Multi-parameter distributed fiber optic sensor system and methods of sensor manufacturing
11320291 · 2022-05-03
Assignee
Inventors
Cpc classification
International classification
Abstract
In accordance with embodiments there is provided manufacturing processes for fibre optic sensors. In an example, a portion of a fiber optic cable is coated with a thin film layer and placed in a channel of a fiber carrying flexible member for a fiber optic sensor. The portion is embedded in the channel using one of: a thermal curing process after filling the channel with a metallic liquid suspension or polymeric adhesive; and an electroplating or electroless plating process. Filling the channel may comprises performing a controlled dispensing using an automated process such as a drop-on-demand deposition process. In an example, a fiber optical cable is placed in a channel of a flexible member. Micro-laser welding or electron beam welding is used to locally melt the member areas adjacent to the cable resulting in the flow of liquid around the fiber creating a solid structure with embedded fiber after solidification.
Claims
1. A process of manufacturing comprising: coating a portion of a fiber optic cable with a thin film layer; placing the portion of the fiber optical cable as coated in a channel of a fiber carrying flexible member for a fiber optic sensor; and embedding the portion of the fiber optical cable as coated in the channel using one of: a thermal curing process after filling the channel with a metallic liquid suspension or polymeric adhesive; and an electroplating or electroless plating process.
2. The process of claim 1 wherein filling the channel comprises performing a controlled dispensing using an automated process.
3. The process of claim 2 wherein the automated process comprises an automated drop-on-demand deposition process.
4. The process of claim 1 wherein the thin film layer is a conductive thin film layer.
5. The process of claim 1 further comprising: assembling the fiber carrying flexible member and the portion of the fiber optical cable as coated, as embedded, in a housing body with an expanding/collapsing capable flexible member; wherein a first surface of the expanding/collapsing capable flexible member is exposed at one end, through a port in the body, with the immediate external environment to the sensor, the expanding/collapsing capable flexible member changing size in response to changes in pressure or level of liquid in the immediate external environment; wherein the fiber carrying flexible member is coupled to and housed in the body and further coupled to a second surface of the expanding/collapsing capable flexible member such that an expanding or collapsing of the expanding/collapsing capable flexible member changes a shape of the fiber carrying flexible member; and wherein at least one end of the fiber optic cable extends out through the body.
6. A process of manufacturing comprising: placing a coated or uncoated portion of a fiber optical cable in a channel of a flexible member for a fiber optic sensor; and using micro-laser welding or electron beam welding to locally melt the flexible member areas adjacent to the fiber optic resulting in the flow of the melted liquid around the fiber to create a solid structure with embedded fiber after solidification.
Description
DESCRIPTION OF THE DRAWINGS
(1) One or more examples of the various aspects disclosed are illustrated in the drawings in which:
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DETAILED DESCRIPTION
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(28) In an example as shown in
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(30) Chamber 1 and Chamber 2 are connected through a hole where the fiber optic passes through. From Chamber 2 to Chamber 3 there is a fiber optic seal fitting 414 to isolate Chamber 2 and Chamber 1 from the external fluid. Chamber 3 is connected to a liquid/gas fitting 416 connected to a pipe (see
(31) The fiber optic seal fitting is shown in more detail in
(32) Another example of the pressure/level and temperature sensor 300A is shown in
(33) The example of
(34) The distribution of strain in the respective beam (
(35) Fiber embedding process is a multi-stage process. In one method, the sections of the fiber optic to be embedded are coated with a conductive thin-film layer (i.e., metal nano particle suspensions such as silver nano-particle suspension) and thermally cured. Fiber coating can also be conducted through a controlled dipping process, in which the fiber optic is inserted and moved in a liquid along its longitudinal axis and the surface tension will allow the fiber to be coated by the liquid. Fiber optic coating can also be conducted through physical deposition methods (such as Physical Vapor Deposition (PVD) or sputtering) or chemical deposition methods (such as Chemical Vapor Deposition). The thickness of the coating on the fiber varies between 20 nanometer and 10 micrometer and is a function of the coating material and deposition process. Thermal curing is conducted either by bulk heating (using furnace or hot plate) or point and localized heating using laser or infra-red heat sources. Both bare fiber optic (fiber optic with no jacket) and fiber optic cables with standard acrylate or polyimide coatings can be used in this process without removing the jackets. The coated fiber is then placed in a pre-cut groove on the flexible membrane (beam or ring) (e.g. in groove 1002A of
(36) The thermal curing temperature range depends on the type of bonding material and can vary from room temperature (i.e., 20° C.) to 1000° C.
