Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Sensor packaging”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Evaluation of Low Cost Infrasound Sensor Packages

Sandia National Laboratories has tested and evaluated the performance of the following five models of low-cost infrasound sensors and sensor packages: Camas microphone, Gem Infrasound Logger, InfraBSU sensor, Raspberry Boom, and the Samsung S10 smartphone utilizing the Redvox app. The purpose of this infrasound sensor evaluation is to measure the performance characteristics in such areas as power consumption, sensitivity, self-noise, dynamic range, response, passband, linearity, sensitivity variation due to changes in static pressure and temperature, and sensitivity to vertical acceleration. The infrasound monitoring community has leveraged such sensors and integrated packages in novel ways; better understanding the performance of these units serves the geophysical monitoring community.

42 ENGINEERING↗
DOE OSTI2016

Sensor Fish: an autonomous sensor package for characterizing complex flow fields and fish passage

Fish passing through dams or other hydraulic structures may be injured or killed despite advances in turbine design, project operations, and other fish bypass systems. The Sensor Fish (SF) device is an autonomous sensor package that characterizes the physical conditions and stressors to which fish are exposed during passage through hydro facilities. It was designed to move passively as a neutrally buoyant object through severe hydraulic environments, while collecting high-resolution sensor data. Since its first generation1, the SF device has been successfully deployed in many fish passage studies and has evolved to be a major tool for characterizing fish passage conditions during fish passage in the Columbia River Basin. To better accelerate hydropower development, the U.S. Department of Energy Water Power Program provided funding to develop a new generation (Gen 2 SF) to incorporate more capabilities and accommodate a wider range of users over a broader range of turbine designs and operating environments. The Gen 2 SF (Figure 1) is approximately the size and density of a yearling salmon smolt and is nearly neutrally buoyant. It contains three-dimensional (3D) rotation sensors, 3D linear acceleration sensors, a pressure sensor, a temperature sensor, a 3D orientation sensor, a radiofrequency (RF) transmitter, and a recovery module2. A low-power microcontroller collects data from the sensors and stores up to 5 min of data on internal flash memory at a sampling frequency of 2048 Hz. The recovery module makes the SF positively buoyant after a pre-programmed period of time, causing it to float to the surface for recovery.

Sensor Fish↗
DOE OSTI2020

Metal-embedded fiber optic sensor packaging and signal demodulation scheme towards high-frequency dynamic measurements in harsh environments

Optical fiber-based sensors are commonly used for industrial monitoring and control processes due to their small size, resistance to electromagnetic interference, and ability to perform a wide variety of high-precision measurements. However, implementing optical fiber sensors in harsh environments is challenging because they are small and fragile. Proper packaging of fiber-optic sensors could extend their use to harsh environments, including at high temperature and under high radiation. Furthermore, conventional fiber optic-based measurement systems often use computationally expensive signal processing algorithms which hinder their use in high-frequency dynamic applications. This work reports on the design of an optical fiber-pressure sensor system based on low-coherence interferometry that uses a metal-embedded optical fiber to provide a robust sensor package. Additionally, a novel phase demodulation scheme is proposed to extract length changes from the deformation of a thin diaphragm within a Fabry–Pérot cavity to measure pressure. The sensor has been tested to ±100 kPa, has a theoretical linear response over a 270 kPa dynamic range (24 dB maximum signal-to-noise ratio), and can resolve pressure transients up to 3910 kPa/s. Sampling at 100 kHz, the present sensor can resolve 2 kPa dynamic pressures at frequencies up to 2 kHz. Faster transients on the order of tens to hundreds of kHz can theoretically be resolved at the expense of decreasing the maximum resolvable amplitude. A methodology for designing a LCI pressure sensor for a given application is outlined based on the limitations imposed by the Nyquist criterion, the diaphragm's resonant frequency, the LCI optoelectronics, and the phase demodulation scheme. The sensor is the first to implement a low-coherence light source and a Fabry–Pérot interferometer designed to provide real-time high-fidelity pressure measurements using a metal-embedded optical fiber. The demonstrated sensor provides a platform for sensing in harsh conditions such as in nuclear and energy applications.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Fiber-optic sensor packaging assessment and benchmarking for embedded sensing applications

