fourier transform apply co mplex · for in-situ monitoring in advanced energy systems hai xiao 1 ,...
TRANSCRIPT
Objective
Prove and demonstrate the new concept of sensor-integrated
“smart part” that can be easily installed in existing and new
energy systems for in situ monitoring of the health statues
of critical components and key operational parameters
under harsh conditions.
Novel Optical Carrier based Microwave Interferometry (CCMI)
Single crystal sapphire fiber Michelson OCMI sensor for high temperature and strain sensing. Excellent signal
quality, temperature measurement repeatability, and stability.
Assembly-Free Sensor Fabrication
Background
INTRODUCTION • Demands: Success of clean coal technologies will rely heavily on
sensors and instrumentation for: advanced process control/
optimization, Key components protection, System maintenance
and lifecycle management
• Requirements: Sensors need to survive and operate in the high-T,
high-P and corrosive/erosive harsh environments for a long of
time.
• Status: Current sensor and monitoring technologies capable of
operating in harsh conditions are extremely limited
Additive Manufacturing of Smart Parts
• Sensor-integrated smart parts: a new paradigm for
sensing in advanced energy systems
• Innovative approaches to tackle challenging problems • Robust sensors: The novel concept of OCMI and fs laser
assembly-free device fabrication
• Sensor embedment: Additive manufacturing
• Survivability: Transition layers between the sensor and host
• Dependable performance: Comprehensive thermal-mechanical
modeling/simulations of the “smart parts”
• Distributed sensing: Joint frequency-time domain method
uniquely enabled by mixing microwave with optics
• Demonstration: Tests and performance evaluations in simulated
laboratory conditions using existing facilities
Protective transition layers
Acknowledgement
DOE/NETL funding: DE-FE0012272, 10/01/2013 – 09/30/2016
Program manager: Richard Dunst
Technical POC: Hai Xiao, [email protected], (864) 656-5912
Additive Manufacturing of Smart Parts with Embedded Sensors
for In-Situ Monitoring in Advanced Energy Systems Hai Xiao1, Xinwei Lan1, Jie Huang1, Ming C. Leu2, Hai-Lung Tsai2, and Junhang Dong3
1 Department of Electrical and Computer Engineering, the Center for Optical Materials Science and Engineering Technologies (COMSET), Clemson University
2 Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology
3 Department of Chemical Engineering, University of Cincinnati
Spatially continuous distributed strain measurement
using cascaded intrinsic Fabry-Perot OCMI sensors.
The spatial resolution can be as high as 1 cm. The
distance can be as long a few kilometers.
The essence of OCMI is to read optical interferometers in
microwave domain. the system offers many unique features
that are particularly advantageous for sensing applications
• High signal quality and excellent visibility
• Relieved requirement on fabrication
• Insensitive to the variations of polarization
• Low dependence on multimodal influences and can be
implemented in special optical fibers (e.g., multimode,
single crystal sapphire, polymer fibers) and free space
• Spatially continues distributed sensing with high
resolution
Dual-laser additive manufacturing of metal smart
parts
Summary
Additive manufacturing (AM) of ceramic smart parts based on freeze-form extrusion process
CURRENT TECHNOLOGIES AND LIMITATIONS
• Traditionally, sensors are attached to or installed onto the
component after the structure is fabricated
• Costly and complicated sensor packaging before installation
• Poor survivability and reliability of the sensors
• Discrepancy between the sensor reading and the actual status
• Potential performance compromise of the host
materials/structures
