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Search Results (2,671)

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Keywords = strain sensor

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13 pages, 3605 KB  
Article
SWCNT/PEDOT:PSS/SA Composite Yarns with High Mechanical Strength and Flexibility via Wet Spinning for Thermoelectric Applications
by Keisuke Uchida, Yoshiyuki Shinozaki, Hiroto Nakayama, Shuya Ochiai, Yuto Nakazawa and Masayuki Takashiri
Sensors 2025, 25(19), 6202; https://doi.org/10.3390/s25196202 - 7 Oct 2025
Viewed by 159
Abstract
To fabricate thermoelectric generators (TEGs) with high mechanical strength using single-walled carbon nanotubes (SWCNTs), we combined SWCNTs, poly(3, 4-ethylenedioxythiophene):poly(4-styrenesulfonate) (PEDOT:PSS), and sodium alginate (SA) to synthesize flexible SWCNT/PEDOT:PSS/SA composite yarns via wet spinning. The composite yarns were flexible and dense, with a diameter [...] Read more.
To fabricate thermoelectric generators (TEGs) with high mechanical strength using single-walled carbon nanotubes (SWCNTs), we combined SWCNTs, poly(3, 4-ethylenedioxythiophene):poly(4-styrenesulfonate) (PEDOT:PSS), and sodium alginate (SA) to synthesize flexible SWCNT/PEDOT:PSS/SA composite yarns via wet spinning. The composite yarns were flexible and dense, with a diameter of approximately 290 µm. Their tensile strength and breaking strain were 151 MPa and 12.7%, respectively, which were approximately 10 and 4 times those of the SWCNT films. However, the thermoelectric properties of the composite yarns were inferior to those of the SWCNT films. The temperature distribution and output voltage of the fabricated TEG with composite yarns were measured at a heater temperature of 100 °C. The temperature difference generated by the TEG with composite yarns was approximately 75% of that generated by the TEG with SWCNT films because the composite yarn had a smaller specific surface area. The output voltage of the TEG with two composite yarns (0.21 mV) was lower than that of the TEG with two SWCNT films. However, arranging the composite yarns at a high density resulted in an output voltage exceeding that for the TEGs with SWCNT films. These findings are highly beneficial for yarn-based TEGs used in wearable sensors. Full article
(This article belongs to the Special Issue Nanotechnology Applications in Sensors Development)
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17 pages, 3003 KB  
Article
Development of a Large-Range FBG Strain Sensor Based on the NSGA-II Algorithm
by Wenjing Wu, Zhenpeng Yang, Xinxing Chen, Heming Wei, Xiao Wu and Dengwei Zhang
Photonics 2025, 12(10), 985; https://doi.org/10.3390/photonics12100985 - 3 Oct 2025
Viewed by 126
Abstract
To monitor large deformations in dovetail tenon joints of Dong ethnic wooden drum towers, this study designs a large-range Fiber Bragg Grating (FBG) strain sensor based on the FBG sensing principle. The NSGA-II algorithm is utilized to optimize the packaging structure of FBG [...] Read more.
To monitor large deformations in dovetail tenon joints of Dong ethnic wooden drum towers, this study designs a large-range Fiber Bragg Grating (FBG) strain sensor based on the FBG sensing principle. The NSGA-II algorithm is utilized to optimize the packaging structure of FBG strain sensors. Consequently, an adaptive optimization methodology for its packaging configuration is proposed. This study sets the optimization objectives as a 5000 με measurement range and 0.1 pm/με sensitivity. It employs the NSGA-II algorithm to optimize the structural dimensions and material properties of the large-range FBG strain sensor. This process yields three combinations that meet the requirements for monitoring large deformations in dovetail tenon joints of Dong wooden drum towers. Subsequent linearity experiments were conducted to verify the sensitivity stability and measurement range of the three large-range FBG strain sensors. The results show that within the measurement range of 0–6000 με, all three sensors achieve a strain sensitivity of 0.099 pm/με, with a fitted linear correlation coefficient of 0.999. Full article
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34 pages, 3928 KB  
Article
Simulation of Chirped FBG and EFPI-Based EC-PCF Sensor for Multi-Parameter Monitoring in Lithium Ion Batteries
by Mohith Gaddipati, Krishnamachar Prasad and Jeff Kilby
Sensors 2025, 25(19), 6092; https://doi.org/10.3390/s25196092 - 2 Oct 2025
Viewed by 313
Abstract
The growing need for efficient and safe high-energy lithium-ion batteries (LIBs) in electric vehicles and grid storage necessitates advanced internal monitoring solutions. This work presents a comprehensive simulation model of a novel integrated optical sensor based on ethylene carbonate-filled photonic crystal fiber (EC-PCF). [...] Read more.
