DEVICE FOR DETECTING A DEFECT IN A STRUCTURAL ELEMENT MADE OF COMPOSITE MATERIAL
20250389670 · 2025-12-25
Inventors
- Léo RICHARD (LE TAILLAN-MEDOC, FR)
- Lionel QUETEL (PLEUMEUR BODOU, FR)
- Jean-François RIBOULET (TREBEURDEN, FR)
- Florent LYPHOUT (CAOUENNEC-LANVEZEAC, FR)
Cpc classification
International classification
Abstract
The present invention relates to a device for detecting a defect in a structural element made of composite material. The device includes a structural element made of composite material and having an elongate shape, at least one detection optical fiber arranged inside the structural element, and a light-emitting device comprising a plurality of light sources connected to a strand of optical fibers, all of the strands being grouped into a bundle of strands.
Claims
1. A device for detecting a defect in a structural element made of composite material, the device comprising: a structural element made of composite material and having an elongate shape, a plurality of detection optical fibers arranged inside the structural element, and extending from a first longitudinal end of the structural element to a second longitudinal end of the structural element, and a light-emitting device operatively connected to the first longitudinal end of the structural element, so as to transmit the light emitted by the light-emitting device to a first longitudinal end of the detection optical fibers, wherein: the light-emitting device comprises a plurality of light sources, each light source being operatively connected to a strand of optical fibers, so as to transmit the light emitted by the light source to the optical fibers of the strand, all the strands being grouped together in a bundle of strands, the end of the strands of the bundle being operatively connected to the first longitudinal end of the structural element, wherein the light-emitting device is further able to successively actuate the different light sources, so as to successively transmit the light emitted by the different light sources to the different strands and detection optical fibers.
2. The device according to claim 1, wherein the device further comprises a detection light detection device, capable of detecting light from each detection optical fiber at a second longitudinal end of each detection optical fiber.
3. The device according to claim 2, wherein the light detection device is rotatable, so as to successively detect light from the various optical detection fibers.
4. The device according to claim 1, wherein the end of the strands of the bundle is arranged inside a sheath and is aligned with the first longitudinal end of the structural element.
5. The device according to claim 1, wherein the composite material comprises a carbon fiber core surrounded by a glass layer.
6. The device according to claim 1, wherein the device comprises a plurality of detection optical fibers.
7. The device according to claim 6, wherein the detection optical fibers comprise at least one single-mode optical fiber and/or at least one multimode optical fiber.
8. The device according to claim 1, wherein the first longitudinal end and the second longitudinal end of the structural element are polished.
9. The device according to claim 1, wherein the plurality of light sources comprises light-emitting diodes.
10. The device according to claim 9, wherein the light-emitting diodes have an emission wavelength between 1400 and 1600 nm or between 380 and 780 nm.
11. The device according to claim 1, wherein the number of strands is at least equal to the number of detection optical fibers.
12. The device according to claim 1, wherein the light detection device comprises a photodiode.
Description
[0032] Further advantages and particularities of the present invention will become apparent from the following description, given as a non-limiting example and made with reference to the attached figures:
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DETAILED DESCRIPTION
Operating Principle of the Detection Device According to the Invention
[0075] As shown in
[0076] The light emitter 2 is able to emit optical power, part of which is injected into the optical fibers 33, 34, 35, 36 of the ring 3. The optical fibers 33, 34, 35, 36 are detection optical fibers that are arranged inside the ring 3, and extend from a first longitudinal end 31 of the ring 3 to a second longitudinal end 32 of the ring 3.
[0077] The light emitter 2 comprises a plurality of emitters 21. The emitters 21 are advantageously infrared or visible light-emitting diodes (LEDs), which are switched on in a rotating sequence to illuminate each of the fibers 33, 34, 35, 36 of the ring 3 in turn. The rotation produces a waveform at the detector 4 with as many local maxima as there are passing (undamaged) fibers.