Fiber optic-based sensing for non-destructive evaluation (NDE) and structural health monitoring of various infrastructure and energy assets is an increasingly important sensing scheme. Because of their immunity to electromagnetic interferences, versatility in sensing mechanisms and designs as well as capability for distributed sensing, the fiber optic sensing is of great interest for embedding within infrastructures using advanced manufacturing methods. However, the protection of fiber optic sensors during advanced manufacturing-based embedding is an important aspect for infrastructure monitoring in practice. While successful installation of fiber optic sensors has been accomplished through application of epoxy or adhesives on infrastructure surfaces, there has been only limited investigation of fiber protection packaging schemes which are compatible with in-situ repair techniques such as the metallic cold-spray. With increasing interest and importance of cold spray-based repair processes, the integration of fiber optic sensors simultaneously during the repair is equally important. In this work, we focus our efforts on investigating various types of packaging schemes for their compatibility and integrability on the surfaces of metallic structures such as oil and gas pipelines during an in-situ repair coating. First, we consider sandblasting using silica sand particles of various size for optical fibers on the surface of a metallic coupon as a useful proxy test of sensor packaging stability. Structural damage of packaging is characterized by means of optical microscopy and the optical integrity of embedded fiber optic cables is examined using optical backscatter reflectometry (OBR). In addition, initial investigation of metallic cold-spray embedded fiber optic cables under various packaging on metallic substrates is also considered with early conclusions and future directions.

Fiber-optic sensors, Sensors packaging, Metallic C↗
DOE OSTI2016

Advanced Sensor Arrays and Packaging

Novel sensor packaging elements were designed, fabricated, and tested in order to facilitate the transition of electrochemical mixed-potential sensors toward commercialization. Of the two designs completed, the first is currently undergoing field trials, taking direct measurements within vehicle exhaust streams, while the second is undergoing preliminary laboratory testing. The sensors’ optimal operating conditions, sensitivity to hydrogen, and long-­term baseline stability were also investigated. The sensing capabilities of lanthanum chromite (La 0.8 Sr 0.2 CrO 3 ) and indium-­doped tin oxide (ITO) working electrodes were compared, and the ITO devices were selected for pre-­commercial field trials testing at a hydrogen fuel cell vehicle fueling station in California. Previous data from that fueling station were also analyzed, and the causes of anomalous baseline drift were identified.

47 OTHER INSTRUMENTATION↗
DOE OSTI2015

Near Field Intensity Trends of Main Laser Alignment Images in the National Ignition Facility (NIF)

The National Ignition Facility (NIF) utilizes 192 high-energy laser beams focused with enough power and precision on a hydrogen-filled spherical, cryogenic target to potentially initiate a fusion reaction. NIF has been operational for six years; during that time, thousands of successful laser firings or shots have been executed. Critical instrument measurements and camera images are carefully recorded for each shot. The result is a massive and complex database or ‘big data’ archive that can be used to investigate the state of the laser system at any point in its history or to locate and track trends in the laser operation over time. In this study, the optical light throughput for more than 1600 NIF shots for each of the 192 main laser beams and 48 quads was measured over a three year period from January 2009 to October 2012. The purpose was to verify that the variation in the transmission of light through the optics over time performed within design expectations during this time period. Differences between average or integrated intensity from images recorded by the input sensor package (ISP) and by the output sensor package (OSP) in the NIF beam-line were examined. A metric is described for quantifying changes in the integrated intensity measurements and was used to view potential trends. Results are presented for the NIF input and output sensor package trends and changes over the three year time-frame.