The growing need for efficient and safe high-energy lithium-ion batteries (LIBs) in electric vehicles and grid storage necessitates advanced internal monitoring solutions. This work presents a comprehensive simulation model of a novel integrated optical sensor based on ethylene carbonate-filled photonic crystal fiber (EC-PCF). The proposed design synergistically combines a chirped fiber Bragg grating (FBG) and an extrinsic Fabry–Pérot interferometer (EFPI) on a multiplexed platform for the multifunctional sensing of refractive index (RI), temperature, strain, and pressure (via strain coupling) within LIBs. By matching the RI of the PCF cladding to the battery electrolyte using ethylene carbonate, the design maximizes light–matter interaction for exceptional RI sensitivity, while the cascaded EFPI enhances mechanical deformation detection beyond conventional FBG arrays. The simulation framework employs the Transfer Matrix Method with Gaussian apodization to model FBG reflectivity and the Airy formula for high-fidelity EFPI spectra, incorporating critical effects like stress-induced birefringence, Transverse Electric (TE)/Transverse Magnetic (TM) polarization modes, and wavelength dispersion across the 1540–1560 nm range. Robustness against fabrication variations and environmental noise is rigorously quantified through Monte Carlo simulations with Sobol sequences, predicting temperature sensitivities of ∼12 pm/°C, strain sensitivities of ∼1.10 pm/με, and a remarkable RI sensitivity of ∼1200 nm/RIU. Validated against independent experimental data from instrumented battery cells, this model establishes a robust computational foundation for real-time battery monitoring and provides a critical design blueprint for future experimental realization and integration into advanced battery management systems. Full article
(This article belongs to the Special Issue Feature Papers in Optical Sensors 2025)
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23 pages, 2058 KB  
Article
Inductive Displacement Sensor Operating in an LC Oscillator System Under High Pressure Conditions—Basic Design Principles
by Janusz Nurkowski and Andrzej Nowakowski
Sensors 2025, 25(19), 6078; https://doi.org/10.3390/s25196078 - 2 Oct 2025
Viewed by 265
Abstract
The paper presents some design principles of an inductive displacement transducer for measuring the displacement of rock specimens under high hydrostatic pressure. It consists of a single-layer, coreless solenoid mounted directly onto the specimen and connected to an LC oscillator located outside the [...] Read more.
The paper presents some design principles of an inductive displacement transducer for measuring the displacement of rock specimens under high hydrostatic pressure. It consists of a single-layer, coreless solenoid mounted directly onto the specimen and connected to an LC oscillator located outside the pressure chamber, in which it serves as the inductive component. The specimen’s deformation changes the coil’s length and inductance, thereby altering the oscillator’s resonant frequency. Paired with a reference coil, the system achieves strain resolution of ~100 nm at pressures exceeding 400 MPa. Sensor design challenges include both electrical parameters (inductance and resistance of the sensor, capacitance of the resonant circuit) and mechanical parameters (number and diameter of coil turns, their positional stability, wire diameter). The basic requirement is to achieve stable oscillations (i.e., a high Q-factor of the resonant circuit) while maintaining maximum sensor sensitivity. Miniaturization of the sensor and minimizing the tensile force at its mounting points on the specimen are also essential. Improvement of certain sensor parameters often leads to the degradation of others; therefore, the design requires a compromise depending on the specific measurement conditions. This article presents the mathematical interdependencies among key sensor parameters, facilitating optimized sensor design. Full article
(This article belongs to the Topic AI Sensors and Transducers)
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16 pages, 2798 KB  
Article
Simple Preparation of Conductive Hydrogels Based on Precipitation Method for Flexible Wearable Devices
by Bolan Wu, Jiahao Liu, Zunhui Zhao, Na Li, Bo Liu and Hangyu Zhang
Sensors 2025, 25(19), 6032; https://doi.org/10.3390/s25196032 - 1 Oct 2025
Viewed by 191
Abstract
Conductive polymer hydrogels have attracted extensive attention in wearable devices, soft machinery, and energy storage due to their excellent mechanical and conductive properties. However, their preparation is often complex, expensive, and time-consuming. Herein, we report a facile precipitation method to prepare conductive polymer [...] Read more.