[0078] The rotary effect should make it possible to do away with the absolute power level measured at the output of the ring 3 to conclude on the state of the fibers 33, 34, 35, 36, and thus use a criterion relative to the local maxima. The absolute power measured at the output of the ring 3 must be sufficient to obtain a quantifiable extinction by the detector 4.
[0079] The multiplicity of diodes 21 also minimizes the impact of the relative angular position between the ring 3 and the light emitter 2, since the orientation of the ring 3 in front of the diodes 21 is excluded.
[0080] As shown in
[0081] The bundle 6 makes it possible to multiply the number of diodes 21 without reducing light intensity. The bundle allows the diodes 21 to be moved further away from the end of the ring 3, which greatly increases the number of diodes (one diode per strand 5 of the bundle 6) and the choice of diodes, which are bulkier but have a more directional bundle (higher luminous intensity). The improved directivity of the diodes 21 thus facilitates the injection of light into the fibers of the bundle 6.
[0082] Additionally, the diodes 21 no longer need to be mechanically positioned according to the geometry of the ring 3, as this constraint is shifted to the placement of the fibers in the body of the bundle 6.
[0083] As previously mentioned, the optical fibers 33, 34, 35, 36 embedded in the ring 3 tolerate a maximum light injection angle .sub.A. In practice, projecting light opposite the end of the ring 3, without physical connection such as welding, requires greater precision in alignment with the optical fibers 33, 34, 35, 36. A misalignment of a few degrees is enough to prevent light from effectively entering one of the optical fibers 33, 34, 35, 36 of the ring 3. As is well understood, misalignment can compromise the assessment of the material health of the composite ring 3 from the outset, as non-detection of light at the output can correspond to a false positive of structural alteration.
[0084] Multiplying the number of diodes 21 and the corresponding strands 5 of the bundle 6 according to the invention thus maximizes the chances that the light emitted by the various diodes 21 will meet this alignment condition. In other words, the light signal is statistically more likely to be adequately conveyed along the optical fibers 33, 34, 35, 36 of the ring 3 to assess its integrity.
[0085] It should therefore be noted that sequential actuation of the diodes 21, as recommended, enhances the quality of defect assessment. In fact, the rotary effect obtained by sequentially firing the diodes 21 according to the invention is not subject to the axis stability problems or vibratory behavior that can be observed in the case of a light source mechanically driven in rotation opposite the ring. Such phenomena generate deviations and therefore pollute the results.
[0086] This so-called digital rotation, which differs from a so-called physical rotation, therefore makes it possible to aim for the most precise alignment and maintain it throughout the material health assessment process. Since the device according to the invention does not rely on mechanical movement, the result is greater repeatability of results and, as a result, greater reliability. It should also be noted that the invention is not limited to generating a rotary effect by cascade actuation of the diodes 21. In practice, the diodes 21 can be operated sequentially in any pattern, or even randomly. A single diode can be switched on in isolation, or several diodes 21 can be switched on simultaneously to project light onto a particular segment of the ring 3.
[0087] This sequential actuation feature is of particular interest when damage to optical fibers 33, 34, 35, 36 seems to be detected prima facie. In fact, it is possible to multiply the passes to form a redundancy by actuating the same diodes 21, and/or adjacent diodes in the form of a cloud of points around the potential fault, several times in a row to ensure that the first detection is indeed representative of reality. Such flexibility would not be possible if a light source were moved mechanically along a predefined path, for example in a circle.
[0088] To evaluate the performance of the bundle 6, a prototype has been designed in the form of a diode 21 driver board 7 and a mechanical plate for aligning diodes 21 with the fibers of the bundle 6. The board 7 comprises diode connection terminals 71, a microcontroller socket 72, a diode current control system 73, and power supplies 74.
Comparative Test: Evaluation of Injection Losses and Linear Attenuation with a Single Transmitter
[0089] For a ring fiber, the output power level Pout will depend on the injected power Pinj and the linear attenuation in the fiber AttLin:
[0090] And the injected power is a function of the transmitter power P.sub.Tx, the power rate on the fiber core .sub.i, and the reflection rate related to the polishing quality .sub.pol.