OPPORTUNITIES - SENSOR-EMBEDDED “SMART PARTS”
• Smart parts – widely used and proven successful in structural
health monitoring (SHM)
• Provide the real-time information on the component and system
• Reduce the complexity in sensor packaging and installation
• Increase the robustness and reliability of the system
Smart Parts
Distributed temperature, strain and pressure sensors embedded in the tube/pipe wall
Distributed pressure, temperature, and strain sensors embedded circumferentially in the tube/pipe wall
OCMI #3: Strain & crack detection
OCMI #1: Temperature & wall thinning
OCMI #2: Strain & crack detection
OCMI #4: temperature & wall thinning
z
y x
SMART PIPE SMART LINER
Scope of Work
• Robust, high-temperature tolerated, embeddable optical carrier
based microwave interfereometry (CCMI) sensors
• Novel signal processing and instrumentation for distributed sensing
• Comprehensive thermal and mechanical models for optimal sensor
embedment and rational interpretation of the sensor outputs
• Multifunctional protective layers between the sensor and the host
for thermal, mechanical and chemical protection of the sensors
• Additive manufacturing of the “smart parts”
• Feasibility tests and performance evaluation
Path 1
Path 2
Control
Intensity
Modulator
Optical broadband
source
Δλ
High-speed optical detection
Frequency
scanning
Sync
Optical interferometer
Microwave source Vector microwave
detector
Data acquisition
(c) Propagation delay
+ Fourier
transform
OPD
2 1 22 cos2
O OL LA M
c
1 22
2
O OW L L
c
(a) Amplitude spectrum (b) Phase spectrum W+LO1 W+LO2
High speed
Photodetector
030
6090
120 0
10
20
0
0.5
1
1.5
2
2.5
3
x 10-3
Deflectio
n (mm)
Axial location (cm)
str
ain
Measurement data
Axi
al s
trai
n
Apply complex Fourier Transform on the window-gated data to reconstruct the interferogram of Section 8
Fibre core
(9 m in diameter)
Push
IFPI 1 IFPI 5 IFPI 2 IFPI 4 IFPI 8 IFPI 3 IFPI 6 IFPI 7 IFPI 9
L
Cascaded OCMI-IFPI sensor epoxied on the beam
Aluminum cantilever beam
(e)
(a)
Fs laser inscribed reflector
(d)
1423 1462 1500 1538 1577
0.0
0.2
0.4
0.7
0.9
1.1
1.3
1.6
Ref
lect
ion
(mU
nit)
Distance (cm)
Time gating window to isolate Section 8 (b)
500 1000 1500 2000 2500 3000
-90
-85
-80
-75
-70
-65
-60
Am
pli
tude
(dB
)
Frequency (MHz)
(c)
(a)
(b)
(c)
(d) (e) (f)
Joint by fusion
R1
3dB multimode
fiber coupler Input
Output
Joint by fusion
R2
10.2 cm
Silica graded-index multimode
(62.5 m core and 125 m
cladding) Single crystal sapphire fiber (125
m diameter, uncladded)
1000 1500 2000 2500 3000 3500 4000 4500
-60
-50
-40
-30
Am
plit
ude
(dB
)
Frequency (MHz)0 200 400 600 800 1000
4090
4100
4110
4120
4130
4140
Increasing
Decreasing
Res
onan
t fr
equen
cy (
MH
z)
Temperature (C)
Slope 0.044 MHz/C
1840 1850 1860 1870 1880 1890
4092.50
4092.60
4092.70
4092.80
Res
on
ant
freq
uen
cy (
MH
z)
Time (minutes)
1000C, with a standard deviation of 2.7C
20 μm
125 m
75 m
Silica fiber pressure sensor Sapphire fiber EFPI
sensor
Silica fiber temperature sensor Sapphire fiber grating
20 μm 20 μm
(a) (b)
Core (9m in diameter)
Fs laser inscribed reflector (15m × 40m)
Silica fiber IFPI sensor
Femtosecond laser micromachining
YLR-100 laser/
YLR-1000 laser Galvo
Laser coupler Beam expanderOptical fiber
F-θ lens
Working planeLaser
controller
UV nanosecond
laser
Beam expanderHalf wave
plate
Powder bed
Dichroic
Mirror
Motion stage
Z axis
Focusing lens
Motion stage
X-Y axis
Co-axial gas nozzle
Sapphire/Quartz fiber/rod
Dense
cladding
Sintered porous
layer of cladding
Dense metal
layer
(Porous) ceramic
adhesion
Host
component
T
i
A
l
M
g
O
Multiple layers of coatings to interface the embedded sensor
and the host and to provide the chemical, thermal,
mechanical and optical protections of the embedded sensors.
MgAl2O4-Ti0.98Pd0.2 - 1000oC