Conductive polymer hydrogels have attracted extensive attention in wearable devices, soft machinery, and energy storage due to their excellent mechanical and conductive properties. However, their preparation is often complex, expensive, and time-consuming. Herein, we report a facile precipitation method to prepare conductive polymer composite hydrogels composed of poly(acrylic acid) (PAA), poly(vinyl alcohol) (PVA), and poly(3,4-ethylenedioxythiophene) (PEDOT) via straightforward solution blending and centrifugation. During the preparation, PEDOT, grown along the PAA template, is uniformly dispersed in the hydrogel matrix. After shaping and rinsing, the PEDOT/PAA/PVA hydrogel shows good mechanical and electrical properties, with a conductivity of 4.065 S/m and a Young’s modulus of 311.6 kPa. As a strain sensor, it has a sensitivity of 1.86 within 0–100% strain and a response time of 400 ms. As a bioelectrode, it exhibits lower contact impedance than commercially available electrodes and showed no signs of skin irritation in the test. The method’s versatility is confirmed by the observation of similar performance of hydrogels with different compositions (e.g., polyaniline (PANI)/PAA/PVA). These results demonstrate the broad applicability of the method. Full article
(This article belongs to the Section Wearables)
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15 pages, 2939 KB  
Article
DIC-Aided Mechanoluminescent Film Sensor for Quantitative Measurement of Full-Field Strain
by Guoqing Gu, Liya Dai and Liyun Chen
Sensors 2025, 25(19), 6018; https://doi.org/10.3390/s25196018 - 1 Oct 2025
Viewed by 252
Abstract
To break through the bottleneck in the mapping of the mechanoluminescent (ML) intensity field to the strain field, a quantification method for full-field strain measurement based on pixel-level data fusion is proposed, integrating ML imaging with digital image correlation (DIC) to achieve precise [...] Read more.
To break through the bottleneck in the mapping of the mechanoluminescent (ML) intensity field to the strain field, a quantification method for full-field strain measurement based on pixel-level data fusion is proposed, integrating ML imaging with digital image correlation (DIC) to achieve precise reconstruction of the strain field. Experiments are conducted using aluminum alloy specimens coated with ML film sensor on their surfaces. During the tensile process, ML images of the films and speckle images of the specimen backsides are simultaneously acquired. Combined with DIC technology, high-precision full-field strain distributions are obtained. Through spatial registration and region matching algorithms, a quantitative calibration model between ML intensity and DIC strain is established. The research results indicate that the ML intensity and DIC strain exhibit a significant linear correlation (R2 = 0.92). To verify the universality of the model, aluminum alloy notched specimen tests show that the reconstructed strain field is in good agreement with the DIC and finite element analysis results, with an average relative error of 0.23%. This method enables full-field, non-contact conversion of ML signals into strain distributions with high spatial resolution, providing a quantitative basis for studying ML response mechanisms under complex loading. Full article
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48 pages, 912 KB  
Review
Convergence of Integrated Sensing and Communication (ISAC) and Digital-Twin Technologies in Healthcare Systems: A Comprehensive Review
by Youngboo Kim, Seungmin Oh and Gayoung Kim
Signals 2025, 6(4), 51; https://doi.org/10.3390/signals6040051 - 29 Sep 2025
Viewed by 581
Abstract
Modern healthcare systems are under growing strain from aging populations, urbanization, and rising chronic disease burdens, creating an urgent need for real-time monitoring and informed decision-making. This survey examines how the convergence of Integrated Sensing and Communication (ISAC) and digital-twin technologies can meet [...] Read more.