[0091] The transmitter power P.sub.Tx is deduced from the angular intensity I.sub.L [mW.Math.sr.sup.1] (per unit solid angle), the spherical receiving surface S and the distance d between the transmitter and the end of the fiber.
[0092] For small solid angles, the spherical surface can be approximated by the flat surface of radius R resulting from the scattering half-angle (
[0093] As high-power diodes, it is possible to use diodes with angular intensity equal to 1500 mW.Math.sr.sup.1, half-angle I.sub.L=50% I.sub.Lnom equal to 10, dimensions L*L*H in mm of 3.5*3.5*2.39, and angular intensity per mm.sup.2 equal to 122.
[0094] As high-power diodes, it is possible to use diodes with angular intensity equal to 5 mW.Math.sr.sup.1, half-angle/L=50% I.sub.Lnom equal to 70, dimensions L*L*H in mm of 1*0.5*0.5, and angular intensity per mm.sup.2 equal to 10.
[0095] Furthermore (
[0096] It is possible to use a single-mode fiber with a core diameter of 9 m, a numerical aperture of 0.12 and a maximum injection angle .sub.A of 6.9.
[0097] It is also possible to use a multi-mode fiber with a core diameter of 50 m, a numerical aperture of 0.22 and a maximum injection angle .sub.A of 12.7.
[0098] All power with an angle of incidence greater than OA cannot be injected into the fiber (regardless of the distance between the diode and the fiber), which makes it possible to calculate P.sub.Tx as a function of the diode and fiber used. Thus, for a high-power diode and a single-mode fiber, P.sub.Tx=132.5 mW. For a high-power diode and multimode fiber, P.sub.Tx=455.6 mW. For a low-power diode and a single-mode fiber, P.sub.Tx=0.23 mW. For a low-power diode and multimode fiber, P.sub.Tx=0.79 mW.
[0099] Of the power whose incidence is less than .sub.A (P.sub.Tx(.sub.A)), only a portion can actually be injected into the fiber, due to the distance between the diode and the fiber. This loss rate .sub.i can be expressed as the ratio between the surface area of the fiber core Sc and the surface area illuminated by the diode SE. The power incident on the fiber core P.sub.i(d) can be used to compare different fibers:
[0100] Considering the distance d reasonably closest to the ring (d=1 mm), the injected power as a function of diode type and fiber type is as follows: [0101] for a high-power diode and a single-mode fiber P.sub.i(d=1 mm)=0.74 mW, [0102] for a high-power diode and a multimode fiber P (d=1 mm)=22.78 mW, [0103] for a low-power diode and a single-mode fiber P.sub.i(d=1 mm)=1.27 mW, [0104] for a low-power diode and a multimode fiber P.sub.i(d=1 mm)=38.9 mW.
[0105] In the end, not all the P.sub.i(d) power will be injected due to imperfections on the core surface, despite polishing. It is difficult to predict these losses precisely, but a plausible upper bound can be considered: .sub.pol=3 dB.
[0106] The power actually injected into the fiber core will be progressively attenuated through the fibers, according to the linear attenuation at the working wavelength. The diodes found operate between 800 and 950 nm, corresponding to around 3.5 dB/km, that is, Att.sub.Lin=7 dB for the maximum ring length of 2 km.
Comparative Test: Evaluation of Injection Losses and Linear Attenuation with Multiple Transmitters
[0107] As explained above, the aim is to achieve continuity of the power emitted at the surface of the ring by means of a diode array. This objective of continuity also means that the beams from each diode must be juxtaposed in pairs (or even overlap), which determines the diode/fiber distance d and the center distance between diodes.
