Fused tension-based fiber grating pressure sensor

• US 6,490,931 B1
• Filed: 09/20/1999
• Issued: 12/10/2002
• Est. Priority Date: 12/04/1998
• Status: Expired due to Term

• Current Assignee: Weatherford Technology Holdings, LLC (Weatherford International PLC)
• Original Assignee: Weatherford/Lamb Incorporated (Weatherford International PLC)
• Inventors: Maron, Robert J., Miller, Matthew B., Kersey, Alan D., Fernald, Mark R., Bailey, Timothy J., Putnam, Martin A., Dunphy, James R., Grunbeck, John J., Wright, Christopher J., Daigle, Guy A., Jones, Richard T., Sullivan, James M.
• Primary Examiner(s): OEN, WILLIAM L
• Application Number:
  US09/399,403
• Time in Patent Office: 1,177 Days
• Field of Search: 737/05, 737/08, 737/291, 731/522.2, 731/522.7, 731/525.1, 738/00, 250/231.19, 250/227.14, 250/227.18, 250/227.21, 356/32, 356/34, 356/345, 356/349, 356/350, 356/352
• US Class Current: 73/705
• CPC Class Codes: G01L 1/242 the material being an optical fibre
• CPC Class Codes: G01L 11/025 using a pressure-sensitive optical fibre

Abstract

A fused tension-based fiber grating pressure sensor includes an optical fiber having a Bragg grating impressed therein. The fiber is fused to tubes on opposite sides of the grating and an outer tube is fused to the tubes to form a chamber. The tubes and fiber may be made of glass. Light is incident on the grating and light is reflected from the grating at a reflection wavelength λ₁. The grating is initially placed in tension as the pressure P increases, the tension on the grating reduced and the reflection wavelength shifts accordingly. A temperature grating may be used to measure temperature and allow for a temperature-corrected pressure measurement.

Claims

1. A pressure sensor, comprising:

an optical fiber, having at least one pressure reflective element embedded therein, the pressure reflective element having a pressure reflection wavelength;

sensing means, fused to at least a portion of the fiber on opposite sides of the reflective elements, for holding the fiber on opposite axial sides of the reflective element and for adjusting the strain on the fiber in response to external pressure;

the reflective element having a predetermined amount of tension pre-stain; and

the sensing means being strained due to a change in pressure, the strain causing a change in the pressure reflection wavelength, and the change in the pressure reflection wavelength being indicative of the change in pressure.

2. The pressure sensor of claim 1, wherein the sensing means comprises:

a pair of end tubes being fused to at least a portion of the fiber on opposite sides of the reflective element; and

an outer tube being fused to the end tubes.

3. The pressure sensor of claim 1, wherein the sensing means comprises a tube fused to at least a portion of the fiber on opposite axial sides of the reflective element.

4. The pressure sensor of claim 1, wherein the reflective element is a Bragg grating.

5. The pressure sensor of claim 3, wherein at least a portion of the tube has a cylindrical shape.

6. The apparatus of claim 1 wherein the sensing means is made of a glass material.

7. The apparatus of claim 1 wherein the sensing means has at least one axially extended region.

8. The apparatus of claim 1 wherein the sensing means has at least one outer tapered axial end.

9. The apparatus of claim 1 wherein the sensing means has at least one inner tapered axial end.

10. The apparatus of claim 1, wherein the sensing means comprises a plurality of optical fibers encased in the tube.

11. The apparatus of claim 1, wherein the fiber has a plurality of reflective elements embedded therein.

12. The apparatus of claim 1, wherein the fiber has at least one pair of reflective elements and the fiber is doped with a rare-earth dopant at least between the pair of elements to form a fiber laser.

13. The apparatus of claim 12, wherein the fiber laser lases at lasing wavelength which changes as pressure changes.

14. The apparatus of claim 1, wherein at least a portion of the fiber is doped with a rare-earth dopant where the reflective element is located and the reflective element is configured to form a DFB fiber laser.