Modern healthcare systems are under growing strain from aging populations, urbanization, and rising chronic disease burdens, creating an urgent need for real-time monitoring and informed decision-making. This survey examines how the convergence of Integrated Sensing and Communication (ISAC) and digital-twin technologies can meet that need by analyzing how ISAC unifies sensing and communication to gather and transmit data with high timeliness and reliability and how digital-twin platforms use these streams to maintain continuously updated virtual replicas of patients, devices, and care environments. Our synthesis compares ISAC frequency options across sub-6 GHz, millimeter-wave, and terahertz bandswith respect to resolution, penetration depth, exposure compliance, maturity, and cost, and it discusses joint waveform design and emerging 6G architectures. It also presents reference architecture patterns that connect heterogeneous clinical sensors to ISAC links, data ingestion, semantic interoperability pipelines using Fast Healthcare Interoperability Resources (FHIR) and IEEE 11073, and digital-twin synchronization, and it catalogs clinical and operational applications, together with validation and integration requirements. We conduct a targeted scoping review of peer-reviewed literature indexed in major scholarly databases between January 2015 and July 2025, with inclusion restricted to English-language, peer-reviewed studies already cited by this survey, and we apply a transparent screening and data extraction procedure to support reproducibility. The survey further reviews clinical opportunities enabled by data-synchronized twins, including personalized therapy planning, proactive early-warning systems, and virtual intervention testing, while outlining the technical, clinical, and organizational hurdles that must be addressed. Finally, we examine workflow adaptation; governance and ethics; provider training; and outcome measurement frameworks such as length of stay, complication rates, and patient satisfaction, and we conclude that by highlighting both the integration challenges and the operational upside, this survey offers a foundation for the development of safe, ethical, and scalable data-driven healthcare models. Full article
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27 pages, 4892 KB  
Review
Progress in Cellulose-Based Polymer Ionic Conductors: From Performance Optimization to Strain-Sensing Applications
by Rouyi Lu, Yinuo Wang, Hao Pang, Panpan Zhang and Qilin Hua
Nanoenergy Adv. 2025, 5(4), 12; https://doi.org/10.3390/nanoenergyadv5040012 - 28 Sep 2025
Viewed by 182
Abstract
Intrinsically stretchable polymer ionic conductors (PICs) hold significant application prospects in fields such as flexible sensors, energy storage devices, and wearable electronic devices, serving as promising solutions to prevent mechanical failure in flexible electronics. However, the development of PICs is hindered by an [...] Read more.
Intrinsically stretchable polymer ionic conductors (PICs) hold significant application prospects in fields such as flexible sensors, energy storage devices, and wearable electronic devices, serving as promising solutions to prevent mechanical failure in flexible electronics. However, the development of PICs is hindered by an inherent trade-off between mechanical robust and electrical properties. Cellulose, renowned for its high mechanical strength, tunable chemical groups, abundant resources, excellent biocompatibility, and remarkable recyclability and biodegradability, offers a powerful strategy to decouple and enhance mechanical and electrical properties. This review presents recent advances in cellulose-based polymer ionic conductors (CPICs), which exhibit exceptional design versatility for flexible electrodes and strain sensors. We systematically discuss optimization strategies to improve their mechanical properties, electrical conductivity, and environmental stability while analyzing the key factors such as sensitivity, gauge factor, strain range, response time, and cyclic stability, where strain sensing refers to a technique that converts tiny deformations (i.e., strain) of materials or structures under external forces into measurable physical signals (e.g., electrical signals) for real-time monitoring of their deformation degree or stress state. Full article
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13 pages, 4071 KB  
Article
Synthesis and Studies of PAM-Ag-g/WS2/Ti3C2Tx Hydrogel and Its Possible Applications
by Anar Arinova, Danil W. Boukhvalov, Arman Umirzakov, Ekaterina Bondar, Aigul Shongalova, Laura Mustafa, Ainagul Kemelbekova and Elena Dmitriyeva
Polymers 2025, 17(19), 2588; https://doi.org/10.3390/polym17192588 - 24 Sep 2025
Viewed by 235
Abstract
In this study, a new hybrid hydrogel based on PAM (polyacrylamide)-Ag-g/WS2/Ti3C2Tx was synthesized by radical polymerization using a conductive heterostructural nanocomposite WS2/Ti3C2Tx. The synergy between the polymer matrix [...] Read more.
