FIBER OPTIC FLUID SENSORS

Abstract: An optical fluid sensor 20 with a light emitter 2, a photodetector 11 and a sensing tip element 15 which is optically connected by first optical fiber means (4) to the light emitter 2 and by second otpical fiber means (9) to the photodetector 11 is disclosed, said sensing tip element 15 being provided with a coating 14 of a material impermeable by the fluid to be sensed and resistant to the formation of fluid film or droplets thereon thereby reducing undesirable effects or false readings. By constantly monitoring low-level light returned to the photodetector 11 under all operating conditions, the optical fluid sensor of the invention provides a fault finding system.

Description: This invention relates to a fiber optic sensing device for sensing the presence, level and/or nature of fluids. It is often necessary or desirable to sense the presence, level and/or other characteristics of fluids. Thus, it is known to use sensors with storage tanks, reservoirs, fuel tanks and pipelines to determine fluid level, conditions of overfill or underfill, or to detect contamination. For example, sensors are used in gasoline storage tanks at service stations to monitor fluid level and to detect contamination in the outer water jacket now commonly installed around such fuel tanks. EP O 124415 discloses an optical probe for the detection of the separating interface of two hostile media comprising a cone made of a material having a refrative index able to reflect an incident light beam if it is located in one of the two media and is characterized in that it comprises a tight casing for the cone, that said cone is made of materials able to resist chemical and thermal stresses in the two media and that optical fi-bres are used for transmitting the incident and the reflected light beams. U.S.patent 4,468,567 describes a liquid level detecting device comprising a plurality of optical fibers, their end portions arranged in close vicinity to one another, each having a core made of transparent material and a cladding layer made of another transparent material having a lower refractive index; and a detecting portion composed of an inner substantially spherical body formed by heating mutually adjacent end portions of said optical fibers to fuse with one another and made of the same material as that of the transparent material forming said core, said inner spherical body being in one body with said cores; and a cladding layer covering said inner spherical body made of the same material as that of the transparent material forming said cladding layers of said optical fibers and forming a continuous layer with each cladding layer of said optical fibers. From British paptent specification GB-A-1508 085 an optical-electrical liquid probe known, comprising a light emitter, a light receiver in the form of a photoelectric transducer, a body which is translucent to light rays and having at least one surface which can be exposed to a liquid, said light emitter being arranged to emit light rays, so that the strike, from within the body, the said surface which can be exposed to liquid, and are refracted, in absence of liquid at the said surface, in the direction of the light receiver, wherein said translucent body is in the form of a hollow body defining an internal space, and said body comprises a widened hollow upper part, a narrowed hollow part having a circumferential wall, and a shoulder part located between the said parts, the narrowed lower part has a closed end remote from the shoulder part and is arranged to be externally exposed to liquid, the light emitter is located in the said internal space of the hollow body such that light rays emitted by the light emitter pass outwards through the outer surface of the circumferential wall of the narrowed lower part at an acute angle and in such predetermined directions that, in the case of the absence of liquid from the vicinity of the narrowed lower part, the light rays pass through the shoulder part of the hollow body into the widened upper part, but in the presence of liquid the light rays do not reach the shoulder part, the light receiver is located in the interior of the widened upper part, and means are provided to prevent access to the light receiver, of light rays which enter through the shoulder part from directions other than said predetermined direction. Heretofore known sensors rely upon a variety of principles to measure the fluid level and other characteristics. The most common type of sensor is the capacitance type sensor. Unfortunately, these sensors require electrical power at the sensing location, creating a hazard of explosion when volatile fluids are being sensed. Optical sensors also have electrical components in the sensing zone and, thus, suffer from the same explosion hazard. In addition, prior optical sensors have been known to give false indications due to fluids adhering to optical surfaces. Therefore, it is an object of this invention to provide a fluid sensing device capable of performing various sensing functions without presenting any hazard of explosion. Another object of this invention is to provide a remote fluid sensor in which all electrical components are positioned away from the sensing zone. Yet another object of the invention is to provide a remote optical sensor which does not suffer from the undesirable effects of fluid films forming at the optical sensing tip. A still further object of the invention is to provide an optical fluid sensor in which the performance of the sensor components is monitored and a separate output signal provided to indicate failure of any components. There is provided an optical fluid sensor comprising a light-emitter, a photodetector for producing a signal from light incident thereon, a sensor tip including sensor tip element being in optical communication with said light emitter by means of first optical fiber means and second fiber optic means for communicating the light reflected from said sensor tip element to photodetector which is characterized in that the conical sensor tip element is provided with a coating