光纤光栅传感产业化技术研究及应用
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摘要
发展高技术实现产业化是培育新的经济增长点,保持国民经济持续稳定增长的关键环节；是促进产业结构优化升级,提高产业整体素质的强大动力。光纤光栅作为当今先进传感技术的研究始于30年前,其应用的研究有十余年时间,光纤光栅传感器的研究已经发展形成了多参量、多种类和多用途的格局,显示出良好的技术前景和广阔的应用前景。光纤光栅传感器在国外不断地商业化,在传感器市场所占份额不断增长,形成了可观的经济规模和效益。近年来面对经济和国防建设的迫切需求,国内掀起了光纤光栅传感技术的研究热潮,但研究多数体现在原理性或少量的个别样机研制方面,对其产业化研究较少。因此打破国外技术垄断、提高新产品竞争力,满足国家建设的需求,其产业化研究是关键。
光纤光栅传感器种类繁多,但一般是由光纤光栅、传感探头、解调仪三部分组成,在设计、生产制备、工程应用等光纤光栅传感系统产业化过程中有诸多共性。本论文主要以布喇格光纤光栅传感器以及基于布喇格光纤光栅温度传感器的火灾报警系统为研究对象,分别对光纤光栅传感系统三大组成部分(光纤光栅、传感探头、解调仪)规模化生产制备中存在的关键技术、核心工艺、生产规范及其工程应用进行了系统研究,优化形成了规模化的生产体系和国产化的成套技术。具体研究内容如下：
(1)敏感元件光纤光栅的产业化研究：从传感用光纤光栅的要求出发,通过对光栅写入工艺、规模化技术和封装工艺的研究,总结出一套完整的光纤光栅规模化生产工艺和满足传感要求的质量控制规范。
(2)光纤光栅传感器的产业化研究：以目前最具生产规模化的光纤光栅温度传感器为研究对象,从温度传感的要求出发,通过传感器封装实验,研究了传感器的结构合理性和规模化生产的封装工艺。通过对生产工艺中关键技术问题的研究,形成了FBG温度传感器工业化生产的工艺规范和生产线技术经济指标。根据FBG传感器的特点,综合光通信等行业的相关标准,对光纤光栅传感器的可靠性进行了研究,提出了FBG传感器可靠性分析的步骤和传感器失效的判据。
(3)解调仪的规模化生产与工程应用研究：由于光纤光栅传感信号解调除包含电路、光路部分外,还有光电转换部分的关键器件,解调技术非常复杂。通过分析光纤光栅传感信号解调方法,对解调仪关键技术进行研究,突破技术瓶颈,实现了解调仪的国产化、规模化生产。通过解调仪在工程现场的应用研究,形成了一套完整的解调仪规模化生产工艺和质量控制规范。
(4)光纤光栅传感系统的工程化应用：以光纤光栅火灾报警系统在油罐、桥梁中的应用实例,研究分布式FBG传感系统在工程应用中的特殊要求,包括传感器保护、安装与现场检测以及提高传感器的成活率和耐久性等问题。
High-tech industrialization is the key link to cultivate new economic growth point and maintain the sustainable and steady growth of the domestic economy. It drives the optimization and upgrading of industrial structure as well as that of improving the overall quality of the industry. A new sensing technology, Fiber Bragg grating (FBG) was invented 30 years ago and the research on its application started since more than ten years ago. As today's advanced sensing technology, FBG sensing technology has already seen a promising future and various potential applications, it has developed in the trend of multi-parameter, multi-category and multi-functional. In western country, commercial instrument based on FBG sensing technology has already been put on the shelf, gaining increasing market share and considerable profit. In order to meet the urgent domestic economic needs and national defense construction, FBG sensing technology become a hot research topic in China. However, most of the researches focus on operational principle or individual prototyping, while the research on its industrialization is limited. Industrialization of FBG sensor plays an important role in breaking foreign technology monopolization, improving the competitiveness of new products and meeting the increasing demands of national construction.
Although there are various kinds of FBG sensing system serving different measuring purpose, these sensing system all are composed of three components including FBG sensing unit, metallic sensor capsulation, optical signal modulation device, they share many things in common in FBG sensing system industrialization process such as the design, production and engineering application,etc. In this thesis, we discussed the technical challenge, key technology and solutions in designing, manufacturing the three parts of FBG sensing system, as well as the criterion of mass production and its engineering application. Especially, we take FBG temperature sensor and fire alarm system Based on the FBG temperature sensor as examples. The production technology is optimized, the mass production system and the whole set of localization technology on FBG sensing is formed.The specific content is as follows:
(1) The industrialization study of sensitive element Fiber Bragg grating: According to the requirements of sensing application, manufacturing technics, mass production technique,and encapsulation process of FBG are researched,and a complete set of FBG mass production technics and its quality control standard are summarized,which meet the need of sensing.
(2) The industrialization study of Fiber Bragg grating sensor:With FBG temperature sensor as research subject,which has the most large-scale production at present, according to the requirements of temperature sensing, the structure design rationality and mass encapsulation technics of FBG sensor are researched by the sensor encapsulation experiment. Through the research of the technical challenge, industrialized production process specification, technical and economic indexes of FBG temperature sensor are formed. According to the characteristics of the FBG sensor, referring to the related standards such as communication industries,etc. the reliability of FBG sensor are studied, its reliability analysis steps and failure criterion are put out.
(3) Large-scale production and engineering application study of FBG demodulation device:Optical fiber Bragg grating sensing signal demodulator Contains circuit, optical path and the key components of photoelectric transformation, demodulation technology is very complicated. Through the analysis of fiber grating sensing signal demodulation method, the key technology of demodulation devices is studied, its technical bottleneck is conquered, localization and mass production of the demodulator are realized. Through engineering field application research of demodulation device, a complete set of Large-scale production process and quality control standard about the demodulator are formed.