In this study, a new hybrid hydrogel based on PAM (polyacrylamide)-Ag-g/WS2/Ti3C2Tx was synthesized by radical polymerization using a conductive heterostructural nanocomposite WS2/Ti3C2Tx. The synergy between the polymer matrix and the interface between two-dimensional nanomaterials ensured the production of a hydrogel with high extensibility and conductivity, as well as sensory characteristics. The composite hydrogel exhibited excellent strain-sensing capabilities, with gauge factors of 1.4 at low strain and 2.8 at higher strain levels. In addition, the material showed a fast response time of 2.17 s and a short recovery time of 0.46 s under cyclic stretching, which confirms its high reliability and reproducibility. The integration of Ti3C2Tx and WS2 promoted the formation of a conductive network in the hydrogel structure, which simultaneously increased its mechanical strength and signal stability under variable loads. Measurements confirm some potential of the PAM-Ag-g/WS2/Ti3C2Tx composite hydrogel as a flexible wearable strain sensor. Based on measured numbers, we discussed the impact of the WS2/Ti3C2Tx interface on the Gauge factor and conductivity of the composite. Theoretical modeling demonstrates significant changes in the electronic structure of the WS2/Ti3C2Tx interface, and especially the WS2 surface, induced by substrate strain. Possible applications of the peculiar properties of PAM-Ag-g/WS2/Ti3C2Tx composite were proposed. Full article
(This article belongs to the Section Polymer Composites and Nanocomposites)
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22 pages, 16594 KB  
Article
Innovative Flexible Conductive Polymer Composites for Wearable Electrocardiogram Electrodes and Flexible Strain Sensors
by María Elena Sánchez Vergara, Joaquín André Hernández Méndez, Carlos Ian Herrera Navarro, Marisol Martínez-Alanís, Selma Flor Guerra Hernández and Ismael Cosme
J. Compos. Sci. 2025, 9(10), 512; https://doi.org/10.3390/jcs9100512 - 23 Sep 2025
Viewed by 467
Abstract
This work reports the fabrication of innovative flexible conductive polymer composites (FCPCs), composed of poly (2,3-dihydrothieno-1,4-dioxin)-poly (styrenesulfonate) (PEDOT:PSS), polypyrrole (PPy) and copper phthalocyanine (CuPc). These FCPCs were deposited by the drop-casting technique on flexible substrates such as polyethylene terephthalate (PET), Xuan paper and [...] Read more.
This work reports the fabrication of innovative flexible conductive polymer composites (FCPCs), composed of poly (2,3-dihydrothieno-1,4-dioxin)-poly (styrenesulfonate) (PEDOT:PSS), polypyrrole (PPy) and copper phthalocyanine (CuPc). These FCPCs were deposited by the drop-casting technique on flexible substrates such as polyethylene terephthalate (PET), Xuan paper and ethylene–vinyl acetate (EVA) foam sheets. Wearable photoactive electrocardiogram (ECG) electrodes and flexible strain sensors were fabricated. Morphological characterization by SEM revealed a stark contrast between the smooth, continuous PEDOT:PSS films and the rough, globular PPy films. EDS confirmed the successful and homogeneous incorporation of the CuPc, evidenced by the strong spatial correlation of the nitrogen and copper signals. The highest mechanical resistance was present in the FCPCs on PET with a limit of proportionality between 4074–6240 KPa. Optical parameters were obtained by Ultraviolet–Visible Spectroscopy and their Reflectance is below 15% and could be used as photoelectrodes. Three Signal Quality Indexes (SQIs) were used to evaluate the ECG signal obtained with the electrodes. The results of all the SQIs demonstrated that the obtained signals have a comparable quality to that of a signal obtained from commercial electrodes. To evaluate the flexible strain sensors, the change in output voltage caused by mechanical deformation was measured. Full article
(This article belongs to the Special Issue Biomedical Composite Applications)
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14 pages, 2128 KB  
Article
Safety Monitoring Method for Pipeline Crossing the Mining Area Based on Vibration–Strain Fusion Analysis
by Jianping He, Tongchun Qin, Zhe Zhang, Ronggui Liu and Yuping Bao
Micromachines 2025, 16(9), 1074; https://doi.org/10.3390/mi16091074 - 22 Sep 2025
Viewed by 430
Abstract
The overlying rock layers in a mining area may collapse or settle, subjecting pipelines to uneven forces that can lead to deformation or even fracture. This paper proposes a pipeline safety monitoring method that combines fiberoptic vibration and strain sensing to detect vibrations [...] Read more.