[0108] Considering the exclusive two-by-two juxtaposition, the situation can be modeled as shown in
[0109] For a given diode obstruction, the minimum distance to achieve beam overlap d.sub.min is:
[0110] The minimum obstruction corresponds to the situation where the diodes are juxtaposed, that is, E.sub.min=L: [0111] for a high-power diode, and for L=3.5 mm, for a single-mode fiber, d.sub.min=14.5 mm, [0112] for a high-power diode, and for L=3.5 mm, for a multimode fiber, d.sub.min=7.8 mm, [0113] for a low-power diode, and for L=0.5 mm, for a single-mode fiber, d.sub.min=2.1 mm, [0114] for a low-power diode, and for L=0.5 mm, for a multimode fiber, d.sub.min=1.1 mm.
[0115] Thus, the size of the high-power diodes means that they have to be spaced apart considerably in order to achieve beam continuity, which degrades intensity by a factor squared (=S/d.sup.2).
[0116] To visualize the impact of the diode/fiber distance (d),
Comparative Test: Increase in Injected Light Output
[0117] Because of their size, the high-power diodes need to be spaced apart considerably in order to achieve overlap between adjacent beams, which lowers the power density at the surface of the ring.
[0118] To compensate for this loss of density, a convergent lens could be used to position diodes on a larger diameter than that of the ring. However, the convergent lens will increase the angle of incidence of the beams at the lens periphery, preventing the beam from remaining within the fiber's numerical aperture. It would therefore be possible to add a divergent lens to restore the beam angle (
[0119] Conversely, the solution based on low-power diodes is not subject to a loss of power density (the diodes being closer to the ring). However, the disadvantage of these diodes is that the angle of diffusion is much greater than the numerical aperture of the fiber.
[0120] In this case, a single convergent lens can be used to reduce the beam scattering angle to approach the numerical aperture of the fiber (
Comparative Test: Characterizing the Drum
[0121] In a first embodiment, a 250 m long, 8 mm diameter cable is supplied, instrumented with 4 optical fibers. This cable was characterized by reflectometry. [0122] on a first multimode fiber, the wavelength is 1550 nm, the measured linear attenuation is 30 dB/km, the attenuation inhomogeneity is greater than 10 dB, the detected fiber length is 160 m, and the red pointer is detected at the 250 m exit, [0123] on a second multimode fiber, the wavelength is 1550 nm, the measured linear attenuation is 15 dB/km, the attenuation inhomogeneity is greater than 10 dB, the detected fiber length is 250 m, and the red pointer is not detected at the 250 m exit.
[0124] These initial measurements reveal high inhomogeneity in linear attenuation, reflecting inhomogeneous stresses, and average attenuation of about 20-30 dB/km, reflecting high stresses or micro-curvatures.
[0125] These high attenuations at 1550 nm will require very high measurement dynamics.
[0126] In a second embodiment, a cable is produced by modifying the detection fiber insertion method. The fibers are more taut during the manufacturing method to even out the stresses applied between the same fibers of a ring. This 120 m cable was characterized by reflectometry.
[0127] The four detection fibers are unbroken and freely accessible at both ends. The reflectometer measurements are as follows: [0128] for multimode fiber number 1, the wavelength is 1550 nm, the measured linear attenuation is greater than 50 dB/km, the attenuation inhomogeneity is greater than 20 dB, the detected fiber length is 130 m, and the red pointer is detected at the 130 m exit, [0129] for multimode fiber number 2, the wavelength is 1550 nm, the measured linear attenuation is greater than 50 dB/km, the attenuation inhomogeneity is greater than 20 dB, the detected fiber length is 130 m, and the red pointer is detected at the 130 m exit, [0130] for single-mode fiber number 1, the wavelength is 1550 nm, the measured linear attenuation is 14 dB/km, the attenuation inhomogeneity is about 3-4 dB, the detected fiber length is 130 m, and the red pointer is detected at the 130 m exit, [0131] for single-mode fiber number 2, the wavelength is 1550 nm, the measured linear attenuation is 3 dB/km, the attenuation inhomogeneity is about 2 dB, the detected fiber length is 130 m, and the red pointer is detected at the 130 m exit.
