This work was supported by the UK Engineering and Physical Sciences Research Council (EPSRC) HOME-Offshore: Holistic Operation and Maintenance for Energy from Offshore Wind Farms Consortium under grant EP/P009743/1.

1. Fiber optic thermal sensor design
<ol>
	<li>First identify the sensor design and specifications based on the target coil structure and the interrogation system features. The test coil used in this work has an oval geometry typical of electric machine coils (as illustrated in Figure 1A. Before individual sensing locations are determined, make design decisions to ensure that the optical sensing fiber remains operative in the mechanical and thermal environment typical of embedded wound coil application.</li>
	<li>Use a standard bend-insensitive polyimide-coated single mode fiber that is generally known to be able to operate in temperatures up to approximately 300 &#176;C; this fiber is thus suitable for application in wound coils used in conventional electric machines. 
	NOTE: The chosen optical fiber ensures sensor functionality in the thermal environment of a typical random wound coil operating in electric machines such as used in this work (class F and H with rated temperature of 155 and 180 &#176;C10, respectively. Bend-insensitive fiber is preferred for this application since it is designed to allow a small bending radius and to have a lower bending loss. This enables the sensor to be effectively conformed to the desired coil structure and sensing location(s) with minimal detrimental effect to sensing functionality.</li>
	<li>Set fiber length to 1.5 m. 
	NOTE: Fiber length is set according to the geometry of the target wound coil to be instrumented and the desired distance to the interrogation unit. The test coil circumferential length (shown in Figure 1A) is 0.3 meters and the chosen fiber length to interrogator from coil is 1.2 meters giving a total length of 1.5 m &#8211; this allows for sufficient fiber length to be looped within the test coil to ensure desired sensing locations are appropriately established and there is suitable distance between the test coil and the interrogator: Figure 3A illustrates the general length design approach. 
	NOTE: FBGSs can be located several kilometers from the interrogation unit. This is because an optic fiber is an efficient single carrier.</li>
	<li>Design the FBG array to consist of four FBG heads (5 mm) to enable distributed sensing within the coil structure so that two sensing locations are positioned in the coil sides and two are in the coil ends. 
	NOTE: Thermal sensing locations are identified based on relevant thermal monitoring standards for electric machines (i.e., 2 FBGS for slot sections and 2 for end-winding sections)10. The commercial interrogator design used in this work can enable simultaneous interrogation of up to 16 FBG sensing points down a single optical fiber.</li>
	<li>Use an FBG sensing head length of 5 mm; this is deemed sufficient to enable localized hot spot monitoring in current carrying random wound coils. 
	NOTE: Alternative commercial values of FBG head length (3 mm, 5 mm or 10 mm) can also be used in case a different sensing point dimension is required by the sensing application.</li>
	<li>Specify individual FBG heads to be grated with different wavelengths spaced in a bandwidth of 1529&#8211;60 nm to match the used commercial interrogator rating; this ensures prevention of FBG shifted wavelengths interference. 
	NOTE: The FBG heads wavelength, their expected wavelength shift bandwidth, and the application temperature variation need to be within the interrogation unit broadband light bandwidth to ensure that the sensing system can properly operate.</li>
	<li>Use an FC/APC fiber probe connector type, which is consistent with the interrogator unit. 
	NOTE: FC/APC is generally the preferred choice for FBG sensing due to low return losses.</li>
	<li>Provide the design and specifications of the sensor to a commercial FBG manufacturer - Figure 3B shows a final sketch of the FBG array design used in this work.</li>
</ol>
2. Interrogation system and sensor configuration
<ol>
	<li>Check and configure the designed and manufactured FBG array sensor to operate with the commercial interrogation system.</li>
	<li>Remove the protective cap from the FC/APC connector ferrule.</li>
	<li>Clean the connector end-face by wiping it gently with an optical connector cleaner. 
