Development of a Load Monitoring Sensor for the Wire Tightener

The wire tightener is a critical tool in the construction and maintenance of power lines. Failure to detect tension overload in a timely manner may lead to plastic deformation or even breakage of the tool, potentially causing serious safety accidents. To address this issue, a force monitoring sensor was developed to track the real-time load on wire tighteners. In terms of hardware design, a foil strain gauge was integrated with an ultra-low-power mixed-signal microcontroller based on the mechanical characteristics of the wire tightener, enabling accurate acquisition and processing of load data. Low-power LoRa technology was employed for wireless data transmission, and an adaptive sleep–wake strategy was implemented to optimize power efficiency during data collection. The sensor’s material, geometry, and structure were tailored to the tool’s composition and working environment. Experimental results showed that the average relative error between the sensor readings and the reference values was less than 0.5%. The sensor has been successfully deployed in practical engineering applications, consuming approximately 4500 mWh over an 8 h continuous monitoring period.