Fiber optic sensor integration system and measurement technique

Kelly L. Stinson-Bagby
a
, Michael A. Marcus
b
, and Robert S. Fielder
a

a
Luna Innovations, Inc. 2851 Commerce Street, Blacksburg, VA 24060 US;
b
Eastman Kodak Company, Building 81
Kodak Park, Rochester, NY 14650-2036 USA

ABSTRACT

Fiber optic measurement systems are on the cutting edge of instrumentation for many industries from military
and government applications to commercial needs such as the automotive, aerospace, and power turbine industries.
Measurement parameters including temperature, pressure, and strain can provide valuable information. Sensor
mapping allows for larger scale monitoring capabilities and provide flexibility in sensing applications. A sensor and
readout system is being developed to expand the capabilities of fiber optic sensing. Several iterations of multiplexed
sensors have been tested using a high-resolution fiber optic coupled dual Michelson interferometer based-instrument
that has the capability of reading gaps of 25m to 6.5mm. This measurement range opened the opportunity to read
several different sensors on the same fiber, i.e. the same channel. Sensor strings combining temperature and strain
extrinsic Fabry-Perot interferometric sensors were tested. These sensor strings produced were either serial
multiplexed, parallel multiplexed, or a combination. This paper will discuss the capabilities of the sensors and
instrumentation systems developed.

Keywords: Fiber Optic Sensing, Multiplexed Sensing, Low-coherence Interferometry.

1. INTRODUCTION
Fiber optic measurement systems are on the cutting edge of instrumentation for many industries. For
example, during recent development efforts, high-temperature fiber optic-based sensors have been tested in turbine
applications. The Wall Street Journal recently reported that the world's power industry represents the fastest growing
market for gas turbines.
4
Forecast International predicts that ~64,000 gas turbines for power generation will be
produced over the next decade, for a total revenue of about $300billion.
5
With in these applications sensor
requirements include operating temperatures well above the range of current sensors. Current state-of-the-art strain
and temperature sensors employ piezoelectric and piezoresistive crystals, foil-strain gauges, MEMS devices in silicon,
thermocouples, and other transducing mechanisms. All of these methods have in common the fundamental limitation
of requiring an electrical signal to be sent to or received from the transducer. Extreme temperature applications
prohibit the use of conductive or piezo material, and thereby the competing technology. Furthermore, all electrical-
based sensors are subject to electromagnetic interference generated in many potential applications. Fiber optic sensors
are immune to electromagnetic interference, are constructed of high-temperature and chemically inert materials, and
can be made into extremely small geometries.
Large scale monitoring capabilities are required for a multitude of applications and can be addressed with
multiplexed fiber optic sensor technologies. Multiplexed sensors increase in the number of sensors per channel,
opening the opportunity for a greater number of sensors per channel. Luna Innovations has addressed numerous
applications with EFPI-based (Extrinsic Fabry- Perot Interferometer) sensor technology
1
. Highly multiplexed fiber
optic-based systems have been using for post-impact evaluation of ballistic armor. Using the high-speed, highly-
multiplexed system may enable the evaluation of damage to armor during actual impact. Other development has
involved the distribution of sensors on directed energy targets with successful results. In addition, multiplexed sensor
systems can provide multiple sensing parameters. For example, producers of angle of attack sensors for jet aircraft are
in highly sensitive co-located pressure and temperature sensors to replace bulky components in their current sensor
modules.
This paper will discuss the capabilities of the multiplexed fiber-optic-based sensors and instrumentation
systems. Extrinsic Fabry- Perot interferometer sensors were used as the basis for the multiplexed sensors developed.
Section 1.1 discusses the basic operation of these sensors, while Section 1.2 will provide an understanding of the Gap
Division Multiplexing method used to gather multiple measurements on a single channel. The system discussed in this

bagbyk@lunainnovations.com; PHONE 1 540 961-4525; fax 1 540 951-0760; lunainnovations.com