	NOTE: It is highly recommended to perform this step each time the sensor is connected to the interrogator. A Cletop-s commercial series optical cleaner was used in this work.</li>
	<li>Plug-in the cleaned FBG probe connector to the interrogator channel connector. 
	NOTE: Ensure that the keyway is correctly aligned when mating the connectors.</li>
	<li>Turn on the interrogator. 
	NOTE: The interrogator is connected to the PC via an RJ45 connector and internet cable.</li>
	<li>Run the configuration software. 
	NOTE: The interrogator software is a proprietary LabVIEW based software package provided by the interrogator manufacturer designed to enable the interrogator hardware unit operation.</li>
	<li>On the instrument set-up tab observe the reflected wavelength spectrums from the FBG array probe (for the FBG array design used in this work four peaks should be observed in the related channel spectrum). 
	NOTE: The reflected light intensity depends on FBG characteristics (above 50% is accepted).</li>
	<li>Set the sampling frequency to 10 Hz. This directly determines the number of temperature readings provided in a given 1 s period. 
	NOTE: The used interrogation system can operate at sampling frequencies up to 2.5 kHz; however, for thermal dynamics of current carrying coils monitored in this work 10 Hz is deemed a sufficient acquisition rate.</li>
	<li>In the measurements setting, name the FBG heads as FBG1, FBG2, FBG3 and FBG4. Choose wavelength as type of quantity to be presented graphically at this stage. The FBG array is configured and ready for the calibration step.</li>
</ol>
3. Packaging preparation
<ol>
	<li>Appropriately package the areas where FBG heads are imprinted (i.e., grated) in the array fiber to ensure sensing head isolation from mechanical excitation and thus yield exclusively thermal excitation responsive sensor. In addition, the fiber structure is fragile and it is not desirable to directly embedded it within the coil conductors: it requires adequate mechanical protection to retain integrity. In this work, the sensing area containing the four FBG heads that is embedded within the coil structure is packaged with polyetheretherketone (PEEK) and the remainder of the fiber is protected by Teflon &#8211; this is illustrated in Figure 3C.</li>
	<li>Design the packaging in the form of a narrow round capillary tube so the sensing fiber can be routed through and thus protected by the capillary. 
	NOTE: The capillary dimensions and thermal properties are particularly important where packaging of the area containing FBG sensing heads is concerned. It is generally desirable to ensure a relatively narrow wall thickness and use material that is not electrically conductive but provides a reasonable degree of thermal conductivity. The outer diameter of the PEEK capillary used in this work was 0.8 mm and its wall thickness is 0.1 mm.</li>
	<li>Prepare the PEEK capillary by cutting the adequate length of commercial PEEK tubing (length of the target coil structure with a few extra centimeters to allow for fiber insertion and Teflon to PEEK capillary joint preparation). 
	NOTE: The in situ instrumentation of the FBG array requires installation of the packaging first which is then inserted with the sensing fiber. Care must be taken to ensure smooth and cleaned capillary end openings.</li>
	<li>Take careful measurements of the FBG array and the PEEK capillary to accurately identify sensing locations on the outer surface of the PEEK capillary. This enables positioning of FBG sensing heads in target locations within the motorette test coil.</li>
	<li>Prepare the Teflon capillary by cutting an adequate length of commercial Teflon tubing to ensure that the fiber section outside the test coil geometry is protected and contained. 
	NOTE: The external packaging material of the non-sensing array section needs to have sufficient rigidity to provide adequate mechanical protection but also be flexible to allow for a practical connection to the interrogator; it is also desirable for this material to be EMI immune in this application. Teflon is found to provide satisfactory performance in this study however alternative materials can be applied.</li>
	<li>Prepare the appropriate shrink tube length to make the joint between the PEEK and the Teflon capillaries.</li>
</ol>
4. Free thermal calibration
<ol>
	<li>Calibrate the packaged FBG array sensor by inserting it into the thermal chamber to extract its discrete temperature versus wavelength points. 
