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Optical Sensors for Industrial Applications

A special issue of Sensors (ISSN 1424-8220). This special issue belongs to the section "Optical Sensors".

Deadline for manuscript submissions: 20 May 2025 | Viewed by 4732

Special Issue Editor

Dr. Grzegorz Fusiek

E-Mail Website
Guest Editor
Department of Electronic and Electrical Engineering, University of Strathclyde, Glasgow G1 1XW, UK
Interests: photonic sensors; sensor networks; interrogation techniques; distributed sensing; remote monitoring; photonic instrumentation for industrial applications
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Over the past few decades, optical sensors have been effectively used in various industrial applications in the electrical power, oil and gas, nuclear engineering, and civil engineering sectors, among others. They have proven to be valuable tools in physical, chemical, and biomedical applications, offering several advantages over their traditional equivalents, such as a light weight, a small size, a wide bandwidth, a high accuracy, electromagnetic interference immunity, galvanic isolation, and multiplexibility. Many optical sensing technologies have advanced to meet industry standards, offering a direct replacement for their conventional counterparts, providing passive measurements over long distances and improving measurement quality, thus overcoming the current technological limitations to ensure safety, reliability, and data security. They have been successfully applied in harsh environments where their traditional equivalents are not suitable due to operational constraints.

This Special Issue aims to present the latest research advances in the field of optical sensors, distributed sensing, and sensor networks and their applications across various industry sectors. It will also focus on new sensor designs, fabrication methods, sensing techniques, and system architectures to achieve improved measurement accuracy, resolution, and unique functionalities. Authors are invited to submit both review and original research articles describing recent advances in optical sensors across a broad range of industrial applications.

The topics of interests include but are not limited to the following:

  • Polarimetric, interferometric, and intensity sensors;
  • Fiber Bragg grating sensors;
  • Novel concepts of photonic sensing;
  • Design and development of novel optical sensors;
  • Sensor fabrication and packaging;
  • Sensor interrogation and multiplexing techniques;
  • Sensor networks;
  • Sensor characterization, calibration and performance evaluation;
  • Remote and distributed sensing;
  • Harsh-environment sensing;
  • Optical sensors for industrial applications.

Dr. Grzegorz Fusiek
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Sensors is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • polarimetric, interferometric, and intensity sensors
  • fiber bragg grating sensors
  • novel concepts of photonic sensing
  • design and development of novel optical sensors
  • sensor fabrication and packaging
  • sensor interrogation and multiplexing techniques
  • sensor networks
  • sensor characterization, calibration and performance evaluation
  • remote and distributed sensing
  • harsh-environment sensing

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Published Papers (8 papers)

