Highly Sensitive Flexible Strain-Sensing Systems Based on HfSe₂–Carbon Nanomaterial Composites for In Situ Tension Monitoring in Advanced Chain-Link Structural Interconnects

Mining chains operating in adverse underground environments and experiencing elevated coal transportation volumes are susceptible to critical failures including overloading, chain jamming, and fracture due to their role as essential transmission components. Realtime chain strain monitoring systems provide continuous assessment capabilities and early warning of potential failure events. Conventional strain sensors employed for tension monitoring exhibit significant limitations including insufficient sensitivity, excessive power requirements, and substantial dimensional constraints. In this investigation, we have synthesized strain sensors specifically engineered for downhole applications by leveraging the exceptional properties of graphene and HfSe2. The integration of HfSe2 into graphene-based composites resulted in the formation of heterointerfaces, which enhanced the sensors’ sensitivity and linearity. These sensors demonstrate superior performance characteristics, including enhanced gauge factor (GF = 22.8) within the linear strain range of 0–2000 με, exceptional linearity ( $R^{2}_{L} = 0.98$ ), ultralow detection threshold (100 με), and minimal power consumption (2.05 mW), while maintaining measurement accuracy across extreme thermal conditions (0 °C–60 °C). The acquired strain signals underwent fast Fourier transform (FFT) analysis, with subsequent application of a Butterworth filter to attenuate high-frequency components and mitigate environmental noise interference. The developed graphene-/HfSe2-based strain sensor substantially enhances monitoring precision and operational safety, presenting significant implementation potential for advanced mine intelligence systems.