Industrial and Highway Sensors Technology, edited by Brian Culshaw, Michael A. Marcus,
John P. Dakin, Samuel D. Crossley, Helmut E. Knee, Proceedings of SPIE Vol. 5272
(SPIE, Bellingham, WA, 2004) 0277-786X/04/$15 doi: 10.1117/12.515171
150

paper is a Dual Michelson interferometer based-instrument used to measure the multiplexed sensors. Testing and
results of the total system operation are presented.
1.1. Extrinsic Fabry-Perot Interferometery
Extrinsic Fabry-Perot interferometer (EFPI) sensors use a distance measurement technique based on the
formation of a low-finesse Fabry-Perot cavity between the polished end face of a fiber and a reflective surface, shown
schematically in Figure 1. Light is passed through the fiber, where a portion of the light is reflected off the fiber/air
interface (R1). The remaining light propagates through the air gap between the fiber and the reflective surface and is
reflected back into the fiber (R2). These two light waves interfere constructively or destructively based on the path
length difference traversed by each. In other words, the path length modulates the interaction between the two light
waves in the Fabry-Perot cavity. The resulting light signal then travels back through the fiber to a detector where the
signal is processed to produce a distance measurement. Several different signal processing methods exist to convert
the return signal into a distance measurement. Virtually any transducer that will modulate a gap proportional to a
specific environmental parameter can be optically interrogated to measure that environmental parameter.


R
1
R
2
Fabry-Perot
Cavity
Fiber
Light
End Face
Reflective
Surface

Figure 1: Extrinsic Fabry-Perot interferometer concept

Shown in Figure 2 is a close-up of an EFPI fiber optic strain gage. The EFPI strain gage is fabricated by
inserting two optical fibers into a silica capillary tube. During fabrication, the input/output and reflector optical fibers
are joined to the inside of the silica capillary tube, either with an adhesive or by directly fusing the fibers to the tube.
The distance between the Input/Output and Reflector attachment points in the Silica Capillary Tube define the gage
length. Temperature and strain measurements can be combined by adding a SiC layer on the reflector fiber. The layer
produces a second gap measurement that can be calibrated for temperature. This sensor then will have a temperature
sensor incorporated into the sensor internals. One design is depicted in Figure 3.

Reflector
Gage Length (L)
Silica Capillary
Tube
Adhesive
s
High Temperature
Coating
Input/Output
Optical Fiber
R1
R2
Air Gap

Figure 2. EFPI fiber optic strain gage.

1.2. Gap Division Multiplexing
Optical path length multiplexing, or Gap Division Multiplexing (GDM), is a method in which optical fiber
sensors (such as EFPIs) are biased at specific gaps or optical path lengths, and then limited in operation to some
specific range around the bias point. These signals can be isolated and tracked through Absolute Measurement System
(AMS) techniques, provided the individual signals do not interfere with each other. Optical path length multiplexing
is very useful for multiplexing a small number of sensors for a given source and detector. It is topology independent
Proc. of SPIE Vol. 5272 151

and works well with numerous sensor types. Optical path length multiplexing also does not require additional sources,
detectors, or signal processing electronics over conventional AMS techniques. The transformed signal showing the
static gaps of multiplexed strain and temperature sensor is shown in Figure 3 and Figure 4.


Reflector
Gage Length (L)
Silica Capillary
Tube
Adhesive
s
High Temperature
Coating
Input/Output
Optical Fiber
R1
R2
Air Gap
SiC Layer

Figure 3. Combined EFPI strain sensor with SiC temperature sensor.

Transform of Dual EFPI Temperature and Strain Sensor Spectrum
0
10000
20000
30000
40000
50000
60000
1
5
2
8
4
1
5
4
6
7
8
0
9
3
1
0
6
1
1
9
1
3
2
1
4
5
1
5
8
1
7
1
1
8
4
1
9
7
2
1
0
2
2
3
2
3
6
2
4
9
2
6
2
2
7
5
2
8
8
Optical Path Length [um]
I
n
t
e
n
s
i
t
y
Strain
R3-R2
Temperature + Strain
R3-R1
Temperature
R2-R1