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Research

10 pages, 2903 KiB  
Communication
Evaluation of Average Quantum Efficiency of Industrial Digital Camera
by Zhuochen Deng, Lingfeng Chen, Xuemeng Wei and Xusheng Zhang
Sensors 2025, 25(3), 899; https://doi.org/10.3390/s25030899 (registering DOI) - 2 Feb 2025
Viewed by 194
Abstract
Quantum efficiency (QE) is a critical metric for assessing the performance of industrial digital cameras. The current EMVA1288 standard relies on monochromatic light for QE measurements. Comprehensive QE tests across the visible spectrum often involve elaborate setups and extensive data acquisition. Additionally, such [...] Read more.
Quantum efficiency (QE) is a critical metric for assessing the performance of industrial digital cameras. The current EMVA1288 standard relies on monochromatic light for QE measurements. Comprehensive QE tests across the visible spectrum often involve elaborate setups and extensive data acquisition. Additionally, such tests may not fully capture camera performance under broadband illumination, which is frequently encountered in industrial applications. This study introduces the concept of average quantum efficiency (AQE) using white light sources and proposes a novel testing method. Systematic experiments and data analyses were performed on two industrial digital cameras under white light sources with different spectral distributions. The results suggest that AQE testing offers a practical and efficient means to evaluate camera performance under broadband illumination, complementing existing monochromatic QE measurement methods. Full article
(This article belongs to the Special Issue Optical Sensors for Industrial Applications)
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17 pages, 2393 KiB  
Article
Partial Discharge Detection from Large Motor Stator Slots Using EFPI Sensors
by Jinlong Wang, Weizhong Sun, Jun Zhou, Lei Wang, Lianfei Chen, Pengcheng Chen, Qichao Chen and Weichao Zhang
Sensors 2025, 25(2), 357; https://doi.org/10.3390/s25020357 - 9 Jan 2025
Viewed by 404
Abstract
This study addresses the challenges of electromagnetic interference and unstable signal transmission encountered by traditional sensors in detecting partial discharge (PD) within stator slots of large motors. A novel Extrinsic Fabry–Perot Interferometer (EFPI) sensor with a vibration-coupling air gap was designed to enhance [...] Read more.
This study addresses the challenges of electromagnetic interference and unstable signal transmission encountered by traditional sensors in detecting partial discharge (PD) within stator slots of large motors. A novel Extrinsic Fabry–Perot Interferometer (EFPI) sensor with a vibration-coupling air gap was designed to enhance the narrowband resonant detection sensitivity for PD ultrasonic signals by optimizing the diaphragm structure and coupling interface. The sensor features a quartz diaphragm with a thickness of 20 μM, an effective constrained radius of 0.9 mm, a vibration-coupling air gap depth of 100 μM, and a first-order natural resonant frequency of 66 kHz. Simulation and experimental analyses revealed the distribution characteristics and propagation paths of ultrasonic signals within stator slots. The results demonstrate that the EFPI sensor effectively detects PD ultrasonic signals at its resonant frequency of 66 kHz with a localization error of less than 5 mm, meeting engineering requirements. This study provides theoretical and practical insights into the efficient detection and precise localization of insulation faults in large motor stators. Full article
(This article belongs to the Special Issue Optical Sensors for Industrial Applications)
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19 pages, 9140 KiB  
Article
Long-Gauge Fiber Optic Sensors: Strain Measurement Comparison for Reinforced Concrete Columns
by Haoran Lin, Zhaowen Xu, Wan Hong, Zhihong Yang, Yixin Wang and Bing Li
Sensors 2025, 25(1), 220; https://doi.org/10.3390/s25010220 - 2 Jan 2025
Viewed by 567
Abstract
Long-gauge fiber optic sensors have proven to be valuable tools for structural health monitoring, especially in reinforced concrete (RC) beam structures. While their application in this area has been well-documented, their use in RC columns remains relatively unexplored. This suggests a promising avenue [...] Read more.
Long-gauge fiber optic sensors have proven to be valuable tools for structural health monitoring, especially in reinforced concrete (RC) beam structures. While their application in this area has been well-documented, their use in RC columns remains relatively unexplored. This suggests a promising avenue for further research and development. This paper presents a thorough comparison of long-gauge fiber optic sensors and traditional measurement tools when used to monitor RC columns under small eccentric compressive loading. The evaluation focuses on the stability and precision of each sensor type. A monitoring system was developed for laboratory testing to assess the performance of various sensor types under specific conditions. The system incorporated four measurement schemes, utilizing a combination of embedded and surface-mounted long-gauge fiber optic sensors, linear variable differential transformers (LVDTs), and point sensors (strain gauges). Long-gauge fiber optic sensors, securely mounted on the concrete surface near the tensile side, were found to accurately measure both large and small deformations, outperforming LVDTs. Compared to strain gauges and embedded optic sensors, the long-gauge fiber optic sensors demonstrated superior average strain measurement and minimal interference from protective covers. Full article
