Fast, low-cost fiber-optic displacement sensor

Bruno Nilsson, Dan Tilert, Attila Temun, Torgny Carlsson, Lars Mattsson Department of Production Engineering, KTH, 100 44 Stockholm, Sweden
ABSTRACT
We have developed a fiber-optic sensor for measuring dynamic surface displacements caused by shock waves. Light from a LED emitter is sent through a plastic fiber and reflected from the surface back into the fiber. The intensity of the reflected light gives the distance to the surface. Based on simple principles and utilizing inexpensive components, micrometer and microsecond resolution is achieved at lower cost and easier usage than for interferometric methods and with better reliability than an accelerometer. The sensor is comparatively easy to set up. It is battery operated for reduced sensitivity of electromagnetic interference. The design of the fiber probe facilitates access in narrow and hostile environments. Keywords: Displacement, distance, intensity, shock wave, cost

1. INTRODUCTION
Recording small, fast deformations on a micrometer and microsecond scale of surfaces subject to heavy impact puts special demands on the measuring device, especially if there are additional complications such as limited space and potentially hostile environments. In our specific case, we measured the surface displacements of a stone block, the other side of which was subject to the detonation of a small explosive charge. There may also be demands for ease of use, time to set up and cost. Such demands arise if multiple surfaces need to be measured in a few hours, the deformations are due to a shockwave and there is a risk for expulsion, possibly sending shards of rock flying. There are a number of established methods for similar measurements, such as interferometry, holography and accelerometers.1-5 However, under the aforementioned circumstances these methods have drawbacks. Interferometry is not only relatively expensive, it is also cumbersome and time consuming to set up. Additionally, fracturing surfaces can easily cause costly damage to the optics. An accelerometer is sensitive to lateral movements and may break loose from the surface, possibly even break, when accelerated by thousands of g. Using optical fibers for such applications is not a new idea.6-8 This paper outlines how a simple yet effective and reliable fiber sensor was built at small cost. It relies on measuring intensity of light reflected from a diffusely reflecting surface and has been used for long periods of time with excellent results. The sensor is simple to set up between experiments and the parts that are close to the surface are inexpensive and easy to replace.

2. PRINCIPLE
The basis of the construction is a LED, a photodiode (PD) and an optical fiber. The fiber consists of three polymethylmethacrylat (PMMA) fiber pieces forming a Y-branch. The fiber itself has a plastic core with a diameter of 1 mm and a PVC cladding with a diameter of 2 mm. The LED is used to send light down one of the branches of the fiber. At the fiber end, as depicted in fig. 1, some of the light incident on a test surface is scattered back into the fiber and measured by the PD. The amount of light back reflected into the fiber depends on the distance from fiber end to surface and the distribution of the reflected light. For anisotropic surfaces such as stone blocks, spray painting with white matte paint is necessary to alleviate problems with the variation of the reflection distribution.

3. CONSTRUCTION
The Y-shaped fiber was made using a fixing plate of machined Plexiglas, where the fibers were bonded together with a drop of Acrifix (Rhm GmbH, Germany) and cured under a UV light source.

17th International Conference on Optical Fibre Sensors, Marc Voet, Reinhardt Willsch, Wolfgang Ecke, Julian Jones, Brian Culshaw, eds., Proceedings of SPIE Vol. 5855 (SPIE, Bellingham, WA, 2005) 0277-786X/05/$15 doi: 10.1117/12.623631

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The PD signal has to be amplified to a signal appropriate for oscilloscopes. A high speed JFET operational amplifier is used for converting the small photodiode current into a proportional signal voltage. A differential operational amplifier, having 200 kHz bandwidth, is used for zero suppression of the bias signal and further magnification of the useful signal content. Fig. 2 shows the schematic layout of the sensor.
+5V Principal Photo Detector Circuit ~i R +5V Zero Adj. Instr. Amp.
-100X (-10X)

Magnif. Output Direct Output

LED i

PD

OP-Amp

U=iR

-V (Reverse Bias)
Y-Branch Plastic Optic Fiber Probe

Test Obj.

Fig.1 Schematic layout for displacement sensor using a Y-branched fiber-optic probe and accompanying electronics

In order to obtain high noise and interference immunity, the sensor circuitry is designed to operate without galvanic connections to the outside world except for the output signal connection. Therefore two 9V alkaline batteries, lasting for about one day of operation, are used. An external mains power supply of 7 to 15V was added for stand by operation but is disconnected during measurement operations. In the actual instrument four of these fiber sensors are used simultaneously, facilitating statistical data treatment. They were mounted in a metal holder as shown in fig. 2. Held with screws, the fibers can be slid or fixed at will. The micrometer translation stage allows for both coarse movement on a millimeter scale and fine adjustments on a micrometer scale.

Fig. 2 The fiber probe and a close-up of the fiber ends. In 2a, the four fibers come from the left and extend through the metal holder, protruding to the right. The screws near the end - visible in 2b - are used to fasten or loosen the fibers. Using the sled down to the left in 2a the probe can be securely mounted, and the micrometer translation stage on the sled is used for position adjustment.

The detector is built of inexpensive components, the most exposed of which are easy to replace. If the fiber ends are damaged, repairing the sensor simply requires cutting off the ends and pushing the fibers to the desired position again. There are a few meters of spare fiber between the probe and the electronics box. Though not strictly necessary it is

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advisable to polish the fiber ends, but doing so takes little time. The cylindrical narrow design of the probe facilitates access in tight environments.