impermeable to the fluid sensed and resistant to the formation of fluid film or droplets thereon, and that the material of tip element and coating as well as bevel angle (a) are selected so that the light transmitted to said sensing surface is substantially dispersed in the fluid in the presence of fluid to be sensed, and internally reflected and directed to the photodetector in the absence of fluid to be sensed; and that angle B between the incident and internally reflected light rays, Fig. 3, equals B = 180° - 2a; and that the low-light continuously reflected by said sensor tip element independent of the medium surrounding the sensor tip element and received by said photodetector from said sensor tip element provides a self monitoring signal for the operation of the optical fluid sensor indicating malfunction when no light reaches the photodetector; and that it further comprises electronic processing means for the signals provided by photodetector, said electronic processing means being disposed away from the sensing zone. The aforementioned and other highly desirable and unusual results are accomplished by this invention in an economical structure. In accordance with the invention, an optical fluid sensor is provided which detects the presence, level and/or nature of fluids at a sensing tip by means of optical index of refraction matching between the sensing tip and the fluid. The invention provides optical sensing at a location remote from the optical emitter, photodetector and associated electronic signal processing equipment. In order to obtain the proper relationship between the sensing tip and the fluid, the index of refraction and the bevel angel of the tip element are carefully selected in relation to the indices of refraction of the coating and the fluid to be sensed. As a result, when fluid surrounds the tip, light is dispersed into the fluid and lost. When no fluid is present, however, the coating sheds any remaining fluid and the light is internally reflected and refracted back into the detector fiber optic cable and carried to a photodetector for sensing and signal processing. Applicant has found that a low level of light is always returned to the photodetector under all conditions. Remarkably, this low level light can be used to monitor the condition of the sensor. For example, in the absence of this constant low level signal a status output can be triggered to indicate that a failure has occurred somewhere in the sensor. It can be readily appreciated that his invention provides a sensor capable of determining fluid level or differentiating between based upon the respective indices of refraction of the sensing tip and the fluid(s) being detected. As an advantage of this invention this sensing capability is provided without any need to electrical components in the sensing zone, thereby eliminating the serious hazards of explosion which can otherwise occur during the sensing of volatile fluids. The accompanying drawings illustrate preferred embodiments of the invention. Fig. 1 is a top plan view of a preferred embodiment of the invention. Fig. 2 is a partial cross-section view of the sensor tip according to the invention. Fig. 3 is an enlarged partial cross-section view of the sensor tip according to the invention illustrating the internal angles of reflection and refraction at the tip element/coating and coating/fluid interface. The drawings show a preferred embodiment of the remote optical sensor constructed in accordance with this invention. In Fig. 1, the fluid sensor (20) includes an electronic module (12) connected to a power source at electrical connector 1. The electrical power is regulated to provide a constant current to a semiconductor emitter (2), which emits light through an emitter optical connector (3) into a sending fiber cable (4). Sending fiber cable (4) co-joins with return fiber cable (9) at the bifurcation encapsulation (5) to form a fiber cable (6). By way of example only, fiber optic bundles, a duplex pair of fibers or a single fiber provided with a splitter may be used to provide the sending and return fiber optic pathways. The choice among these transmission media is governed by such factors as the required transmission distance, optical efficiency, and particular insta llation requirements. Sending fiber cable 4 is coupled to a sensing tip 8 by a sensing tip optical connector 7. Sensing tip 8 is installed at the sensing location in contact with the fluid to be sensed. Return optical energy from sensing tip 8 travels through fiber cable 6 and return fiber cable 9 through a detection optical connector 10 to a photodetector 11, where the return signal is detected and electronically processed. Fig. 2 is a partial cross-section view of sensing tip 8. Light from fiber cable 6 (see Fig. 1) is directed into optical tip 15 to the conical tip 16, where it is refracted into coating 14 at an angle dependent upon the relative indices of refraction of tip element 15 and coating 14. After passing through coating 14 to the coating/fluid interface the light is refracted into the fluid 22 and lost or is reflected back into the coating 14, depending upon the relative indices of refraction of coating 14 and the fluid 22 being sensed. In the absence of fluid 22 the light is reflected back into coating 14 and again undergoes refraction at the interface of coating 14 and tip element 15. Thereafter, the light travels across tip element 15 perpendicular to the original axis of the light entering tip element 15 from sensing tip optical connector 7 (see Fig. 1) and undergoes a second refraction/reflection process at the other side of the conical tip element 15. The light subsequently reflected and refracted after the second interaction, now travelling in a direction 180° relative to the light entering tip element 15 from sensing element optical connector 7, enters the return fiber of fiber cable 6 through optical connector 7. Referring again to Fig. 1, the return beam of light travels through fiber cable 6 to bifurcation encapsulation 5, where return fiber cable 9 branches away from sensing cable 4. The return