(37) The groove in which the fiber is embedded can be made by a high accuracy CNC machine or other micromachining techniques including laser micromachining.
(38) The depth of the groove varies between 50 micro-meter and 1 mm.
(39) The flexible component on which the fiber 410 is bonded or embedded could be in the form of a hollow cylinder (i.e., a tube). Such a tube could replace the ring or beam of
(40) In general, any flexible body with regular or un-regular shape could be used as a flexible component for bonding the fiber optic. The yield strength of the flexible body should be high enough that it will not be plastically deformed as a result of applied load. Although it is ideal to have a flexible material with linear response (linear deformation vs load without hysteresis and memory effects), any non-linearity could be compensated by calibration. The magnitude of strain in all these cases could be between −4000 to 4000 microstrain; this range is a function of the shape, geometry, and material of the flexible component.
(41) The embedding process could also be conducted through electroplating or electroless plating process. In this process, the coated sections of the fiber are placed in the pre-cut groove, and the beam-fiber assembly is placed in an electroless plating or electroplating bath. In the electroless or electroplating bath metal particles are deposited on the coated fiber and the groove and will result in the embedding of the fiber in the flexible membrane. The electroless or electroplating process can only be applied to flexible components made of metals or pre-coated with a conductive layer. The most common method of electro or electroless plating is Nickel plating; however, a wide range of metals can be used in this process such as gold, silver, and chromium. The thickness of the coating on the fiber varies between 100 nanometer and 2 mm.
(42) The optical signal demodulation to obtain the measurement values is conducted through the measurement and analysis of the optical reflection spectrum from the optical fiber.
(43) In examples, the locations of the fiber embedded or bonded to the flexible components are pre-inscribed with fiber Bragg gratings (FBGs). Usually, the gratings are inscribed before adding the thin film layers. FBGs are periodic modulations of the index of refraction which are laser-inscribed inside the core of optical fiber. FBGs result in the reflection of the light at a certain wavelength, called Bragg wavelength (λ.sub.B), which is a function of the period of the grating modulation (Λ) and the effective mode index of refraction (n.sub.eff) in the optical fiber, i.e. λ.sub.B=2n.sub.effΛ. The shape and the location of the reflection spectrum (
(44) As an example, uniform temperature or strain along the FBG only causes shift in the Bragg wavelength (
(45) In the aforementioned transducer design, the embedded locations on the fiber could be part of a single FBG or each point can have a different Bragg grating. In the former case, the signal analysis will be based on the demodulation of one reflection spectrum and in the later case the signal analysis will be based on the demodulation of multiple reflection spectrums. In both cases, the reflection spectrum may shift or change its shape as a result of the deformation in the flexible component on which the fiber optic cable is bonded or embedded.
(46) Each FBG reflection spectrum is analyzed based on the following parameters (
(47) Table 1 lists the effect of temperature and mechanical load (pressure, change in level, and mechanical strain) on each of these parameters:
(48) TABLE-US-00001 TABLE 1 Effect of temperature and strain on the shape parameters of FBG λ.sub.B FWHM A.sub.ref (I.sub.1.sup.+, I.sub.1.sup.−) Increase in Increase (max Unchanged Unchanged Unchanged temperature or strain change: 20 nm) (zero gradient along FBG) Decrease in Decrease (max Unchanged Unchanged Unchanged temperature or strain change: −20 nm) (zero gradient along FBG) Increase in Increase (max Increase (max Increase (max Depends on temperature or strain change: 20 nm) change: 1 nm) change: 200%) gradient (range (non-zero gradient 0 to 100% of along FBG) maximum peak intensity at λ.sub.B) Decrease in Decrease (max Increase (max Increase (max Depends on temperature or strain change: −20 nm) change: 1 nm) change: 200%) gradient (range: (non-zero gradient 0 to 100% of along FBG) maximum peak intensity at λ.sub.B)
(49) The examples of sensors explained above (e.g.
