Overview of Trends in Optical

Transcription

1 Overview of Trends in Optical Fiber Sensors Alexis Méndez, PhD 1728 Clinton Ave., Alameda, CA (USA) 1

2 Contents Introduction ti Original Driving Factors Applications Market Situation Future Applications Conclusions 2

3 Introduction 3

4 Optical Fiber Sensor Roots: Telecommunications Over 30 years of R&D, testing product development and broad commercial use in telecoms industry! 4 After Personick

5 Why Fiber Optic Sensors? Source: NASA Langley Composite wing IVHM testing 400 conventional strain gage sensors fiber optic FBG strain sensors

6 Advantages of Fiber Optic Sensors Galvanic isolation EMI immunity Intrinsically safe Passive: no need for electrical power Possibility of remote, multiplexed operation Small size and lightweight Integrated telemetry: fiber itself is a data link Wide bandwidth High sensitivity 6

7 Fiber Optic Sensor: Basic Configuration E=E o cos(kz - t) Sensing is based on detecting a change in one or more of the light wave properties: intensity phase polarization frequency 7

8 Photonics Components Needed Optical Sources Quantum Cascade Lasers Tunable lasers Fiber lasers LEDs Broadband sources Detectors CCDs UV, VIS, IR detectors Multi-spectral spectrometers Light Processing Filters Imaging Beam steering Light Guiding IR waveguides Specialty optical fibers Lenses 8

9 Optical Fiber Waveguides: Material & Geometry Choices Glass vs. Crystals vs. Polymer Amorphous glasses (silica, fluorides, chalcogenide) Single crystals (Sapphire) Polycrystalline materials (Halide) Polymeric (PMMA, polycarbonate, etc.) Solid vs. Hollow Index guiding (TIR) Reflection guiding Photonic Bandgap guidingg 9

10 Fiber Sensors Configurations Single-point sensor Fiber Multi-point (quasi-distributed) sensor Sensing element Distributed sensor Multiple sensing points Continuous sensing element 10

11 Example of a Single-Point Sensor: Intensity Pressure Sensor Pressure, displacement, etc A= step index B= graded index C= 2 fibers Source: EOTEC 11

12 Fiber Bragg Gratings Arrays: Multi-Point i t FO Sensing Spool with a continuous FBG Sensor Array Up to 100s of FBGs positioned at discrete points along a continuous fiber. Each FBG can measure a specific parameter. Source: LxSix 12

13 Distributed Fiber Sensing: Raman & Brillouin Scattering Systems The fiber is the sensor Measurements all along a 10km fiber = 10, sensors!! Standard multi-mode optical fibre T 1 T 2 T 3 T 4. Backscattered light provides measurement point every 1m 1m pulse of light T 9,995 T 9,996 T 9, T 9,998 T 9,999 13

14 Original FOS Technology ogy Drivers Given the dielectric nature of optical fibers and their intrinsic immunity to EMI/RFI, they were the natural choice to develop sensors in high voltage and harsh environment applications. Key driving applications were originally: HV Current & Voltage Systems Downhole oil & gas well sensors Military: acoustic & gyro sensors 14

15 1 st Generation Current Sensor: Magneto Optic Current Transducer (MOCT) Quartz glass monoblock with optical fiber link Circa 1991 multimode fiber thin-film polarizers collimators 15

16 2 nd Generation: All-Fiber Current Sensor All fiber sensing coil Polymeric, lightweight insulator Circa 2002 Photos: NxtPhase 16

17 Downhole Instrumentation Comparison: Electronic vs. Fiber Optic ELECTRONIC SYSTEM FIBER OPTIC SYSTEM Power supply Electronic ICs Solder joints Batteries Multi-components Insulation materials Copper cable Moving parts SURFACE UNIT CABLE Light beam source Opto-electronic devices Passive No electronics Low part count No moving parts Fiber optic cable Power supplied electronic circuits SENSOR No electronic circuits 17

18 Downhole Applications: Well Monitoring 18

19 Proven Field Use of FBGs: Downhole P/T Sensors >150 Source: Weatherford 19

20 The Instrumented Oilfield Seismic Land Wells Pipelines Refineries Seismic Offshore Wells Downhole Seismic MultiPoint Temp (MPT) Borehole Pressure (BHP) Sand Detection MultiPoint Temp (MPT) Perimeter Security Leak Detection Inventory Monitoring Leak Detection Perimeter Security Seismic Streamers Ocean Bottom Cables MultiPoint Temp (MPT) Borehole Pressure (BHP) Sand Detection Strain Sensing Picture courtesy of Sabeus Sensor Systems 20

21 FO Seismic & Geophone Sensors: Tow Arrays & OBCs Source: PGS 21

22 Pipeline Leak Detection Fiber cable 22 SNAM-Rete Gas

23 Fiber Optic Gyro (FOG): Applications Mobile Antenna Pointing & Stabilization Vehicle Navigation Autonomous Vehicle Navigation Material Handling Equipment Torpedoes Weapons Simulators Video Camera Stabilization ti Open & closed-loop designs 1,2,3, 6 axes Typically PM fiber with 80um OD. Source: KVH 23