15. The apparatus of claim 14, wherein the DFB fiber laser lases at a lasing wavelength which changes as force on the tube changes.

16. The apparatus of claim 1, wherein the fiber has a temperature reflective element embedded therein disposed in thermal proximity to the pressure reflective element which has a temperature reflection wavelength that changes with temperature.

17. The apparatus of claim 16, wherein the temperature reflective element is encased in the tube.

18. The apparatus of claim 16, wherein the temperature reflection wavelength does not change in response to a change in the pressure wavelength due to a change in the pressure.

19. The apparatus of claim 16, wherein the temperature reflection wavelength changes in response to a change in the pressure wavelength due to a change in the pressure at a different rate than the pressure wavelength changes due to a same change in pressure.

20. The apparatus of claim 1, further comprising an outer housing, which contains the sensing means, the sensing means being suspended in the housing by suspension means.

21. The apparatus of claim 18, wherein the suspension means comprises a fluid.

22. The apparatus of claim 18, wherein the suspension means comprises spacers in a fluid.

23. A pressure sensor, comprising:

an optical fiber with at least one reflective element therein; and

a sensing element fused to at least a portion of the fiber on opposite sides of the reflective element.

24. The sensor of claim 23, wherein the fiber and the sensing element are made of a glass material.

25. The sensor of claim 23, wherein the sensing element comprises a tube.

26. The sensor of claim 23, wherein the sensing element comprises a pair of end tubes and an outer tube.

27. A method of making a pressure sensor comprising the steps of:

obtaining an optical fiber with at least one reflective element therein; and

fusing a sensing element to at least a portion of the fiber on opposite sides of the reflective element.

28. The method of claim 27, wherein the fiber and the sensing element are made of a glass material.

29. The method of claim 27, wherein the sensing element comprises a tube.

30. The method of claim 27, wherein the sensing element comprises a pair of end tubes and an outer tube.

31. A pressure sensor, comprising:

an optical waveguide comprising a pressure-sensitive reflective element; and

a first housing fused to a cladding of the optical waveguide at first and second axial locations to form a cavity around the pressure-sensitive reflective element,

wherein the optical waveguide is pre-tensioned within the cavity.

32. The sensor of claim 31, wherein the housing is cylindrical.

33. The sensor of claim 31, wherein the housing comprises a single tube.

34. The sensor of claim 31, wherein the housing comprises a first tube fused to the optical waveguide at the first axial location, a second tube fused to the optical waveguide at the second axial location.

35. The sensor of claim 34, wherein the housing further comprises a third tube affixed to the first and second tubes.

36. The sensor of claim 35, wherein the third tube is affixed to the outside surfaces of the first and second tubes.

37. The sensor of claim 35, wherein the third tube is fused to the first and second tubes.

38. The sensor of claim 31, wherein the housing is comprised of quartz.

39. The sensor of claim 31, wherein the reflective element comprises a Bragg grating.

40. The sensor of claim 31, wherein the support constitutes a unitary member.

41. The sensor of claim 31, further comprising a temperature-sensitive reflective element in the optical waveguide.

42. The sensor of claim 41, wherein the temperature-sensitive reflective element comprises a Bragg grating.

43. The sensor of claim 41, wherein the temperature-sensitive reflective element is not located proximate to the cavity.

44. The sensor of claim 41, wherein the temperature-sensitive reflective element is located proximate to the first or second axial locations.

45. The sensor of claim 31, wherein the cavity is hermetic.

46. The sensor of claim 31, further comprising a port coupling the cavity to an external environment.

47. The sensor of claim 31, wherein the cavity contains a fluid.

48. The sensor of claim 31, further comprising an additional optical waveguide.

49. The sensor of claim 31, wherein the optical waveguide comprises a plurality of reflective elements.

50. The sensor of claim 31, wherein the optical waveguide comprises at least one pair of reflective elements and is doped at least between the pair of elements to form a laser.