(4) Engineering application study of FBG sensing system:Taking practical safety monitoring application of FBG fire alarm system in oil tank and bridge for example, special requirements of distributed FBG sensing system in engineering application are discussed, including sensor protection, installation on-site inspection and the improved survival rate and durability of FBG sensor,etc.
光纤光栅传感器种类繁多,但一般是由光纤光栅、传感探头、解调仪三部分组成,在设计、生产制备、工程应用等光纤光栅传感系统产业化过程中有诸多共性。本论文主要以布喇格光纤光栅传感器以及基于布喇格光纤光栅温度传感器的火灾报警系统为研究对象,分别对光纤光栅传感系统三大组成部分(光纤光栅、传感探头、解调仪)规模化生产制备中存在的关键技术、核心工艺、生产规范及其工程应用进行了系统研究,优化形成了规模化的生产体系和国产化的成套技术。具体研究内容如下：
(1)敏感元件光纤光栅的产业化研究：从传感用光纤光栅的要求出发,通过对光栅写入工艺、规模化技术和封装工艺的研究,总结出一套完整的光纤光栅规模化生产工艺和满足传感要求的质量控制规范。
(2)光纤光栅传感器的产业化研究：以目前最具生产规模化的光纤光栅温度传感器为研究对象,从温度传感的要求出发,通过传感器封装实验,研究了传感器的结构合理性和规模化生产的封装工艺。通过对生产工艺中关键技术问题的研究,形成了FBG温度传感器工业化生产的工艺规范和生产线技术经济指标。根据FBG传感器的特点,综合光通信等行业的相关标准,对光纤光栅传感器的可靠性进行了研究,提出了FBG传感器可靠性分析的步骤和传感器失效的判据。
(3)解调仪的规模化生产与工程应用研究：由于光纤光栅传感信号解调除包含电路、光路部分外,还有光电转换部分的关键器件,解调技术非常复杂。通过分析光纤光栅传感信号解调方法,对解调仪关键技术进行研究,突破技术瓶颈,实现了解调仪的国产化、规模化生产。通过解调仪在工程现场的应用研究,形成了一套完整的解调仪规模化生产工艺和质量控制规范。
(4)光纤光栅传感系统的工程化应用：以光纤光栅火灾报警系统在油罐、桥梁中的应用实例,研究分布式FBG传感系统在工程应用中的特殊要求,包括传感器保护、安装与现场检测以及提高传感器的成活率和耐久性等问题。
High-tech industrialization is the key link to cultivate new economic growth point and maintain the sustainable and steady growth of the domestic economy. It drives the optimization and upgrading of industrial structure as well as that of improving the overall quality of the industry. A new sensing technology, Fiber Bragg grating (FBG) was invented 30 years ago and the research on its application started since more than ten years ago. As today's advanced sensing technology, FBG sensing technology has already seen a promising future and various potential applications, it has developed in the trend of multi-parameter, multi-category and multi-functional. In western country, commercial instrument based on FBG sensing technology has already been put on the shelf, gaining increasing market share and considerable profit. In order to meet the urgent domestic economic needs and national defense construction, FBG sensing technology become a hot research topic in China. However, most of the researches focus on operational principle or individual prototyping, while the research on its industrialization is limited. Industrialization of FBG sensor plays an important role in breaking foreign technology monopolization, improving the competitiveness of new products and meeting the increasing demands of national construction.
Although there are various kinds of FBG sensing system serving different measuring purpose, these sensing system all are composed of three components including FBG sensing unit, metallic sensor capsulation, optical signal modulation device, they share many things in common in FBG sensing system industrialization process such as the design, production and engineering application,etc. In this thesis, we discussed the technical challenge, key technology and solutions in designing, manufacturing the three parts of FBG sensing system, as well as the criterion of mass production and its engineering application. Especially, we take FBG temperature sensor and fire alarm system Based on the FBG temperature sensor as examples. The production technology is optimized, the mass production system and the whole set of localization technology on FBG sensing is formed.The specific content is as follows:
(1) The industrialization study of sensitive element Fiber Bragg grating: According to the requirements of sensing application, manufacturing technics, mass production technique,and encapsulation process of FBG are researched,and a complete set of FBG mass production technics and its quality control standard are summarized,which meet the need of sensing.
(2) The industrialization study of Fiber Bragg grating sensor:With FBG temperature sensor as research subject,which has the most large-scale production at present, according to the requirements of temperature sensing, the structure design rationality and mass encapsulation technics of FBG sensor are researched by the sensor encapsulation experiment. Through the research of the technical challenge, industrialized production process specification, technical and economic indexes of FBG temperature sensor are formed. According to the characteristics of the FBG sensor, referring to the related standards such as communication industries,etc. the reliability of FBG sensor are studied, its reliability analysis steps and failure criterion are put out.
(3) Large-scale production and engineering application study of FBG demodulation device:Optical fiber Bragg grating sensing signal demodulator Contains circuit, optical path and the key components of photoelectric transformation, demodulation technology is very complicated. Through the analysis of fiber grating sensing signal demodulation method, the key technology of demodulation devices is studied, its technical bottleneck is conquered, localization and mass production of the demodulator are realized. Through engineering field application research of demodulation device, a complete set of Large-scale production process and quality control standard about the demodulator are formed.
(4) Engineering application study of FBG sensing system:Taking practical safety monitoring application of FBG fire alarm system in oil tank and bridge for example, special requirements of distributed FBG sensing system in engineering application are discussed, including sensor protection, installation on-site inspection and the improved survival rate and durability of FBG sensor,etc.
引文
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