The overlying rock layers in a mining area may collapse or settle, subjecting pipelines to uneven forces that can lead to deformation or even fracture. This paper proposes a pipeline safety monitoring method that combines fiberoptic vibration and strain sensing to detect vibrations and deformations caused by rock layer collapse in mining zones. First, pipeline deformation monitoring under unknown force directions was investigated using fiber Bragg grating (FBG) sensing technology. Second, we constructed a mining area pipeline model and conducted vibration/deformation monitoring tests employing FBG sensors, distributed Brillouin strain sensing, and distributed fiberoptic vibration sensing technologies. The experimental results demonstrate that FBG sensor arrays deployed at 90-degree intervals can effectively identify the pipeline’s primary force direction and maximum strain, with direction angle errors of less than 5.2%. The integrated analysis of vibration and strain data enables accurate identification and measurement of extended vibration responses and pipeline deformations in open-air zones. This study establishes a comprehensive monitoring framework for ensuring pipeline safety in mining areas. Full article
(This article belongs to the Special Issue Fiber-Optic Technologies for Communication and Sensing)
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23 pages, 5544 KB  
Article
Strain-Tunable Gas Sensing Properties of Ag- and Au-Doped SnSe2 Monolayers for the Detection of NO, NO2, SO2, H2S and HCN
by Yulin Ma, Danyi Zhang, Zhao Ding and Kui Ma
Nanomaterials 2025, 15(18), 1454; https://doi.org/10.3390/nano15181454 - 21 Sep 2025
Viewed by 351
Abstract
In this work, the gas sensing properties and adsorption mechanisms of Ag- and Au-doped SnSe2 monolayers toward NO, NO2, SO2, H2S, and HCN were systematically investigated via first-principles calculations. The results demonstrate that NO2 exhibits [...] Read more.
In this work, the gas sensing properties and adsorption mechanisms of Ag- and Au-doped SnSe2 monolayers toward NO, NO2, SO2, H2S, and HCN were systematically investigated via first-principles calculations. The results demonstrate that NO2 exhibits the strongest interaction and the highest charge transfer in both doped systems, indicating superior sensing selectivity. Biaxial strain (ranging from −8% to 6%) was further applied to modulate adsorption behavior. By evaluating changes in equilibrium height, adsorption energy, charge transfer, and recovery time across ten representative adsorption systems, it was found that both compressive and tensile strains enhance the interaction between gas molecules and doped SnSe2 monolayers. Specifically, H2S/Au–SnSe2 and HCN/Au–SnSe2 are highly sensitive to tensile strain, while NO/Au–SnSe2, H2S/Ag–SnSe2, NO/Ag–SnSe2, and NO2/Ag–SnSe2 respond more strongly to compressive strain. Systems such as NO2/Au–SnSe2, SO2/Au–SnSe2, and SO2/Ag–SnSe2 respond to both types of strain, whereas HCN/Ag–SnSe2 shows relatively low sensitivity in charge transfer. Recovery time analysis indicates that NO2 exhibits the slowest desorption kinetics and is most affected by strain modulation. Nevertheless, increasing the operating temperature or applying appropriate strain can significantly shorten recovery times. While other gas systems show smaller variations, strain engineering remains an effective strategy to tune desorption behavior and enhance overall sensor performance. These findings offer valuable insights into strain-tunable gas sensing behavior and provide theoretical guidance for the design of high-performance gas sensors based on two-dimensional SnSe2 materials. Full article
(This article belongs to the Section Environmental Nanoscience and Nanotechnology)
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18 pages, 4786 KB  
Article
Feasibility Study for Wearable Sensor-Based Vibrotactile Feedback for Posture and Muscle Activation in a Relevant Dentistry Setting
by Demir Tuken, Samuel J. Murphy, Robert D. Bowers and Rachel V. Vitali
Sensors 2025, 25(18), 5891; https://doi.org/10.3390/s25185891 - 20 Sep 2025
Viewed by 533
Abstract
This feasibility study evaluated a wearable sensor-based haptic feedback system designed to promote ergonomic awareness and influence posture and muscle activation patterns during a standard dental procedure. Inertial measurement units (IMUs) monitored posture by tracking back and neck angles, while four surface electromyography [...] Read more.