51. The sensor of claim 50, wherein the laser lases at a lasing wavelength which changes in response to pressure changes presented to the pressure-sensitive reflective element.

52. The sensor of claim 31, wherein at least a portion of the optical waveguide is doped and wherein the reflective element is configured to form a DFB fiber laser.

53. The sensor of claim 52, wherein the DFB fiber laser lases at lasing wavelength which changes in response to pressure changes presented to the pressure-sensitive reflective element.

54. The sensor of claim 31, further comprising a second housing which suspends the first housing through a suspension means.

55. The sensor of claim 54, wherein the suspension means comprises a fluid.

56. The sensor of claim 54, wherein the suspension means comprises spacers placed between the first and second housings.

57. A method for manufacturing a pressure sensor, comprising, in no particular order:

providing an optical waveguide comprising a pressure-sensitive reflective element; and

fusing a first housing to a cladding of the optical waveguide at first and second axial locations to form a cavity around the pressure sensor; and

pre-tensioning the optical waveguide within the cavity.

58. The method of claim 57, wherein the housing is cylindrical.

59. The method of claim 57, wherein the housing comprises a single tube.

60. The method of claim 57, wherein the housing comprises a first tube fused to the optical waveguide at the first axial location, a second tube fused to the optical waveguide at the second axial location.

61. The method of claim 60, wherein the housing further comprises a third tube affixed to the first and second tubes.

62. The method of claim 61, wherein the third tube is affixed to the outside surfaces of the first and second tubes.

63. The method of claim 61, wherein the third tube is fused to the first and second tubes.

64. The method of claim 57, wherein the housing is comprised of quartz.

65. The method of claim 57, wherein the reflective element comprises a Bragg grating.

66. The method of claim 57, wherein the support constitutes a unitary member.

67. The method of claim 57, further comprising a temperature-sensitive reflective element in the optical waveguide.

68. The method of claim 67, wherein the temperature-sensitive reflective element comprises a Bragg grating.

69. The method of claim 67, wherein the temperature-sensitive reflective element is not located proximate to the cavity.

70. The method of claim 67, wherein the temperature-sensitive reflective element is located proximate to the first or second axial locations.

71. The method of claim 57, wherein the cavity is hermetic.

72. The method of claim 57, further comprising coupling the cavity to an external environment.

73. The method of claim 57, further comprising placing a fluid within the cavity.

74. The method of claim 57, further comprising an additional optical waveguide.

75. The method of claim 57, wherein the optical waveguide comprises a plurality of reflective elements.

76. The method of claim 57, wherein the optical waveguide comprises at least one pair of reflective elements and is doped at least between the pair of elements to form a laser.

77. The method of claim 76, wherein the laser lases at a lasing wavelength which changes in response to pressure changes presented to the pressure-sensitive reflective element.

78. The method of claim 57, wherein at least a portion of the optical waveguide is doped and wherein the reflective element is configured to form a DFB fiber laser.

79. The method of claim 78, wherein the DFB fiber laser lases at a lasing wavelength which changes in response to pressure changes presented to the pressure-sensitive reflective element.

80. The method of claim 57, further comprising a second housing for suspending the first housing through a suspension means.

81. The method of claim 80, wherein the suspension means comprises a fluid.

82. The method of claim 80, wherein the suspension means comprises spacers placed between the first and second housings.

83. The method of claim 57, wherein pre-tensioning comprises heating the housing after it is fused to the cladding of the optical waveguide.

84. The method of claim 83, wherein pre-tensioning further comprises pulling the optical waveguide during the heating of the housing.

85. The method of claim 57, wherein pre-tensioning occurs before fusing the housing to the cladding of the optical waveguide.

86. The method of claim 85, wherein pre-tensioning further comprises pulling the optical waveguide as the housing is fused to the cladding of the optical waveguide.