods exist for detecting bolt loosening, such as strain gauges and ultrasonic waves. However, these technologies have some limitations that impede their widespread application. In this paper, for the high-pressure pipe manifolds that may experience leakage accidents due to the loosening of bolts, an early bolt loosening detection method based on digital image correlation is proposed. Initially, a model is established through tensile tests to relate the average strain on the side of the bolt head to the axial force. Subsequently, an industrial camera captures images of bolts with random speckles under operational conditions. Using digital image correlation technology, the average strain in a specific region on the side of the bolt head is calculated. By integrating the average strain into the established relationship model between the average strain and axial force, the axial force of the bolt under operational conditions can be predicted, enabling the early assessment of bolt loosening. The findings show that the average strain on the side of the bolt head increases proportionally with the axial force, indicating a strong linear relationship. This method enables accurate prediction of the bolt's axial force, offering a new approach for identifying the early loosening of bolts in high-pressure manifolds and monitoring structural health.