42 ENGINEERING↗
DOE OSTI2013

APPLICATIONS OF CURRENT TECHNOLOGY FOR CONTINUOUS MONITORING OF SPENT FUEL

Advancements in technology have opened many opportunities to improve upon the current infrastructure surrounding the nuclear fuel cycle. Embedded devices, very small sensors, and wireless technology can be applied to Security, Safety, and Nonproliferation of Spent Nuclear Fuel. Security, separate of current video monitoring systems, can be improved by integrating current wireless technology with a variety of sensors including motion detection, altimeter, accelerometer, and a tagging system. By continually monitoring these sensors, thresholds can be set to sense deviations from nominal values. Then alarms or notifications can be activated as needed. Safety can be improved in several ways. First, human exposure to ionizing radiation can be reduced by using a wireless sensor package on each spent fuel cask to monitor radiation, temperature, humidity, etc. Since the sensor data is monitored remotely operator stay-time is decreased and distance from the spent fuel increased, so the overall radiation exposure is reduced as compared to visual inspections. The second improvement is the ability to monitor continuously rather than periodically. If changes occur to the material, alarm thresholds could be set and notifications made to provide advanced notice of negative data trends. These sensor packages could also record data to be used for scientific evaluation and studies to improve transportation and storage safety. Nonproliferation can be improved for spent fuel transportation and storage by designing an integrated tag that uses current infrastructure for reporting and in an event; tracking can be accomplished using the Iridium satellite system. This technology is similar to GPS but with higher signal strength and penetration power, but lower accuracy. A sensor package can integrate all or some of the above depending on the transportation and storage requirements and regulations. A sensor package can be developed using off the shelf technology and applying it to each specific need. There are products on the market for smart meters, industrial lighting control and home automation that can be applied to the Back End Fuel Cycle. With a little integration and innovation a cost effective solution is achievable.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Sensors Umbra Package v 1.0

This package contains modules that model sensors in Umbra. There is a mix of modalities for both accumulating and tracking energy sensors: seismic, magnetic, and radiation. Some modules fuss information from multiple sensor types. Sensor devices (e.g., seismic sensors), detect objects such as people and vehicles that have sensor properties attached (e.g., seismic properties).

Oppel, Fred J.↗
DOE OSTI2024

A Hermetic Package Technique for Multi-Functional Fiber Sensors through Pressure Boundary of Energy Systems Based on Glass Sealants

This paper presents a hermitic fiber sensor packaging technique that enables fiber sensors to be embedded in energy systems for performing multi-parameter measurements in high-temperature and strong radiation environments. A high-temperature stable Intrinsic Fabry–Perot interferometer (IFPI) array, inscribed by a femtosecond laser direct writing scheme, is used to measure both temperature and pressure induced strain changes. To address the large disparity in thermo-expansion coefficients (TECs) between silica fibers and metal parts, glass sealants with TEC between silica optical fibers and metals were used to hermetically seal optical fiber sensors inside stainless steel metal tubes. The hermetically sealed package is validated for helium leakages between 1 MPa and 10 MPa using a helium leak detector. An IFPI sensor embedded in glass sealant was used to measure pressure. The paper demonstrates an effective technique to deploy fiber sensors to perform multi-parameter measurements in a wide range of energy systems that utilize high temperatures and strong radiation environments to achieve efficient energy production.

