Fiber Optic Sensors

Authored by Nazario Biala

Photoelectric Sensors Product Marketing Manager, Omron Electronics LLC
nazario.biala@omron.com

More and more users today are turning to fiber optic sensors to address sensing
applications that have minimal space, adverse environment or electromagnetic
interference and radio frequency interference problems. Why? The answer to this
question lies in knowing what a fiber optic sensor is.

What is a Fiber Optic Sensor?

A fiber optic sensor system consists of a fiber optic cable and a remote sensor
(see Figure A), where the fiber optic cable is connected to the remote sensor.
The remote sensor emits, receives and converts the light energy into an electrical
signal. The fiber optic cable, on the other hand, is the mechanical component
that transports light energy into and out of areas that are either too space
constrained or too hostile back to the remote
sensor (amplifier).
Figure A

Fiber optic cable is comprised of a plastic or glass core, which is surrounded by a

layer of cladding material (see Figure B). These two components have different
densities; the difference in densities serves a special purpose in enabling fiber
optic cables to meet the principle of total internal reflection, which will later be
discussed.

Figure B

Cladding

Core

Glass Fiber Optics

Fiber optics is made of either glass or plastic. Glass optical fibers consists of a
bundle of very thin glass strands that typically each measure 0.051 mm (0.002
inch) diameter. A flexible stainless steel armored sheath typically protects the
bundle of cladded fibers, but polyvinyl chloride jacket (PVC) are also sometimes
used.
Glass, by nature, is very resilient. It is this trait that enables it to perform reliably
in extreme conditions (high temperatures, corrosive environment, etc.). Glass
fiber bundle can withstand operating temperatures as high as 450F as standard
product. Customers with applications that have operating temperatures that
exceed 450F, can also special order cables that can withstand operating
temperatures as high as 1200F.
With reasonable radius corners, glass fibers have the ability to withstand
indefinite cyclic bending. Given this premise, one would think that glass fibers
have the ability to withstand sharp bending, stretching, extreme vibration, pulling,
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etc. This, however, is not the case. As a matter of fact, users who use glass
fibers in applications that require repeated flexing or sharp bending tend to
experience breakage. The reason for this is the fact that individual glass fibers
can easily receive excessive stress and fracture. Breakage of a few strands of
glass fibers in a bundle is generally not noticeable. As more and more fiber
strands break, however, the signal strength loss will increase proportionately.
In order to achieve a high degree of light coupling efficiency, fiber manufacturers
optically polish the sensing surface of the sensing face; the polishing process
ensures that the end of each fiber is perfectly flat. Since glass fibers require
polishing to ensure high degree of light coupling efficiency, it is recommended
that customers not cut the fiber.
Non-standard cable lengths need to be special-ordered.

Plastic Fibers
Whereas glass fiber optic cable is made of multiple glass fiber bundles, plastic
fiber optic cable is usually a single strand (typically .254 mm to 1.52 mm in
diameter). Unlike glass fibers, plastic fibers are flexible, and are excellent
solution for applications that require repeated flexing. Its flexibility enables it to be
used in extremely tight areas. In recent years, companies such as Omron,
among others, have released plastic fibers that they call multi-core high-flex
plastic fiber. Unlike conventional plastic fibers, which use a single core of
material, multi-core fibers use multiple independent cores. This configuration
allows a bending radius as small as 1mm, and as result gives it a flexibility similar
to electric wire. These Omron fibers can be bent at 90 with no reduction of light
transmission. The 1 mm bending radius enables these fibers to conform to
machine contours without experiencing any problems normally associated with
extreme vibrations or pulling. Various vendors also offer coiled versions of plastic
fibers for applications that require articulated or reciprocating motions.
Applications that are exposed to chemicals or solvents, and have high operating
temperatures are generally more conducive for glass fibers. Plastic fibers are
less tolerant to these types of conditions. There are instances, however, where
sheathing materials such as Teflon, nylon, and polypropylene are used to shield
plastic fibers; these sheathing materials enable plastic fibers to withstand these
extreme conditions.
The level of attenuation of light energy as it travels through fiber optics is
influenced by three factors. These factors are the fiber material, the distance
traveled in the fiber, and the wavelength of the light. The performance of glass
fibers is fairly consistent at all wavelengths. However, in the case of plastic fibers,
the attenuation of infrared light emitting diodes (LEDs) is greater than the
attenuation of visible LEDs, such as red. Plastic fibers tend to absorb infrared
LEDs. As a result, red LEDs are generally used to ensure effective sensing.

When ordered, plastic fibers typically come with a cutting device. The cutting
device enables customers to cut fibers to their desired length.

Principle of Total Internal Reflection

The complete transmission of light through fiber optics is based on the principle
of total internal reflection; a principle that states that all of the incident light that
hits a boundary between two medium will be totally reflected. That is, no light
energy will ever be lost across the boundary. The principle of total internal
reflection only occurs when both of the two following conditions are met:

The critical angle is less than the angle of incidence for the particular
combination of materials (see Figure C). The materials in this case are
the core and the clad of the optical fiber; the materials that make up an
optical fiber.

Figure C

Cladding
Critical Angle

Core

The light is in the denser medium and approaching the less dense
medium. The cladding material is less dense than the core material,
and as a result has a lower index of refraction.

As long as the two conditions are met, the principle of total internal reflection
applies whether the fiber optic cable is bent or straight (within a defined minimum
bend radius).