(This article belongs to the Special Issue Optical Sensors for Industrial Applications)
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14 pages, 9635 KiB  
Article
Monitoring a Railway Bridge with Distributed Fiber Optic Sensing Using Specially Installed Fibers
by Kinzo Kishida, Thein Lin Aung and Ruiyuan Lin
Sensors 2025, 25(1), 98; https://doi.org/10.3390/s25010098 - 27 Dec 2024
Viewed by 564
Abstract
This article explores the use of distributed fiber optic sensing (DFOS) technology in monitoring civil infrastructure, with a concrete example of an elevated railway bridge in Taiwan. The field test utilized multiple strain-sensing fibers attached to a 1 km span of a bullet [...] Read more.
This article explores the use of distributed fiber optic sensing (DFOS) technology in monitoring civil infrastructure, with a concrete example of an elevated railway bridge in Taiwan. The field test utilized multiple strain-sensing fibers attached to a 1 km span of a bullet train railway bridge, which were combined to calculate the 3-dimensional bridge deformation. The installed sensing system and continuous measurements enabled quick safety confirmation after earthquakes of Richter scale 6.4 and 6.8 magnitudes occurred. Finally, the dynamic monitoring of a bullet train using Distributed Acoustic Sensing (DAS) demonstrated the merits of fiber optic sensing for both static and dynamic measurements. The empirical data gathered through this work aid in the evaluation of DFOS technology for structural-monitoring applications. Full article
(This article belongs to the Special Issue Optical Sensors for Industrial Applications)
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15 pages, 14666 KiB  
Article
Exploration of Optical Fiber and Laser Cutting Head Applications in High-Radiation Environments for Fast Reactor Spent Fuel Reprocessing
by Qi Chen, Jiarong Zheng, Jia Zhou, Zhengbin Chen, Zengliang Mo, Zhi Cao, Chunwei Tang, Tianchi Li, Fang Liu, Taihong Yan and Weifang Zheng
Sensors 2025, 25(1), 31; https://doi.org/10.3390/s25010031 - 24 Dec 2024
Cited by 1 | Viewed by 455
Abstract
Fast-neutron reactors are an important representative of Generation IV nuclear reactors, and due to the unique structure and material properties of fast reactor fuel, traditional mechanical cutting methods are not applicable. In contrast, laser cutting has emerged as an ideal alternative. However, ensuring [...] Read more.
Fast-neutron reactors are an important representative of Generation IV nuclear reactors, and due to the unique structure and material properties of fast reactor fuel, traditional mechanical cutting methods are not applicable. In contrast, laser cutting has emerged as an ideal alternative. However, ensuring the stability of optical fibers and laser cutting heads under high radiation doses, as well as maintaining cutting quality after irradiation, remains a significant technical challenge. Here, we study the performance changes in optical fibers exposed to a total radiation dose of 105 Gy, focusing on power transmission and thermal characteristics. By integrating irradiated optical fibers with irradiated laser cutting heads, simulated cutting experiments on the hexagonal tubes of spent fuel from fast reactors (fast reactor simulation assembly) were conducted. Critical cutting quality parameters, including kerf width, surface roughness, and slagging length, were analyzed. The results indicate that, while the power transmission performance of irradiated optical fibers shows slight degradation, its impact on cutting quality is minimal. High-quality cutting can still be achieved under optimized parameters. This study confirms the feasibility of laser cutting technology in high-radiation environments and provides essential technical support for its application in nuclear fuel reprocessing. Full article
(This article belongs to the Special Issue Optical Sensors for Industrial Applications)
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23 pages, 4503 KiB  
Article
Design and Evaluation of a Cloud Computing System for Real-Time Measurements in Polarization-Independent Long-Range DAS Based on Coherent Detection
by Abdusomad Nur, Almaz Demise and Yonas Muanenda
Sensors 2024, 24(24), 8194; https://doi.org/10.3390/s24248194 - 22 Dec 2024
Viewed by 446
Abstract
CloudSim is a versatile simulation framework for modeling cloud infrastructure components that supports customizable and extensible application provisioning strategies, allowing for the simulation of cloud services. On the other hand, Distributed Acoustic Sensing (DAS) is a ubiquitous technique used for measuring vibrations over [...] Read more.
CloudSim is a versatile simulation framework for modeling cloud infrastructure components that supports customizable and extensible application provisioning strategies, allowing for the simulation of cloud services. On the other hand, Distributed Acoustic Sensing (DAS) is a ubiquitous technique used for measuring vibrations over an extended region. Data handling in DAS remains an open issue, as many applications need continuous monitoring of a volume of samples whose storage and processing in real time require high-capacity memory and computing resources. We employ the CloudSim tool to design and evaluate a cloud computing scheme for long-range, polarization-independent DAS using coherent detection of Rayleigh backscattering signals and uncover valuable insights on the evolution of the processing times for a diverse range of Virtual Machine (VM) capacities as well as sizes of blocks of processed data. Our analysis demonstrates that the choice of VM significantly impacts computational times in real-time measurements in long-range DAS and that achieving polarization independence introduces minimal processing overheads in the system. Additionally, the increase in the block size of processed samples per cycle results in diminishing increments in overall processing times per batch of new samples added, demonstrating the scalability of cloud computing schemes in long-range DAS and its capability to manage larger datasets efficiently. Full article