	NOTE: Preferably the sensing area is shaped to match that of the target coil structure to provide calibration under strain levels similar to those when the package is embedded within the test coil.</li>
	<li>Connect the grated optical fiber to the interrogator and launch the pre-configured interrogator software routine.</li>
	<li>Set the thermal chamber oven to operate in a sequence of thermal steady state points &#8211; these are in a range of ambient to 170 &#176;C and in steps of every 10 degrees in this work. Create a table from the measured reflected wavelengths of each individual FBG in the array for every constant temperature emulated in the chamber. 
	NOTE: Sufficient time has to be allowed during calibration tests for thermal equilibrium to be reached at every examined steady state thermal point.</li>
	<li>Use the recorded shifted wavelength versus temperature measurements in 10 &#176;C steps to determine the optimal temperature-wavelength shift fit curves and their coefficients for each FBG. Figure 4 and Table 1 show the recorded calibration data measurements and the calculated fit curve, respectively. 
	NOTE: The relationship between the wavelength shift and the temperature variation of the FBG heads in the array is analyzed by polynomial quadratic regression in this work as this was found to deliver optimal characterization. From this analysis the polynomial quadratic regression fit curve coefficients are calculated11.</li>
	<li>Input the calculated coefficients in the relevant setting of the interrogator software to enable on-line temperature measurements from the FBG array.</li>
</ol>
5. Test coil build and FBG instrumentation
<ol>
	<li>First build and instrument the motorette random wound coil.
	<ol>
		<li>Design a winding bobbin to fit onto the winder device. 
		NOTE: The bobbin geometry is designed to match the desired turn geometry of the coil and ensure that the desired wound coil dimensions. The bobbin is designed to be easily dismantled so to facilitate straightforward removal of the wound coil without damaging its insulation.</li>
		<li>Place the selected enameled copper wire reel in the winder device and pull the copper wire through the winder rollers and the tension controller. 
		NOTE: Class F enameled copper wire is used in this work.</li>
		<li>Set the winder device turn number counter to zero.</li>
		<li>Set the winder to operate at low speed and control the desired wire tension.</li>
		<li>Wind half of the coil turns.</li>
		<li>Fit the prepared PEEK capillary in the center of the coil using Kapton tape. 
		NOTE: Care must be taken to ensure that the indexes on the PEEK capillary are positioned in the target places.</li>
		<li>Wind the rest of the coil turns.</li>
		<li>Remove the bobbin from the winder machine and disassemble to free the wound coil embedded with a PEEK capillary.</li>
		<li>Place the coil in the motorette frame. 
		NOTE: The motorette coil insulation system (slot insulation and slot wedges) must be appropriately installed with the coil.</li>
		<li>Prepare coil terminals and connect them to motorette terminals.</li>
		<li>Varnish the motorette using a winding varnish and place in an oven at appropriate temperature (150 &#176;C) to cure.</li>
	</ol>
	</li>
	<li>FBG array instrumentation:
	<ol>
		<li>First connect the FBG array to the interrogator; launch the interrogator software to monitor the FBG reflected wavelength while installing.</li>
		<li>Pull the fiber through the prepared shrinking tube.</li>
		<li>Carefully insert the fiber (sensing area) into the PEEK capillary until the end openings of Teflon and PEEK capillaries are in contact.</li>
		<li>Move the shrink tube to cover the capillaries ends and appropriately heat it until the desired fit is achieved.</li>
	</ol>
	</li>
</ol>
6. In situ calibration and evaluation
<ol>
	<li>Validate the obtained thermal calibration in step 4 after embedment and correct if required. The test also enables evaluating the FBG array performance in controlled static thermal condition.</li>
	<li>Place the motorette embedded with the FBG thermal array in the thermal oven. 