beam of light continues through return fiber cable 9 and photodetector optical connector 10 and is incident upon photodetector 11. The electrical output of photodetector 11 is proportional to the number of photons of the returned light incident upon the photodetector. The photodetector electrical output signal is amplified and processed by electronics module is in a known manner according to standard output formats. The output signals of electronics module 12 can be transmitted through electrical coupling 1 for display. Tip element 15 and coating 14 should be constructed of materials carefully selected to have indices of refraction and a tip element bevel angle such that in the presence of the fluid to be sensed light from the sensing tip element 15 will be refracted out into the fluid and lost. In the absence of fluid or in the presence of a second fluid having a different index of refraction the materials selected should cause light to be reflected back in to coating 14, tip element 15 and fiber cable 6 to be detected by photodetector 11. An important consideration in selecting the coating material 14 is the compatibility of that material with the fluid being sensed. Coating 14 should not degrade in the presence of the fluid being sensed and should shed the fluid so that no fluid droplets or films form over the coating when the fluid level drops. This property is very important since fluid droplets or film can lead to false indications. Thus, as a practical matter, the coating material is often selected primarily for its durability and ability to shed the fluid. As a result, the index of refraction of the coating material will often be a secondary consideration in the selection of the coating material and may not be variable by the user. Thus, there are four primary variables in the sensing tip system as illustrated in Fig. 3. These are n₁ - the index of refraction of tip element 15 'a' - the bevel angle of tip element 15 n₂ - the index of refraction of the coating material 14 n₃ - the index o f refraction of the fluid 22 In addition, n₃ is considered to be the index of refraction in the absence of fluid. For example, when the fluid level drops and only air surrounds the sensing tip 15, n₃ equals 1.0, the index of refraction of air. Of the four variables listed above, two are assumed to be fixed while two are variable. First, the index of refraction n₃ of the fluid to be sensed and the index of refraction n₃ of air or a different fluid are determined by the particular application. Therefore, n₃ and n₃ are considered to be invariable. Secondly, since the sensing tip coating 14 is chosen primarily for its properties in relation to the fluid being sensed, i.e. impermeability to the fluid and tendency to shed fluid droplets and/or film, the index of refraction n₂ of this material is also assumed to be invariable. Therefore, the remaining variables which can be adjusted are the bevel angle 'a' of the sensing tip and the index of refraction n₁ of the tip element. As a practical matter, in determining the appropriate values for the sensing tip bevel angle 'a' and index of refraction n₁ several factors should be considered. First, the angle of incidence of the light at the coating/fluid interface must be such that the light will be transmitted into the fluid when the fluid is present and will be internally reflected in the absence of fluid. Secondly, when internally reflected light returns from the coating/fluid interface that light must be transmitted from the coating 14 back into the tip element in order to avoid unnecessary loss of light due to trapping in the coating. Third, the sensing tip 15 should be designed to accomodate a small variation in the index of refraction of the fluid, e.g., the index of refraction for JPA jet fuel, one fluid suitable for sensing, has been reported to vary over a range of about 1.40 to 1.45. Fourth, for very sensitive measurements it is contemplated that it may be necessary to take into account the Fresnel relations for transmission of light at a boundary. This fourth factor is contemplated but not discussed in detail herein. These relationships could be determined by a person of ordinary skill in the art, if necessary. Referring to Fig. 3, in order to satisfy the first three factors discussed hereinabove, the following constraints are assumed. For a totally internally reflected beam at the coating to fluid interface: When the index of refraction n₃ outside the coating is 1.0, i.e., when no fluid is present: and when the light is to be transmitted at the fluid to coating interface, i.e., when fluid is present having an index of refraction n₃: Moreover, in order to avoid internal light trapping at the coating to tip element interface: Noting further that and that The internal reflection angle B (Fig. 3) for light incident at the tip element to coating interface can be expressed as Finally, since by substituting according to the assumed constraints Provided the necessary internal constraints are satisfied, B can simply be expressed as By way of example only, it has been found that a sensor according to the invention useful for detecting standard aviation fuel known by the designation "JP4" can be constructed using a saphire sensing tip element having a bevel angle 'a' of approximately 45° and an index of refraction on the order of 1.77, coated with a thin polytetrafluoroethylene(PTFE) coating having a relatively constant index of refraction of about 2.1. This sensor tip has been found to be useful for sensing the presence of fluids having an index of refraction from 1.1 to 2.1. and has been found to be particularly desirable for sensing jet fuels having an index of refraction from 1.42 to 1.46, depending upon the age of the fuel. Of course, it is contemplated that the sensing tip could be be made from any optical quality glass of other material having an appropriate index of refraction and bevl angle. It is also contemplated that coatings other than PTFE may prove to be suitable depending upon the particular fluid sensing application. Other specific constructions presently contemplated but not yet