Figure 4: Demodulated Multiplexed Strain and Temperature Sensors

In Figure 4 the small peak at 70 um is due to the interference between the reflection R1 and the reflection R2.
The optical path difference between R1 and R2 gives the optical thickness of the silicon cap, which can be equated
to an absolute temperature measurement. Similarly, the optical path length difference between R3 and R2 relates the
optical thickness of the air gap between the silicon cap and the reflector fiber (on the right). The optical path length
through a material is equal to the index of refraction multiplied by the physical length of the waveguide.
Finally, the peak at 210 um is due to the combination of the silicon cap and the air gap of the sensor, and is
unused in either measurement. Unfortunately, the multiplexing ability of GDM is limited by these harmonic signals
created by the interference between any two EFPI signals (the Temperature + Strain signal shown in (Figure 4). This
requires careful selection of the static operating gap for each sensor in order to avoid interference.

1.3. Dual Michelson interferometer based-instrument
Figure 5 shows an optical schematic of the instrument used in this study
2,3
. During operation the path lengths
of the two branches of the interferometer are changed by applying a voltage ramp to the PZT cylinders which have
fibers wrapped around them. The laser interferometer is used to trigger data acquisition of the low coherence light
152 Proc. of SPIE Vol. 5272

interferometric data (1310 nm broad bandwidth LED) at constant distances intervals equal to /4 of the laser. In the
interferometer used in these experiments the laser is a solid-state laser diode with a wavelength = 1.55051 m and is
used to derive the distance scale shown as the x-axis in the rest of the Figures.

WDM
Coherent
Source
50/50
Coupler
Broadband
Light Source
SAMPLE
WDM
Coupler
PZT Fiber
Modulators
Mirror
1
2
1
2
1
1
1
2
Optical
Receivers
Mirror
50/50
Coupler
1
2
lens

Figure 5: Schematic of the all fiber dual interferometer showing coupling to a sample


2. METHODOLOGY
Several iterations of multiplexed sensors strain and temperature were tested using the high-resolution fiber
optic coupled dual Michelson interferometer based-instrument that has the capability of reading gaps between 25m to
6.5mm with reproducibility better than 0.050 m. The feasibility of each of the individual sensors has clearly been
demonstrated in prior research. Each sensor typically utilizes less than 5m of travel. The sensor strings produced
were either serial multiplexed, parallel multiplexed, or a combination.

2.1. Serial Multiplexing
The strain sensors were contructed with varying gap sizes in series at bonded as extensometers to an
aluminum plate. The gap settings were set between 25 m and 4300 m. For testing the strain sensors, a simple
process of bending the aluminum plate will be used. One end of the plate will be clamped to a table using a C-clamp.
A small diameter rod will be used to bend the plate. A thermocouple was placed on the aluminum plate to account for
any temperature effects.

2.2. Parallel Multiplexing
Parallel multiplexed strings were constructed with temperature sensors coupled to a single channel. These
sensors have the advantage of less inline dependence. If one sensor in the assembly is non-operational, the remaining
sensors are not affected. This is unlike the serial sensors which are dependent on the previous sensor to be operational.
To test the temperature sensors, the sensors were exposed to temepratures up to 90 C.

2.3. Co-location
The next set of tests included EFPI strain gages multiplexed in parallel, each having an internally-mounted
temperature sensor which was interrogated in series with the strain sensor. In this way, the sensors were optimized
from several points of view. The parallel multiplexing provided the highest reliability possible. The co-located
serially-multiplexed temperature sensors provided accurate, point measurements of temperature that will be used to
temperature-compensate the strain gages.
Proc. of SPIE Vol. 5272 153


3. DATA RESULTS
The multiplexed sensor strings were tested under temperature and strain conditions depending on the sensor type.

3.1. Serial Multiplexing
The serial multiplexed extensometers were tested in a bend test. Raw interferometer data for the single strain
senor with the plate bent over a 1.5 inch rod on a table. Figure 6 and Figure 7 show the undeformed and deformed
states of the plates respectively for a single strain sensor. The additive intensity can be seen as evenly spaced peaks.


Figure 6: Single strain sensor repetitive scans at
2500 Hz measurement rate.
Figure 7: Single strain sensor deformed at 2500 Hz
measurement rate.