Sensing Modes and Fiber Optic Assemblies

Because a fiber optic sensor system is a derivative of the photoelectric sensing
technology, the sensing modes (diffuse reflective, through beam, retro-reflective)
that are available for the photoelectric sensing technology are also available for
the fiber optic sensor system. Two types of fiber optic assemblies are available
to address these sensing modes. They are individual and bifurcated.
Through beam sensing in fiber optic sensor system (see Figure A) requires two
individual fiber optic cables. One cable is attached to the emitter of the remote
sensor, and is used to guide light energy to a sensing location. The other cable is
attached to the receiver of the remote sensor, and is used to guide light energy
from the sensing location back to the remote sensor. As with standard through
beam photoelectric sensing, the emitter and the detector fiber optic cables are
positioned opposite one another. Sensing is achieved when the light beam that
extends from the emitter to the receiver fiber optic cable is interrupted.
A bifurcated fiber optic assembly is used for diffuse reflective as well as retroreflective sensing. A bifurcated cable assembly differs from an individual cable
assembly in that it combines the emitter and the receiver cable assemblies into
one cable assembly. In the bifurcated cable assembly, the emitter and the
receiver fiber optic cable strands are arranged side-by-side along the length of
the cable (see Figure D). The receiver and the emitter fiber strands are randomly
mixed at the sense point. This configuration is ideal for applications that require
compact sensing tip. Sensing is achieved when an object is present in front of
the sensing tip of the bifurcated fiber topic cable. The light from the emitter cable
reflects off the object and back to the receiver of the remote sensor through the
receiver fiber optic cable.

Figure D

Emitter

Sensing Head
Receiver

Bifurcated Fiber Assembly

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Benefits of Fiber Optics

As discussed previously, fiber optic also known as optical fiber is a flexible, thin,
long cylindrical transparent strand of cable. Fiber optics is essentially a passive,
mechanical component of the fiber optic sensing system. That is, it does not
contain any moving parts or electrical circuitry. Consequently, fiber optics is
completely immune to all forms of electrical interference. This characteristic
makes it a perfect solution to isolating the electronics of a sensing system, in this
case the remote sensor that it connects to, from known sources of electrical
interference.
The fact that an optical fiber does not contain any moving parts, electrical circuit,
and only carries light means that there is no possibility of a spark. This means
that it can be safely used even in the most hazardous sensing environments
such as a refinery for producing gases, grain bins, mining, pharmaceutical,
chemical processing, etc. It also means that there is no danger of electrical shock
to personnel repairing broken fibers.
Another advantage of using optical fibers is the luxury it affords users to route
them through extremely tight areas to the sensing location. Certain fiber optics,
particularly the glass fibers, has very high operating temperatures (450F and
higher).

Latest Developments
As industrial automation applications continue to get more complex, and as real
estate becomes more of an issue, the need to develop a more sophisticated
sensing device in a smaller package continues to increase. Companies such as
Omron, Keyence, Banner, SUNX, to name a few, have started addressing this
need by introducing new waves of fiber optic sensors.
These companies now offer fiber optic amplifiers (remote sensors) that have
easy-to-read digital LED. The numerical values and percentages that are
displayed enable customers to monitor and precisely set up their sensing
application. The digital display provides users real time feedback, which allows
users to know the slightest misalignment or when dust accumulation on the fiber
optic cable tip is beginning to degrade sensor performance.
Some of these new fiber optic sensors have also significantly reduced sensor
wiring. Models that allow 16 sensors to be connected together are now available.
Only one power line is required for all 16 sensors. How? A master connector
(from the master sensor) distributes power to the slave sensors, thereby
eliminating the power lines that each slave sensor would normally require (see
Figure E). Only output wiring is needed for the slave fiber optic sensors. In
addition to reducing wiring, some of these connector designs have also simplified
installation and maintenance. Some have unique connector design that allows

users to easily detach the sensor without disturbing the fiber cable installation or
output wiring.
Figure E

Fiber optic sensors with dual outputs are now also available. This configuration
offers the performance of two sensors in one package. Certain models offer
either two independent digital outputs or a combination of analog and digital
output. Other models now also offer lockout feature; a feature that prevents
unwanted adjustments or tampering of the sensors settings. This feature allows
the customers to give their employees on the shop floor a level of autonomy
without compromising their performance goals.
Most of these sensors now incorporate either a 12-bit or 16-bit CPU as well as
12-bit AD converter, which enable these new sensors to have higher resolution
and faster response time. Some of these sensors have a response time as fast
as 20 microseconds.
Customers can also appreciate the various built-in auto-teach functions that
enable quick sensor setup. Most of the available models now offer as many as
four different self-teaching functions. This enables customers to select the
method that best meets each sensor application.
Certain models also allow customers to perform remote settings. This is
especially important in potentially hazardous environments. A fiber optic sensor
that has a remote control programmer (see Figure F) that comes with a standard
5-foot cable (16 foot cable is also available) is now available. With this remote
control programmer, customers with sensors in potentially hazardous
environments can now monitor and program them from a safe distance. The
remote programmer has a digital display that shows the incident and the
threshold levels simultaneously so that customers can fine-tune the threshold
point while monitoring the incident level. The programmer also saves customers
sensor setup time. With the remote control programmer, customers can quickly
copy the configuration settings from one sensor and pasting them to as many
additional sensors as necessary. The programmer also gives users the ability to
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copy the settings for an entire group of sensors and paste the settings to a new
group of sensors on another machine. This is a real time saver for OEMs and
users with many similar machines.
With all the flexibility and benefits that the fiber optic sensor system provides
users, it is no wonder that it is becoming more widely used. As industrial
automation applications continue to become more sophisticated, expect sensor
experts to continue developing innovative fiber optic sensors.
Figure F

A publication of Omron Electronics, LLC

2002 All Rights Reserved