Dynamic Strain Measurements on Automotive and Aeronautic Composite Components by Means of Embedded Fiber Bragg Grating Sensors

Strain Modal Testing with Fiber Bragg Gratings for Automotive Applications

Strain Modal Testing (SMT), based on strain sensors signal processing, is an unconventional approach to perform Experimental Modal Analysis which is typically based on data measured by accelerometers. SMT is still mainly restricted to academia and requires additional investigation for a successful transition towards industry. This paper critically reviews why the automotive sector can benefit from this relatively new approach for a variety of reasons. Moreover, a case study representative of the automotive field is analyzed and discussed. Specifically, an SMT methodology is applied to evaluate the modal properties of a reinforced composite roof belonging to a racing solar powered vehicle. In the experimental activity, signals from Fiber Bragg Grating (FBG) sensors, strain gauges, and accelerometers were simultaneously acquired and further processed. The advantages of using optical fibers were discussed, together with their weaknesses and ongoing challenges. The FBG results were compared with the conventional analysis performed with the accelerometers, emphasizing the main similarities and discrepancies.

In-Plane Strain Measurement in Composite Structures with Fiber Bragg Grating Written in Side-Hole Elliptical Core Optical Fiber

In this paper, the application of a fiber Bragg grating written in a highly birefringent side-hole elliptical core optical fiber for two-axial strain measurement is presented. Hybrid optical fiber structures achieved by combining large side-holes and elliptical core result in a very high birefringence of 1 × 10^-3 and thus high initial Bragg peak spectral separation of 1.16 nm, as well as a very high transverse force sensitivity, of up to 650 pm/(N/mm) or even -1150 pm/(N/mm), depending on the fiber orientation with respect to the applied force. Due to the ~22 %m/m GeO₂ concentration in the core the fiber being highly photosensitive, which significantly simplifies FBG fabrication by UV illumination without the need for prior hydrogen loading, which worsens thermal stability. Finally, the developed FBGs written in the highly birefringent side-hole elliptical core optical fiber were embedded in the square composite plates and applied for strain measurements. Tests of two-directional four-point bending have shown usability of such FBG for two-axial in-plane strain measurement with a single FBG in iso-thermal conditions.

Fiber Bragg Grating Dynamic Calibration Based on Online Sequential Extreme Learning Machine

The fiber Bragg grating (FBG) sensor calibration process is critical for optimizing performance. Real-time dynamic calibration is essential to improve the measured accuracy of the sensor. In this paper, we present a dynamic calibration method for FBG sensor temperature measurement, utilizing the online sequential extreme learning machine (OS-ELM). During the measurement process, the calibration model is continuously updated instead of retrained, which can reduce tedious calculations and improve the predictive speed. Polynomial fitting, a back propagation (BP) network, and a radial basis function (RBF) network were compared, and the results showed the dynamic method not only had a better generalization performance but also had a faster learning process. The dynamic calibration enabled the real-time measured data of the FBG sensor to input calibration models as online learning samples continuously, and could solve the insufficient coverage problem of static calibration training samples, so as to improve the long-term stability, accuracy of prediction, and generalization ability of the FBG sensor.

Multifunctional Textile Platform for Fiber Optic Wearable Temperature-Monitoring Application

Wearable sensing technologies have been developed rapidly in the last decades for physiological and biomechanical signal monitoring. Much attention has been paid to functions of wearable applications, but comfort parameters have been overlooked. This research presents a developed fabric temperature sensor by adopting fiber Bragg grating (FBG) sensors and processing via a textile platform. This FBG-based quasi-distributed sensing system demonstrated a sensitivity of 10.61 ± 0.08 pm/°C with high stability in various temperature environments. No obvious wavelength shift occurred under the curvatures varying from 0 to 50.48 m⁻¹ and in different integration methods with textiles. The temperature distribution monitored by the developed textile sensor in a complex environment with multiple heat sources was deduced using MATLAB to present a real-time dynamic temperature distribution in the wearing environment. This novel fabric temperature sensor shows high sensitivity, stability, and usability with comfort textile properties that are of great potential in wearable applications.

Enhancement of the Performance and Data Processing Rate of an Optical Frequency Domain Reflectometer Distributed Sensing System Using A Limited Swept Wavelength Range

A novel optical frequency domain reflectometer (OFDR) processing algorithm is proposed to enhance the measurable range and data processing rate using a narrow swept spectrum range and reducing the time consuming of the process distributed sensing results. To reduce the swept wavelength range and simultaneously enhance strain measurable range, the local similarity characteristics of Rayleigh scattering fingerprint spectrum is discovered and a new similarity evaluation function based on least-square method is built to improve the data processing rate and sensing performance. By this method, the strain measurable range is raised to 3000 µε under a highest spatial resolution of 3 mm when the swept spectrum range is only 10 nm and the data processing rate is improved by at least 10 times. Experimental results indicate that a nonlinearity of less than 0.5%, a strain resolution of better than 10 µε, a repeatability at zero strain of below ±0.4 GHz and a full-scale accuracy is lower than 0.85 GHz under a highest spatial resolution of 3 mm can be achieved. Advantages of this method are fast processing rate, large strain measurable range, high SNR, and applicability with current OFDR systems.