(50) The aforementioned invention for pressure/temperature/level sensing has the ranges and accuracy levels described in Table 2.
(51) TABLE-US-00002 TABLE 2 Technical specifications of the pressure/temperature/level sensor Measured Parameter Range Resolution Accuracy Pressure 0 to 10,000 psi - 0.02% of the full 0.2% of Gauge pressure scale full scale Temperature Low temperature: 0.01° C. 0.1° C. −55° C. to 300° C. High temperature: −55° C. to 800° C.
(52) The fiber optic cable can be monitored by any optical data acquisition system that has the capability for generating light (i.e., lasers, light emitting diodes, or broadband light source) and an optical power detector. These units are commercially available or can be designed and built by integrating standard OEM components.
(53) In an example, an optical data acquisition unit (e.g. a system 1900) can be combined with a micro-electromechanical switch 2002 to form architecture 2000 to monitor multiple cables (
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P=+A.sub.1λ.sub.1.sup.2+A.sub.2λ.sub.1+B.sub.1λ.sub.2.sup.2+B.sub.2λ.sub.2+C
where A.sub.1, A.sub.2, B.sub.1, B.sub.2, and C are constant numbers. This formula has temperature compensation embedded in it. However, temperature can be obtained from a different formula, as follows:
T=D.sub.1λ.sub.1.sup.2+D.sub.2λ.sub.1+E.sub.1λ.sub.2.sup.2E.sub.2λ.sub.2+F
(55) This invention has several industrial applications. One of the applications is the monitoring of the groundwater level and temperature during in-situ thermal remediation (ISTR). ISTR is an industry standard process for remediating contaminated lands. In this process, heating electrodes are inserted into the soil and cause the evaporation of the contaminants which are then collected through a vacuum extraction system. Measurement of groundwater level is important to obtain the hydraulic gradients in the water table and get insight into the direction of the movement of contaminated substances.
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(57) In an in-situ thermal remediation field (environment) and with reference to
(58) In another type of installation, sensor cables with a level sensor point at the end of the cable are lowered in pre-drilled wells down to the groundwater to measure the groundwater level during a remediation project. These cables might have temperature sensing points along the cable in addition to the level sensor at the end of the cable. The level sensor data is used to calculate the hydraulic gradients and mobility of the contaminants during the remediation project.
(59) Both thermal and groundwater level sensor data are required for process performance monitoring and contractual requirements. The data is also used for feedback control of the remediation process. The fiber optic sensor system is applicable to a wide range of in-situ thermal remediation technologies including electric resistance heating (ERH), thermal conduction heating (TCH), steam-enhanced extraction (SEE), and gas thermal heating. In general, the fiber optic sensor system can be applied to any in-situ thermal remediation technology regardless of the type of heating technology. A limiting factor for installation is the diameter of the sensor cable which is an engineering design parameter.
(60) In addition to fiber Bragg gratings, other types of fiber optic sensors can be used in this invention. In an example, the sections of the fiber optic embedded, encapsulated, or bonded is one or a multitude of in-fiber Fabry-Perot interferometers (also known as fiber Fabry-Perot cavity), where each in-fiber Fabry-Perot interferometer is made of two reflection planes separated by a known distance and where the reflection planes are in-fiber Bragg gratings.
(61) In an example, the sections of the fiber optic embedded, encapsulated, or bonded has no in-fiber structures and the sensing of external parameters is based on the scattering of light from the optical fiber including, Raman scattering, Rayleigh scattering, and Brillouin scattering.
(62) In an example, at least one section of the fiber optic embedded, encapsulated, or bonded is made of Photonic Crystal Fiber (PCF).
(63) In an example, at least one section of the fiber optic embedded, encapsulated, or bonded is made of microstructured fiber optics.
(64) Throughout the description and claims of this specification, the word “comprise” and “contain” and variations of them mean “including but not limited to” and they are not intended to (and do not) exclude other components, integers or steps. Throughout the description and claims of this specification, singular encompasses the plural unless the context requires otherwise. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
(65) Features, integers characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example unless incompatible therewith. All of the features disclosed herein (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, ma be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing examples or embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings) or to any novel one, or any novel combination, of the steps of any method or process disclosed.