24 NGC FOG Product Family Single, two, and three axes fiber optic gyros. Self contained and remote operation. ufors product line on top. Performance from 1 to 36 º/hr. Over 7500 ufors sold and production is ongoing. FOG 200 product line below. Performance of 3 º/hr. Lower left FOG packaged for 200 g rms vibration environment. By the 35th FOG anniversary (2011), NGC will have delivered over 100,000 fiber optic gyros! Big market for PM fiber and PM couplers 24

25 Lengthy Commercialization Process: Fiber Optic Gyros (FOG) 1975 First publication 1985 Lab 0.01 º/hr First commercial applications 1995 (Boeing 777) 2005 Broader Applications: (Subsea, automotive, etc) Photo: KVH Industries 25

26 Applications 26

27 FO Sensor Applications: Segment Areas Oil & Gas Reservoir monitoring Downhole P/T sensing Seismic arrays Energy Industry Power plants Boilers & Steam turbines Power cables Civil Bridges Dams Roads Tunnels Land slides Turbines Transportation Refineries Aerospace Jet engines Rocket & propulsion systems Fuselages Rail monitoring i Weight in motion Carriage safety 27

28 Successful Fiber Optic Biosensor: 20 Years of Product Sales! Camino Camino 110-4B Intracranial Pressure Monitoring Kit Reached a sales volume of 60,000 units/year! The ICP Monitoring Catheter is designed ed for Rapid Placement e with instant t monitoring at the source. A rapid rise in intracranial pressure resulting from severe head injury or other pathology requires early recognition and intervention. Pressure Optical Fibers 28

29 Medical Pressure Sensor: Samba 3200/Preclin 29

30 Medical Sensors: Large, Disposable Market! Intra-aortic pressure sensor 30

31 Cardiac Force Probe: Endosense 31 Motivation Atrial Fibrillation, AF, affects 6 million today Improved catheter ablation Real-time feedback Multi-billion dollar market Endosense Touch+ TM Force Sensing Technology is based on a probe fitted with 3 FBGs. Immune to EMI Probe cost allows for one time use no autoclave 31

32 FBG Fabrication: Reel-to-Reel Process: High Volume and FBG Arrays -Fully automated process: - fiber stripping i - recoating - testing - winding - Continuous Write Sequence - Capacity for 150,000 units/yr - Arrays with 100s of FBGs - No Contamination hands free - Flexible and programmable - 100% inspection 32

33 FBG-Based Sensors & Arrays: Multiple l Parameters & Suppliers Accelerometer Displacement meter Strain meter Pressure meter Thermometer Incline meter Reliability is the main commercial issue 33

34 FBG Interrogators: Multiple l Suppliers & Styles New Photo and Bullets Lab Field/OEM Module Hand-held 34

35 Conventional Strain Gages & FBGs In May 2007 HBM the world s largest supplier of strain sensing systems began offering optical strain gages and interrogators based on FBG technology!! This is the first time that a conventional foil strain gage manufacturer has adopted d and embraced FBGs. A broad and hard commercial pull should be expected from this initiative. Will help motivate others in the industry. Source: HBM 35

36 Driving Factors for On-line Monitoring: Decaying Civil il Infrastructure t 36

37 Smart Structures Materials with Integrated "Nervous System" Carbon Fiber Reinforced Polymer Composite with embedded fiber optic Bragg grating sensor 100µm Photo: Daimler-Chrysler Photograph: DaimlerChrysler 37

38 Smart Fabrics: Civil & Geotechnical Applications Source: FOS&S Detect t gases & chemical in landfills Monitor water ground table Detect and monitor corrosion in reinforce concrete Source: BAM, Germany 38

39 Smart Fabrics: Patient t Monitoring OFSETH i Project Monitoring or cardiac and respiratory rhythms in healthcare patients FBG sensors Prevention of SIDS in newborns 59 FBG Sensors woven within a special textile 39

40 Load Monitoring in Wind Turbine Blades FBG Strain / Temperature Sensor Pads D 3.1 D 3.2 D 3.3 Signal Processing D 1.1 D 1.2 D 1.3 Rotor diameter: 112 m Source: IPTH, Jena 40

41 Temperature Monitoring of Rail Cars 20 FBG sensors are mounted on different parts of a train car. Hong Kong Rail System 41

42 Sensor Installation 42

43 Measurement Traces (Temperature differences) Axle box (Front) Axle box (Back) Bare and packaged FBGs in front motor Four brakes 43

44 Cryogenic LNG Tanker: Compartment t Monitoring i 44

45 Active Fiber Coatings External Measurands: Temperature Pressure Stress/strain Electromagnetic fields Biological i l agents Chemical substances Transmitted Light Phase change Transmittance Wavelength Polarization Fiber coating Optical fiber Coating response Refractive index change Fluorescence Absorption An area hardly explored in the Striction ti Specialty Optical Fiber field Spectral shift Scattering 45