[0132] These measurements give much better results than in the first embodiment, particularly for single-mode fibers.
[0133] Single-mode fiber number 2 shows little loss over these 120 m (less than 0.5 dB), identical to the losses of the exciting coil used. The insertion of this fiber into the ring therefore created no losses.
[0134] There are more losses on single-mode fiber number 1 (around 2 dB) and greater inhomogeneity in linear attenuation (3-4 dB). This is the result of inhomogeneous stresses or micro-curvatures on the fiber.
[0135] Both of the multimode fibers exhibit very high linear attenuation and inhomogeneity in this attenuation, reflecting high stresses or micro-bends.
[0136] These results are highly satisfactory, and encourage the use of single-mode rather than multimode fibers.
Polishing the Ring after Cutting
[0137] A polisher 8 is used (
[0138] This polisher will prepare the ring ends for light injection and collection.
[0139] The model used is a polisher. Its polishing plate is large enough (5 cm in diameter) to polish rings up to 10 mm in diameter, making it easy to adapt to ring polishing. A ring holder 9 can be made to hold the ring during polishing (
[0140] In order to validate the polisher's performance, a 5 m long ring was polished without prior treatment. The grain used is P180, corresponding to a very large grain size.
Experimental Results: Comparative Trial with Jumpers
[0141] An initial test was carried out using low-power diodes to evaluate the power injected into SM-single-mode jumpers 11 (and into MM-multimode jumpers 10). The two jumpers are about 50 cm long, making linear attenuation negligible.
[0142] For the SM-single-mode jumper, and with a single-mode fiber, the power measured is between 1 nW and 100 mW. For the MM-multi-mode jumper, and with a multi-mode fiber OM2, the power measured is between 100 and 100 mW.
[0143] The measured values are well below the theoretical values, by a factor of around 100. These deviations are most likely due to the fact that manual alignment of the fiber in front of the diode is not truly precise, especially as the diodes could not be soldered completely flat to the PCB due to their small size.
Experimental Results: Test with a Detection Device According to the Invention
[0144] After producing the diode control board, a prototype strand bundle was assembled from the fiber bundle to maximize the power captured from each diode, as well as the power emitted at the surface of the ring (
[0145] With the plates in contact, the diode being tested is between 1 and 10 mm from the bundle entrance, preferentially between 2 and 8 mm. The output of the beam is then brought to within about 2 mm of the ring, along with a multimode fiber fitted with a factory-installed connector on one end.
[0146] When the diode is powered at its maximum current, the output power from the 200 m ring through a non-cleaved multimode fiber is between 1 nW and 100 mW, preferentially between 5 and 10 nW, and the loss between the beam output and the ring output is equivalent in power.
[0147] A prototype bundle of strands of several hundred multimode optical fibers with an outer diameter of 100 m is built to maximize the power injected into the ring (
Detection System: First Version
[0148] A first version of the detection device was tested on the second drum with the invention's light-emitting device (
[0149] The fibers coming out of the ring are connectorized with a factory-installed connector on one end and are connected to the light detection device 4. The light detection device can be connected to a detection printed circuit 13.
[0150] On the first single-mode fiber of the drum, the prototype detector reaches saturation at the minimum level of the reference detector. This shows that the photodiode/amplifier pair selected will a priori be sensitive enough to work below 100 mW.
[0151] After optimizing the position of the fiber in front of the beam, the power measured at the fiber output is greater than a few nW.
[0152] A test was carried out by breaking the fiber arbitrarily before injection.
[0153] In this case, no power was detected at the output without optimizing the injection (alignment of the fiber in front of the beam), which confirms the importance of the fiber surface finish, particularly on the injection side (and therefore the step of polishing the end of the ring).