(This article belongs to the Special Issue Optical Sensors for Industrial Applications)
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14 pages, 5629 KiB  
Article
FBG and BOTDA Based Monitoring of Mine Pressure Under Remaining Coal Pillars Using Physical Modeling
by Dingding Zhang, Zhi Li, Yanyan Duan, Long Yang and Hongrui Liu
Sensors 2024, 24(21), 7037; https://doi.org/10.3390/s24217037 - 31 Oct 2024
Viewed by 654
Abstract
Strong mine pressure often emerges when the working face of the lower coal seam in a closely spaced coal seam system passes through the remaining coal pillar in the overlying goaf. This study investigates the law of overburden movement and the manifestation of [...] Read more.
Strong mine pressure often emerges when the working face of the lower coal seam in a closely spaced coal seam system passes through the remaining coal pillar in the overlying goaf. This study investigates the law of overburden movement and the manifestation of mine pressure during mining under the remaining coal pillar. A physical model measuring 2.5 × 0.2 × 1.503 m is constructed. Fiber Bragg grating sensing technology (FBG) and Brillouin optical time domain analysis technology (BOTDA) are employed in the physical model experiment to monitor the internal strain of the overlying rock as the working face advances. This study determines the laws of overlying rock fracture and working face pressure while mining coal seams beneath the remaining coal pillar. It analyzes the relationship between the pressure at the working face and the strain characteristics of the horizontally distributed optical fiber. A fiber grating characterization method is established for the stress evolution law of overlying rock while passing the remaining coal pillar. The experimental results indicated that the fracture angle of overlying rock gradually decreases during the mining stage through and after the coal pillar. In the mining stage through the coal pillar, the cycle pressure step distance of the working face is reduced by 33.3% compared to the stage after mining through the coal pillar. Initially, the strain pattern of the horizontal optical fiber is unimodal when pressure is first applied to the working face, and it transitions from unimodal to bimodal during periodic pressure. The peak value of fiber Bragg grating compressive strain and the range of influence of advanced support pressure are 3.6 times and 4.8 times, respectively, before passing through the remaining coal pillar. Finally, the accuracy of the FBG characterization method is verified by comparing it to the monitoring curve of the coal seam floor pressure sensor. The research results contribute to applying fiber optic sensing technology in mining physical model experiments. Full article
(This article belongs to the Special Issue Optical Sensors for Industrial Applications)
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9 pages, 2931 KiB  
Communication
The Method and Experiment of Detecting the Strength of Structural Components Utilizing the Distributed Strain of Sensing Optical Fibers Demodulated by OFDR
by Bin Chen, Jun Yang, Dezhi Zhang, Wenxiang Liu, Jin Li, Min Zhang, Ang Li and Zhao Wang
Sensors 2024, 24(16), 5212; https://doi.org/10.3390/s24165212 - 12 Aug 2024
Viewed by 1055
Abstract
Defects occurring during the welding process of metal structural components directly affect their overall strength, which is crucial to the load-bearing capacity and durability of the components. This signifies the importance of accurate measurement and assessment of weld strength. However, traditional non-destructive testing [...] Read more.
Defects occurring during the welding process of metal structural components directly affect their overall strength, which is crucial to the load-bearing capacity and durability of the components. This signifies the importance of accurate measurement and assessment of weld strength. However, traditional non-destructive testing methods such as ultrasonic and non-contact camera inspection have certain technical limitations. In response to these issues, this paper analyzes the detection principle of weld strength, revealing that weld defects reduce the effective area of the structural bearing section and cause stress concentration around them. Through repeated experimental data analysis of samples, strain distribution data along the one-dimensional direction caused by defects such as slag inclusion and porosity were obtained. Experimental results show that this method can identify defect types in welds, including slag inclusion, porosity, and unevenness, and accurately measure the location and size of defects with a precision of 0.64 mm, achieving qualitative analysis of weld defects. Additionally, by deploying distributed optical fiber sensors (DOFS) at different vertical distances along the weld direction, the propagation law of stress induced by different types of weld defects on samples was thoroughly analyzed. This further validates the advantages of this method in weld strength detection, including high spatial resolution, high sensitivity, and non-destructive measurement. Full article
(This article belongs to the Special Issue Optical Sensors for Industrial Applications)
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