Strain Transfer Analysis of Rubber-Encapsulated Fiber Bragg Grating Sensors for Wind Turbine Blade Strain Monitoring

To resolve the discrepancy between the measured strain and the actual surface strain of wind turbine blades when using rubber-encapsulated fiber Bragg grating (FBG) sensors for strain monitoring, this study establishes a surface-bonded strain transfer model for such sensors. The total strain transfer efficiency of the sensor is decomposed into two components: the strain transfer efficiency from the rubber substrate to the FBG core (encapsulated grating strain transfer efficiency) and that from the wind turbine blade to the rubber substrate (strain transfer efficiency between the rubber substrate and the blade). Based on the theory of mechanics of materials, the strain transfer equation is derived, and the key factors influencing strain transfer efficiency—FBG bonding length and rubber substrate thickness—are analyzed via the control variable method. Three ethylene propylene diene monomer (EPDM)-encapsulated FBG sensors with rubber substrate thicknesses of 3 mm, 4 mm, and 6 mm were fabricated. Tensile strain transfer tests were conducted using fiber-reinforced plastic (FRP) strips to simulate the material properties of wind turbine blades, so as to validate the effectiveness of the proposed model. The experimental results demonstrate that the strain transfer efficiency of the sensor increases with the extension of FBG bonding length and decreases with the increase in rubber substrate thickness, with 4 mm determined as the optimal substrate thickness for EPDM-encapsulated FBG sensors. On the basis of the aforementioned findings, an EPDM-encapsulated FBG strain rosette sensor was developed, which can effectively measure the complex stress of a wind turbine blade model. This study provides a theoretical foundation for the structural design and engineering application of rubber-encapsulated FBG sensors in the strain monitoring of wind turbine blades.