Review of Chirped Fiber Bragg Grating (CFBG) Fiber-Optic Sensors and Their Applications

Fiber Bragg Gratings (FBGs) are one of the most popular technology within fiber-optic sensors, and they allow the measurement of mechanical, thermal, and physical parameters. In recent years, a strong emphasis has been placed on the fabrication and application of chirped FBGs (CFBGs), which are characterized by a non-uniform modulation of the refractive index within the core of an optical fiber. A CFBG behaves as a cascade of FBGs, each one reflecting a narrow spectrum that depends on temperature and/or strain. The key characteristic of CFBGs is that their reflection spectrum depends on the strain/temperature observed in each section of the grating; thus, they enable a short-length distributed sensing, whereas it is possible to detect spatially resolved variations of temperature or strain with resolution on the order of a millimeter over the grating length. Based on this premise, CFBGs have found important applications in healthcare, mechanical engineering, and shock waves analysis, among others. This work reviews the present and emerging trends in CFBG sensors, focusing on all aspects of the sensing element and outlining the application case scenarios for which CFBG sensors have been demonstrated.

Self-Reporting Fiber-Reinforced Composites That Mimic the Ability of Biological Materials to Sense and Report Damage

Sensing of damage, deformation, and mechanical forces is of vital importance in many applications of fiber-reinforced polymer composites, as it allows the structural health and integrity of composite components to be monitored and microdamage to be detected before it leads to catastrophic material failure. Bioinspired and biomimetic approaches to self-sensing and self-reporting materials are reviewed. Examples include bruising coatings and bleeding composites based on dye-filled microcapsules, hollow fibers, and vascular networks. Force-induced changes in color, fluorescence, or luminescence are achieved by mechanochromic epoxy resins, or by mechanophores and force-responsive proteins located at the interface of glass/carbon fibers and polymers. Composites can also feel strain, stress, and damage through embedded optical and electrical sensors, such as fiber Bragg grating sensors, or by resistance measurements of dispersed carbon fibers and carbon nanotubes. Bioinspired composites with the ability to show autonomously if and where they have been damaged lead to a multitude of opportunities for aerospace, automotive, civil engineering, and wind-turbine applications. They range from safety features for the detection of barely visible impact damage, to the real-time monitoring of deformation of load-bearing components.

Review and Analysis of Peak Tracking Techniques for Fiber Bragg Grating Sensors

Fiber Bragg Grating (FBG) sensors are among the most popular elements for fiber optic sensor networks used for the direct measurement of temperature and strain. Modern FBG interrogation setups measure the FBG spectrum in real-time, and determine the shift of the Bragg wavelength of the FBG in order to estimate the physical parameters. The problem of determining the peak wavelength of the FBG from a spectral measurement limited in resolution and noise, is referred as the peak-tracking problem. In this work, the several peak-tracking approaches are reviewed and classified, outlining their algorithmic implementations: the methods based on direct estimation, interpolation, correlation, resampling, transforms, and optimization are discussed in all their proposed implementations. Then, a simulation based on coupled-mode theory compares the performance of the main peak-tracking methods, in terms of accuracy and signal to noise ratio resilience.

RTM Production Monitoring of the A380 Hinge Arm Droop Nose Mechanism: A Multi-Sensor Approach

This research presents a case study of production monitoring on an aerospace composite component: the hinge arm of the droop nose mechanism on the Airbus A380 wing leading edge. A sensor network composed of Fibre Bragg Gratings, capacitive sensors for cure monitoring and thermocouples was embedded in its fibre reinforced lay-up and measurements were acquired throughout its Resin Transfer Moulding production process. Two main challenges had to be overcome: first, the integration of the sensor lines in the existing Resin Transfer Moulding mould without modifying it; second, the demoulding of the component without damaging the sensor lines. The proposed embedding solution has proved successful. The wavelength shifts of the Fibre Bragg Gratings were observed from the initial production stages, over the resin injection, the complete curing of the resin and the cooling-down prior to demoulding. The sensors proved to be sensitive to detecting the resin flow front, vacuum and pressure increase into the mould and the temperature increase caused by the resin curing. Measurements were also acquired during the post-curing cycle. Residual strains during all steps of the process were derived from the sensors’ wavelength shift, showing values up to 0.2% in compression. Moreover, the capacitive sensors were able to follow-up the curing degree during the production process. The sensors proved able to detect the resin flow front, whereas thermocouples could not measure an appreciable increase of temperature due to the fact that the resin had the same temperature as the mould.

A method of measuring dynamic strain under electromagnetic forming conditions

Dynamic strain measurement is rather important for the characterization of mechanical behaviors in electromagnetic forming process, but it has been hindered by high strain rate and serious electromagnetic interference for years. In this work, a simple and effective strain measuring technique for physical and mechanical behavior studies in the electromagnetic forming process has been developed. High resolution (∼5 ppm) of strain curves of a budging aluminum tube in pulsed electromagnetic field has been successfully measured using this technique. The measured strain rate is about 10(5) s(-1), which depends on the discharging conditions, nearly one order of magnitude of higher than that under conventional split Hopkins pressure bar loading conditions (∼10(4) s(-1)). It has been found that the dynamic fracture toughness of an aluminum alloy is significantly enhanced during the electromagnetic forming, which explains why the formability is much larger under electromagnetic forging conditions in comparison with conventional forging processes.