3.2. Parallel Multiplexing
The parallel-coupled temperature sensors were tested on a hot plate to specified temperatures. Figure 8
shows an example raw interferometer trace for the 2 coupled temperature sensor sample. Both peaks are distinct and
separated enough for measurement with the Kodak readout system. Figure 9 is a linear regression of the two
temperature sensor showing good linearity for both sensors which were measured simultaneously. Unfortunately, two
multiplexed sensors was the maximum number of sensor that could be read. This again was a function of gap division
multiplexing, or the resolution between the observed peaks.



Figure 8: 2 coupled temperature sensors at 22
o
C. Figure 9: Two coupled temperature data summary

Figure 10 shows the single temperature sensor interferogram at room temperature. Figure 11 shows the same
sensor interferogram measured at 92
o
C. The separation appears to be better at the higher temperature and is verified
in the measurement. Figure 12 shows a summary of the temperature data obtained for ramping the temperature in an
oven along with the linear fit and regression analysis for the single temperature sensor. The linear fit to temperature is
excellent.

154 Proc. of SPIE Vol. 5272

Figure 10: Single temperature sensor interferogram
2500 Hz measurement rate at 22
o
C.
Figure 11: Single temperature sensor measured at
92
o
C


Figure 12: Single temperature sensor gap versus temperature.

3.3. Co-location
The combination sensors were qualitatively tested to determine feasibility. Measured data for all four
strain/temperature pairs is shown in Figure 13. Fringes produced by constructive interference on the positive side of
the x-axis represent individual strain and temperature sensors. Based on expected gap measurements, the system
response was modeled and compared with the measured data. The modeled response agreed well with the measured
response, and is shown in Figure13 and Figure 14, respectively.

model using given 8 distances
-1200
-900
-600
-300
0
300
600
900
1200
-30 0 30 60 90 120 150 180 210
distance microns
a
m
p
l
i
t
u
d
e

Figure13. Modeled data for expected interference pattern based on reported gap measurements.
Proc. of SPIE Vol. 5272 155

Serial#111502-1
-1200
-900
-600
-300
0
300
600
900
1200
-300 -250 -200 -150 -100 -50 0 50 100 150 200 250 300
distance microns
a
m
p
l
i
t
u
d
e

Figure 14. Measured interference patterns from series of sensors sent to Kodak.


4. CONCLUSIONS
Multiplexed sensors will allow for an increase in the number of sensors per channel, opening the opportunity
for a greater number of sensors. The parallel multiplexed sensors were determined to have the advantage of no inline
dependence as with the serial multiplexed sensors. However, it was determined that collocating temperature and strain
sensors gives the additional advantage of increasing the measurement capabilities per channel and reducing inline
dependence. Finally, the results show the feasibility of using this design of a low-coherence interferometer as a high-
resolution readout for strain and temperature fiber optic-based sensors.


ACKNOWLEDGMENTS
Dr. Nicolas Morley, Air Force Research Laboratory, Directed Energy Directorate at Kirtland AFB, NM
Eastman Kodak, Inc., Rochester, NY


REFERENCES
1. W. Pullman, P. Russler, R. Felder, High-Temperature, High Bandwidth, Fiber-Optic, MEM's Pressure Sensor
Technology for Turbine Engine Component Testing, Proceedings of the SPIE, Fiber Optic Sensor Technology
and Applications 2001, Vol. 4578, pp 229-238, 2002.
2. J. Bush, P. Davis, M. Marcus, "All Fiber Optic Coherence Domain Interferometric Techniques" Proceedings of
the SPIE, Fiber Optic Sensor Technology II, 2001, Vol. 4204, pp 71-80, 2001.
3. M. Marcus, "Fiber Optic Interferometry for Industrial Process Monitoring and Control Applications" Proceedings
of the SPIE, Fiber Optic Sensor Technology And Applications 2001, Vol. 4578, pp 136-144, 2002.
4. The Wall Street Journal, Dow Jones & Company, Inc, 2003
5. Gas Turbine Market Outlook, Forecast International/DMS, Inc., Newtown, CT
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