46 Water Leak Detection: Distributed Moisture Sensor A special polymer coating swells in the presence of moisture, expanding and producing microbending losses on the strapped multi-mode fiber. Source: B. Culshaw 46

47 Evanescent-Wave Sensor Principle Chemically-Induced Cladding Change Chemical agent Waveguide core Waveguide cladding n 2 n 1 S o S 1 S o Presence of chemical agent in cladding region changes optical properties Light propagating through sensor waveguide is affected by changes in exposed region Source: IOS Inc. 47

48 DICAST Chem Sensor Fibers Fully distributed, intrinsically sensitive, chemically active, cladding- based, fiber optic sensor elements provide seamless coverage. Cl 2 HCN H 2 S Nerve Source: IOS Inc. 48

49 PCF Applications: Gas Sensing Side laser-drilled hole Fiber Cross-section Source: IPTH 49

50 Optical Fiber Arrays: Multiple Agent Sensing Individually Clad Optical Fibers Optical Fiber Array 1 mm 5x 80x Specifications: ~50000 fibers 3.1 μm diameter 10x 4.5 μm da diameter Source: D. Walt/Tufts Univ. 50

51 Microsphere Arrays: Assembly Process Microspheres 10 μm 10 μm Source: Dickinson, T. A.; Michael, K. L..; Kauer, J. S.; Walt, D. R.; Anal. Chem. 1999, 71,

52 Surface Micromachining + Active Coatings Chemical or bio agent Source: Fiberlogix, Ltd. 52

53 Market Perspective 53

54 Global Optoelectronics Market Source: OIDA 54

55 Telecom vs. FO Sensors Optical Telecom FO Sensors 55

56 Sensors Market Size Development of the World Market Share of Fiber Optical Sensors until 2008 US $ Million SENSORS WORLD MARKET U$32,534.0M Fiber Optical Sensors Total sensors U$42,158.4M 2008 U$50,594.3M AVERAGE OF ANNUAL GROUTH RATE 4,5% FOS WORLD MARKET U$175,0M MKT SHARE (0,54%) 2003 U$283,4M - MKT SHARE (0,67%) 2008 U$1,450,0M MKT SHARE (2,87%) AVERAGE OF ANNUAL GROUTH RATE 23,5% Source: INTECHNO CONSULTING 56

57 2008 FOS Market Source: Lightwave Venture LLC & Qorex 57

58 Distributed Optical Fiber Sensor Market Source: Lightwave Venture/OIDA 58

59 Market Hurdles & Barriers Fragmented Markets & Applications Unfamiliarity it with the technology Conservative/no-risk attitude of some industries Need for a proven field record & Reliability Compatibility with existing equipment Cost Long R&D and NPI cycles Availability of trained personnel Turn-key type systems (sensing solution) Lack of standards Quality, performance, packaging & reliability deficiencies across vendors 59

60 Technology Development Forces Applications Systems Subsystems Module Device Process Materials Science Application Pull Technology Push 60

61 Where Are The Opportunities? Point Sensing Oil & gas Structural Health Monitoring (SHM) Chem/Bio Sensing Medical/Life Sciences (disposable sensors) Water Quality/Wastewater t t Treatment t Automotive (very low cost requirements) Aerospace & Shipboard applications (reduction in size & weight) Low Cost Sensors (Plastic fibers) Food Industry/Agriculture? Distributed Intrusion detection/perimeter protection Transmission Lines (Dynamic Energy Rating) Homeland security Home Security (FTTH spin-off) New Breakthroughs Photonic Crystal Fibers (OCF) based sensors 61

62 Future Market Opportunities: Low cost sensors all applications & markets Disposable sensors medical & health care Distributed sensors all areas Smart fabrics geotechnical, medical, aerospace Hydrogen sensors fuel cells Food industry water & food safety Environmental power plant & refinery emissions, plane & vehicle cabin air quality 62

63 Future R&D Opportunities: Novel Specialty Fibers & Coatings Custom-tailored specialty fibers Multi-core Tapered Brillouin scattering enhanced Perforated claddings Active fiber coatings Holey and hollow-core fiber based sensors Fiber arrays Plastic fiber sensors & FBGs 63

64 Conclusions 64

65 Conclusions Fiber Optic Sensors (FOS) are an Enabling Technology for diverse civil, industrial and defense applications. FOS technology offers the possibility of sensitive, non-destructive, and in-situ measurements of temperature, stress, strain and deformation of different materials & structures. Novel applications for on-line monitoring and service lifetime in a variety of applications and industries are made possible by FOS. Theoretical and experimental research is needed to investigate: Fiber embedding techniques Mechanics of host material/fiber interfaces Adequate fiber coatings and packaging designs Sensor design and configuration 65