<p>Traditional detection methods for pillar porcelain insulators, both domestically and internationally, are predominantly direct contact-based, which have certain limitations and drawbacks. These methods pose significant operational risks and are incapable of performing online detection of pillar porcelain insulators in their energized state. This paper proposes a monitoring system for fracture failure of porcelain insulators by combining experimental analysis and finite element simulation. The interface bonding hypothesis and load loading hypothesis are made when the model is established. Taking the actual production of double-section pillar porcelain insulators as the research object, the structural static test is conducted to measure some material parameters of the porcelain column. Based on the theory of finite element analysis, a full-scale model of the double-section pillar porcelain insulator is established to analyze the stress response of the porcelain column and the mechanical behavior of the entire insulator under different boundary loads. A non-contact optical monitoring system for the double-section pillar porcelain insulator is constructed based on the Digital Image Correlation (DIC) method. The results of the monitoring system are compared with those of the finite element analysis, showing that the system has high accuracy in identifying high-stress states, with a minimum relative error of only 0.7%. This system demonstrates strong feasibility for early warning of fracture failure risks.</p>