This feasibility study evaluated a wearable sensor-based haptic feedback system designed to promote ergonomic awareness and influence posture and muscle activation patterns during a standard dental procedure. Inertial measurement units (IMUs) monitored posture by tracking back and neck angles, while four surface electromyography sensors recorded muscle activation in the lower erector spinae (LES) and upper trapezius (UT) muscles. Two IMUs with vibrotactile motors delivered real-time haptic feedback when participants maintained mechanically disadvantageous postures for extended periods during a cast metal crown preparation procedure on a manikin typodont. Data from four dental students participating in a total of 24 trials, half with and half without feedback, were analyzed via a two-way ANOVA to determine the effects of feedback and activity (e.g., inspections or drilling) on posture and muscle activation. Feedback slightly increased neck angles, but back angles remained nominally unchanged. Reduced UT activation and increased right LES activation suggests altered muscle recruitment strategies. Heatmap and RULA analyses indicated a shift toward more varied and potentially safer postural distributions during feedback trials. Postural and muscle activation data were also analyzed across four activity labels, which revealed that Drilling was consistently associated with higher ergonomic risk. Real-time haptic feedback influenced posture and muscle activation in dental students, particularly by reducing UT strain despite increased neck flexion. These findings support the integration of wearable feedback systems into preclinical training to enhance ergonomic awareness and potentially reduce the risk of developing musculoskeletal disorders, to which dentists are particularly prone. Full article
(This article belongs to the Collection Wearable Sensors for Risk Assessment and Injury Prevention)
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19 pages, 4815 KB  
Article
Strain Sensor-Based Fatigue Prediction for Hydraulic Turbine Governor Servomotor in Complementary Energy Systems
by Hong Hua, Zhizhong Zhang, Xiaobing Liu and Wanquan Deng
Sensors 2025, 25(18), 5860; https://doi.org/10.3390/s25185860 - 19 Sep 2025
Viewed by 324
Abstract
Hydraulic turbine governor servomotors in wind solar hydro complementary energy systems face significant fatigue failure challenges due to high-frequency regulation. This study develops an intelligent fatigue monitoring and prediction system based on strain sensors, specifically designed for the frequent regulation requirements of complementary [...] Read more.
Hydraulic turbine governor servomotors in wind solar hydro complementary energy systems face significant fatigue failure challenges due to high-frequency regulation. This study develops an intelligent fatigue monitoring and prediction system based on strain sensors, specifically designed for the frequent regulation requirements of complementary systems. A multi-point monitoring network was constructed using resistive strain sensors, integrated with temperature and vibration sensors for multimodal data fusion. Field validation was conducted at an 18.56 MW hydroelectric unit, covering guide vane opening ranges from 13% to 63%, with system response time <1 ms and a signal-to-noise ratio of 65 dB. A simulation model combining sensor measurements with finite element simulation was established through fine-mesh modeling to identify critical fatigue locations. The finite element analysis results show excellent agreement with experimental measurements (error < 8%), validating the simulation model approach. The fork head was identified as the critical component with a stress concentration factor of 3.4, maximum stress of 51.7 MPa, and predicted fatigue life of 1.2 × 106 cycles (12–16 years). The cylindrical pin shows a maximum shear stress of 36.1 MPa, with fatigue life of 3.8 × 106 cycles (16–20 years). Monte Carlo reliability analysis indicates a system reliability of 51.2% over 20 years. This work provides an effective technical solution for the predictive maintenance and digital operation of wind solar hydro complementary systems. Full article
(This article belongs to the Section Fault Diagnosis & Sensors)
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16 pages, 5288 KB  
Article
Development of a Load Monitoring Sensor for the Wire Tightener
by Yuxiong Zhang, Qikun Yuan, Tao Shui, Gang Hu, Xuanlin Chen and Yan Shi
Electronics 2025, 14(18), 3716; https://doi.org/10.3390/electronics14183716 - 19 Sep 2025
Viewed by 291
Abstract
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 [...] Read more.
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. Full article
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