[0154] The wavelength of the diode used is 650 nm, and the attenuation of the fiber at 650 nm is given as 4-5 dB/km (see
Detection Device: Second Version (First Ring (30 cm))
[0155] The second version of the detector has been designed for easy handling in front of the ring, so it features a moving part connected to the motherboard with a flexible cable 15. The ring is 30 cm long (
[0156] The end of the beam and the first longitudinal end of the ring are contained within a sheath 12. A cable gland 14 for holding the ring 3 is located at the second longitudinal end of the ring 3.
[0157] Thus, on the detector side, the ring portion has been installed in a cable gland so as to be unaffected by ambient light, thus maximizing detection dynamics.
[0158] The beam was constructed in 12 adjacent sectors.
[0159] The results are visualized using a script that formats the data from the sampling module (
[0160] The test conditions are as follows: there are 10 diodes, the switch-on time for each diode is 500 ms, the sampling frequency/period is 10 Hz/100 ms, the number of rotations is 3, and the duration is 18 s.
Detection Device: Second Version (Second Ring (120 m))
[0161] The beam-detector pairing was tested on the second ring with several levels of polishing.
[0162] To carry out the tests, the ring was cut approximately 4 m from the dry part on the injection side and 10 cm on the reception side.
[0163] In the same way as for the ring portion, the LEDs are lit in sequence, with different levels of polishing to assess its influence.
[0164] The test conditions are as follows: there are 10 diodes, each diode is switched on for 500 ms
[0165] It should be noted that the alignment between the beam and the ring input is not maintained between each test, so the absolute level cannot be accurately taken as a point of comparison between different curves. Nevertheless, the angular position remained largely unchanged during the tests.
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[0173] The overall conclusions of this test phase are: [0174] the three fibers visible to the naked eye when illuminated with a laser pointer are detectable with the beam-detection pair.
Estimation of Injection-Detection System Dynamics
[0175] The results obtained on the portion of the first ring can be used to estimate the dynamics of the final system, and thus to assess the maximum ring length that can be achieved.
[0176] In
[0177] Then, the detection level can drop again until it reaches a low threshold Th.sub.low with a margin relative to the noise floor. The results on the 120 m ring showed that noise is induced by ambient brightness, so Th.sub.low can initially be defined at 100 on a scale of 100. This gives the second element of the dynamic dyn.sub.2, which depends on the detection level at low injection power: [0178] for the first fiber, with a detection level at low injection power, the significant low detection threshold Th.sub.low base 100, and the second element of the dynamic range dyn.sub.2 is 250/100=2.5 or approx. 4 dB, for the second fiber, with a detection level at low injection power (25000 AD), the significant low detection threshold Thow base 100D, and the second element of the dynamic range dyn.sub.2 is 2500/100=25, that is, approx. 14 dB.
[0179] The overall dynamic range can therefore be estimated at dyn=dyn.sub.1+dyn.sub.2, that is, 25.7 dB for the first fiber and 35.7 for the second.
[0180] Given the polishing, it is likely that the difference in detection between these two fibers is directly linked to the type of fiber illuminated (as linear and curvature attenuation can be neglected on a 30 cm section of ring), which would imply that the dynamic range on a single-mode fiber would be around 25 dB.
[0181] With a linear attenuation of around 5 dB per km, and assuming that fiber stresses do not induce significant additional linear attenuation, it would be possible to reach a maximum ring length of around 5 km.
Packaging the Prototype Transceiver
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CONCLUSION
[0183] The tests made it possible to characterize a 130 m ring comprising two single-mode fibers and two multimode fibers.
[0184] The developed characterization system can inject and detect the signal in single-mode or multimode fibers. Proof of concept was achieved on the last ring manufactured, where four optical fibers were detected and characterized. The resulting system dynamic range is between 10 dB and 50 dB, preferentially between 25 dB and 35 dB. This dynamic makes it possible to characterize rings longer than 3 km.
[0185] Alternatively, a long ring (2-3 km) with four single-mode fibers could be used.