4. SENSOR RESPONSE
4.1 Static response The registered voltage as function of distance could not be expected to be linear. An example of detector response is shown in fig. 3. The distance is varied from 0 to 2000 m in 100 m steps. Additionally, a computer simulation of the expected response was made, assuming Lambertian surface characteristics of the matte white paint. It is shown in fig. 4. The distance in the simulation is varied from 600 to 1000 m in 25 m steps. 600 to 1000 m is the distance interval where the sensor is most commonly used.
Amount of light going back into the fiber versus distance

1 Normalized received power

0.8

0.6

0.4

0.2

0 600

650

700 750 800 850 900 Distance from fiber end to surface [ m]

950

1000

Fig. 3. Detector response versus distance

Fig. 4. Simulated detector response versus distance

4.2 Dynamic response The electronics in the detector act as a filter, delaying the signal. In order to evaluate the dynamic properties of the detector the filter characteristics were both tested and simulated. In fig. 5, the step response is tested by optical pulsing of a LED. Both actual response and simulated response are plotted. In fig. 6, a 16 kHz sine pulse is plotted with its simulated response. As a comparison, measured data from an actual experiment is also shown. In the experiment, expectations were that the first part of the measured movement would closely resemble a 16 kHz sine pulse.
Step response of detector 1 16 kHz sine pulse, its simulated response and data from a real experiment 1

0.8 Normalized amplitude Normalized amplitude

0.8

0.6

0.6

0.4 Optical input Measured response Simulated response

0.4 16 kHz sine Simulated response

0.2

0.2

0 -2 0 2 4 Time [ s] 6 8 10

0 -10 0 10 20 Time [ s] 30 40

Fig. 5. Real and simulated step response of the detector

Fig. 6. Simulated response to a 16 kHz sine pulse. Also shown is data from a real experiment with expected initial characteristics akin to a 16 kHz sine pulse.

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The precision and accuracy of the instrument depends on the calibration and micrometer screws. Using a Heidenhain length indicator with optical sensor, both accuracy and precision were determined to be better than 1 m in the measurement interval.

5. DISCUSSION
The response analysis shows that the detector behaves as expected. Though the simulated static response cannot be quantitatively compared to the measured response since it does not take factors such as ambient light and internal losses into account, the qualitative picture is convincing. Of course, in order to get reliable measurements the surface has to have laterally constant reflecting characteristics. In the case of rock surfaces, this is achieved to an adequate level by spraying the surface with white matte paint. Calibration is also necessary. For measurement ranges of up to 50 m a linear approximation is enough, but for larger ranges a polynomial fitting is needed. However, it has turned out that even for a range of 400 m, a second degree polynomial using three data points is enough not to lose discernable accuracy. The dynamic tests, some of which have been shown above, reveal that there is a certain amount of lag in the system but that it is quantifiable and can be corrected for in the data analysis. Time resolution better than 1 s is achieved. In a long series of experiments where a small explosive charge is detonated on one side of a stone block, initiating a shock wave in the block, the sensor has been used to measure the resulting displacement on the other side of the block. Occasionally, there was a risk that the block might shatter, damaging equipment nearby. After long practical use, we believe that the sensor is very reliable. It is also easy to set up, and if the surfaces are prepared in advance, setting up a new measurement and calibrating is relatively straightforward.

6. CONCLUSIONS
A simple, fast and inexpensive fiber-optic displacement sensor has been built. Though primarily designed for dynamic displacements, the sensor can also be used in static mode. It is capable of measuring distances with micrometer accuracy and microsecond time resolution. Based on intensity measurements, it relies on laterally uniform reflectance of the test surface, which is easily achieved with spray paint. Calibration is necessary before use but is quickly done. The only parts near the test surface are the four inexpensive and easily replaceable plastic fibers.

ACKNOWLEDGEMENTS
The authors wish to thankfully acknowledge the support from Gran Svedbjrk, Finn Ouchterloni and Ulf Nyberg, and the financial support from the Swedish Armed Forces.

REFERENCES
1. L. M. Barker and R. E. Hollenbach, Laser interferometer for measuring high velocities of any reflecting surface, Journal of Applied Physics 43(11), 4669-4675, 1972 2. M. Durand, P. Laharrangue, P. Lalle, A. Le Bihan, J. Morvan and H. Pujols, Interferometric laser technique for accurate velocity measurement in shock wave physics, Review of Scientific Instruments, 48(3), 275-278, 1977 3. D. D. Bloomquist, S. A. Sheffield, Optically recording velocity interferometer system (ORVIS) for subnanosecond particle velocity measurements in shock waves, Proceedings of the 15th International Congress on High Speed Photography and Photonics, vol. 348, p 523-528, SPIE, San Diego, 1983 4. Torgny E. Carlsson, Gert Bjarnholt, Nils Abramson, D. C. Holloway, Holographic interferometry applied to a model study of ground vibrations produced from blasting, Opt. Eng. 27(11), 923-927, 1988 5. John L. Remo, Solid state optic vibration/displacement sensors, Opt. Eng. 35(10) 2798-2803, 1996 6. Jing Xu, Practicable fiber optic displacement sensor with subnanometre resolution, Fiber Optic and Laser Sensors VIII, Ramon P. DePaula, Eric Udd; Eds., vol. 1367, p 214-220, 7. Y. L. LO, J. S. Sirkis and W. L. Fourney, In-fiber Doppler Velocimeter for Velocity Measurements of Moving Surfaces, Experimental Mechanics 37(3), 328-332, 1997, The International Society for Optical Engineering, San Jose, 1990 8. S. A. N. Murthy, B. B. Padhy, Fiber optic displacement sensor, Journal of Optics 29(4), 2000

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