Optics↗
DOE OSTI2013

Single-Crystal Sapphire Optical Fiber Sensor Instrumentation

This report summarizes technical progress on the program “Single-Crystal Sapphire Optical Fiber Sensor Instrumentation,” funded by the National Energy Technology Laboratory of the U.S. Department of Energy, and performed by the Center for Photonics Technology of the Bradley Department of Electrical and Computer Engineering at Virginia Tech. This project was completed in three phases, each with a separate focus. Phase I of the program, from October 1999 to April 2002, was devoted to development of sensing schema for use in high temperature, harsh environments. Different sensing designs were proposed and tested in the laboratory. Phase II of the program, from April 2002 to April 2009, focused on bringing the sensor technologies, which had already been successfully demonstrated in the laboratory, to a level where the sensors could be deployed in harsh industrial environments and eventually become commercially viable through a series of field tests. Also, a new sensing scheme was developed and tested with numerous advantages over all previous ones in Phase II. Phase III of the program, September 2009 to December 2013, focused on development of the new sensing scheme for field testing in conjunction with materials engineering of the improved sensor packaging lifetimes. In Phase I, three different sensing principles were studied: sapphire air-gap extrinsic Fabry-Perot sensors; intensity-based polarimetric sensors; and broadband polarimetric sensors. Black body radiation tests and corrosion tests were also performed in this phase. The outcome of the first phase of this program was the selection of broadband polarimetric differential interferometry (BPDI) for further prototype instrumentation development. This approach is based on the measurement of the optical path difference (OPD) between two orthogonally polarized light beams in a single-crystal sapphire disk. At the beginning of Phase II, in June 2004, the BPDI sensor was tested at the Wabash River coal gasifier facility in Terre Haute, Indiana. Due to business conditions at industrial partner and several logistical problems, this field test was not successful. An alternative high-temperature sensing system using sapphire wafer-based extrinsic Fabry-Perot interferometry was then developed as a significant improvement over the BPDI solution. From June 2006 to June 2008, three consecutive field tests were performed with the new sapphire wafer sensors at the TECO coal gasifier in Tampa, Florida. One of the sensors survived in the industrial coal gasifier for 7 months, over which time the existing thermocouples were replaced twice. The outcome of these TECO field tests suggests that the sapphire wafer sensor has very good potential to be commercialized. However packaging and sensor protection issues need additional development. During Phase III, several major improvements in the design and fabrication process of the sensor have been achieved through experiments and theoretical analysis. Studies on the property of the key components in the sensor head, including the sapphire fiber and sapphire wafer, were also conducted, for a better understanding of the sensor behavior. A final design based on all knowledge and experience has been developed, free of any issues encountered during the entire research. Sensors with this design performed well as expected in lab long-term tests, and were deployed in the sensing probe of the final coal-gasifier field test. Sensor packaging and protection was improved through materials engineering through testing of packaging designs in two blank probe packaging tests at Eastman Chemical in Kingsport, TN. Performance analysis of the blank probe packaging resulted in improve package designs culminating in a 3rd generation probe packaging utilized for the full field test of the sapphire optical sensor and materials designed sensor packaging.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Distributed Sapphire Fiber Bragg Gratings Based Thermal Profiling of Submerged Entry Nozzles

This research focuses on the application of sapphire fiber Bragg gratings (FBGs) for instrumentation in submerged entry nozzles (SEN) within the steelmaking industry. The SEN is pivotal for transferring molten steel from a tundish to a mold, while preventing the infiltration of oxygen and nitrogen from the surrounding environment. Maintaining optimal flow conditions in the mold is crucial for ensuring casting process stability and maintaining high quality steel. Sapphire FBG sensors have been instrumented in SENs to enable distributed thermal mapping for monitoring the health of the SEN. The optical sensor comprises three cascaded sapphire FBGs inscribed using femtosecond laser technology into a one-meter-long sapphire crystalline fiber. The sensor underwent characterization in a laboratory setting up to 1600°C and was tested for long-term stability over 40 hours under extreme environmental conditions. The coupling between silica and sapphire fibers was investigated and implemented during sensor packaging. Here, the sensor successfully captured the pre-heat sequence of the SEN in real-world steelmaking operations. Compared to conventional thermocouples, sapphire FBG sensors demonstrated exceptional efficiency and precision. They offer potential benefits such as increased productivity, reduced energy consumption, and minimized carbon footprint in the steel industry.

Sapphire Fiber Bragg Grating↗
DOE OSTI2015

Multipoint Pressure and Temperature Sensing Fiber Optic Cable for Monitoring CO 2 Sequestration

This report describes the work completed on contract DE-FE0010116. The goal of this two year project was to develop and demonstrate in the laboratory a highly accurate multi-point pressure measurement fiber optic cable based on MEMS pressure sensors suitable for downhole deployment in a CO 2 sequestration well. The sensor interrogator was also to be demonstrated in a remote monitoring system and environmental testing was to be completed to indicate its downhole survivability over a lengthy period of time (e.g., 20 years). An interrogator system based on a pulsed laser excitation was shown to be capable of multiple (potentially 100+) simultaneous sensor measurements. Two sensors packages were completed and spliced in a cable onto the same fiber and measured. One sensor package was subsequently measured at high temperatures and pressures in supercritical CO 2 , while the other package was measured prior and after being subjected to high torque stresses to mimic downhole deployment. The environmental and stress tests indicated areas in which the package design should be further improved.

47 OTHER INSTRUMENTATION↗