constructed are set forth in Table I, listing two additional tip element selections for similar sensing conditions. Using the formulae set forth above, it can be shown that the tip materials listed in Table I should satisfy all internal constraints. That is, when these tip materials are used, light should be transmitted to the fluid when the fluid is present (i.e., n₃ = 1.42) or totally internally reflected for detection when the fluid is not present (i.e., n₃ = 1.0). It can also be shown using the above formulae that under the same conditions shown in Table I, a hard plastic tip element having an index of refraction n₁ equal to 1.3 will not satisfy the necessary internal constraints. That is, should a hard plastic tip element be used under these conditions it can be shown that no total internal reflection would occur either in the presence of a fluid having n₃ = 1.42 or in the presence of air having n₃ = 1.0. Thus, a hard plastic tip element would not be satisfactory for this particular application since no distinction could be noted between the presence or absence of the fluid. In this regard, when the coating material is PTFE having n₂ = 2.1 and the tip element bevel angle 'a' = 45°, it can be shown that for any particular fluid and tip element material the exit angle ϑ ₃ must be maintained below 90° in order to distinguish the fluid from air. When ϑ ₃ reaches 90° total internal reflection will occur and no distinction can be made. It has also been found that by varying the sensitivity of the detector and processing electronics the sensor tip according to the invention can be used to sense the presence of water having an index of refraction of 1.33. Thus, it is further contemplated that when two miscible liquids having distinct indices of refraction are present a distinction between such fluids can be made. Indeed, it is believed that an estimate of the relative percentage of such miscible fluids relative to the total fluid can be made using an analog display. That is, where only one fluid is present a certain light level indication would be expected and in the presence of only the second fluid a distinct reading would be expected. In the presence of a mixture of the two fluids, an analog reading somewhere between those two values can be expected. A small amount of light entering tip element 15 from sensing tip optical connector 7 is always dispersed over an emission cone depending upon the effective numerical aperture of the sending fiber(s). Consequently, some light is always returned to photodetector 11 based only upon internal reflections of tip element 15 (see Fig. 3, specifically reflection angle B). Advantageously, this low-level of constant return energy is detected by photodetector 11 and can be used to provide a fail-safe monitor of the fluid sensor. The electronics module is can be arranged to constantly monitor the presence of this low-level constant return beam and, in the absence of this constant signal, trigger a status line output indicating a system failure. Failure at any point in the emitter, fiber cables, tip element or photodetector will result in an insufficient constant return beam and will trigger the status alert. Thus, it will be apparent that the fluid sensor according to the inven tion advantageously provides safe, accurate fluid sensing in the presence of volatile liquids by positioning all electronics which might cause an igniting spark away from the sensing location. Furthermore, the present fluid sensor reduces the likelyhood of false indications due to the formation of residual fluid film or droplets on the sensor and includes desirable fiber optic technology which is capable of operating at relatively long transmission distances without signal interference. Moreover, the fluid sensor according to the invention is remarkably compact and light weight and includes the capability of self-monitor sensor performance. To the extent not already indicated, it also will be understood by those of ordinary skill in the art that any one of the various specific embodiments herein described and illustrated may be further modified to incorporate features shown in other of the specific embodiments.

Claims: An optical fluid sensor (20) comprising a light-emitter (2), a photo-detector (11) for producing a signal from light incident thereon, a sensor tip (8) including a sensor tip element (15) being in optical communication with said light emitter 2 by means of first optical fiber means (4, 6) and second fiber optic means (9, 6) for communicating the light reflected from said sensor tip element (15) to photo-detector (11) characterized in that the conical sensor tip element is provided with a coating (14) impermeable to the fluid (22) sensed and resistant to the formation of fluid film or droplets thereon, and that the material of tip element (15) and coating (14) as well as bevel angle (a) are selected so that the light transmitted to said sensing surface 14 is substantially dispersed in the fluid (22) in the presence of fluid to be sensed, and internally reflected and directed to the photo-detector (11) in the absence of fluid (22) to be sensed; and that angle B between the incident and internally reflected light rays equals 180° - 2a; and that the low level light continuously reflected by said sensor tip element independent of the medium surrounding the sensor tip element and received by said photo-detector (11) from said sensor tip element 15 provides a self monitoring signal for the operation of the optical fluid sensor indicating malfunction when no light reaches the photo-detector; and that it further comprises electronic processing means (12) for the signals provided by photo-detector (11), said electronic processing means being disposed away from the sensing zone. The optical fluid sensor of claim 1, characterized in that the angle of the sensor tip element is 45° The optical fluid sensor of claim 1 or 2, characterized in that the sensor tip element is composed of sapphire.

Inventors: PARK, ERIC D.
Applicants: KOLLMORGEN CORPORATION
Application year: 1987
Main classification: G01F23
IPC codes: G01F23