	NOTE: Conventional thermal sensor can be used for performance comparison purposes. Here thermocouples installed on the motorette coil surface are used.</li>
	<li>Repeat steps 4.3 and 4.4.</li>
	<li>Repeat step 4.5 including the temperature measured by FBG heads based on calibrated fit in step 4.</li>
	<li>Evaluate and compare the FBG array temperature measurements with the reference temperature. If measurement error is high, the recorded measurement in step 6.4 can be used to update the calibration.</li>
	<li>Take the motorette out of the thermal oven; it is ready for testing.</li>
</ol>
7. Testing
<ol>
	<li>Perform a static thermal condition test.
	<ol>
		<li>Connect the motorette to the DC power supply.</li>
		<li>Connect the FBG array to the interrogator; monitor and record its FBG temperature measurements.</li>
		<li>Control the DC power supply to inject the motorette with a DC current. 
		NOTE: The chosen DC current level must ensure that the T-rise in coil internal thermal hotspots is less than the permissible insulation temperature; this allows for non-destructive testing on the prototype coil.</li>
		<li>Stop recording measurements when the motorette coil thermal equilibrium is reached.</li>
	</ol>
	</li>
	<li>Perform a non-uniform thermal condition test.
	<ol>
		<li>Wind the external coil containing 20 turns around a selected test coil section.</li>
		<li>Connect the external coil to a separate DC power supply.</li>
		<li>Energize the motorette with the DC current applied in 7.1.3.</li>
		<li>Start recording thermal measurements once the thermal equilibrium is reached.</li>
		<li>Energize the external coil with a DC current to provide non-uniform thermal conditions by delivering localized thermal excitation on the test coil.</li>
		<li>Stop recording measurements once thermal equilibrium is reached.</li>
	</ol>
	</li>
</ol>

<ol>
	<li>Stone, G. C., Boulter, E. A., Culbert, I., Dhirani, H. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Electrical+insulation+for+rotating+machines-design,+evaluation,+aging,+testing,+and+repair-Book+Review.">Electrical insulation for rotating machines-design, evaluation, aging, testing, and repair-Book Review.</a> IEEE Electrical Insulation Magazine. 20 (3), 65-65 (2004).</li><li>Mohammed, A., Djurovi&#263;, S. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Stator+Winding+Internal+Thermal+Monitoring+and+Analysis+Using+In+Situ+FBG+Sensing+Technology.">Stator Winding Internal Thermal Monitoring and Analysis Using In Situ FBG Sensing Technology.</a> IEEE Transactions on Energy Conversion. 33 (3), 1508-1518 (2018).</li><li>Zhang, H. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Online+thermal+monitoring+models+for+induction+machines.">Online thermal monitoring models for induction machines.</a> IEEE Transactions on Energy Conversion. 30 (4), 1279-1287 (2015).</li><li>Mohammed, A., Djurovi&#263;, S. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=FBG+array+sensor+use+for+distributed+internal+thermal+monitoring+in+low+voltage+random+wound+coils.">FBG array sensor use for distributed internal thermal monitoring in low voltage random wound coils.</a> 2017 6th Mediterranean Conference on Embedded Computing (MECO). , 1-4 (2017).</li><li>Rao, Y. J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=In-fibre+Bragg+grating+sensors.">In-fibre Bragg grating sensors.</a> Measurement Science and Technology. 8 (4), 355 (1997).</li><li>Mohammed, A., Djurovi&#263;, S. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=A+study+of+distributed+embedded+thermal+monitoring+in+electric+coils+based+on+FBG+sensor+multiplexing.">A study of distributed embedded thermal monitoring in electric coils based on FBG sensor multiplexing.</a> Microprocessors and Microsystems. 62, 102-109 (2018).</li><li>Lu, P., Men, L., Chen, Q. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Resolving+cross+sensitivity+of+fiber+Bragg+gratings+with+different+polymeric+coatings.">Resolving cross sensitivity of fiber Bragg gratings with different polymeric coatings.</a> Applied Physics Letters. 92 (17), 171112 (2008).</li><li>Mohammed, A., Djurovi&#263;, S. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=FBG+Thermal+Sensing+Features+for+Hot+Spot+Monitoring+in+Random+Wound+Electric+Machine+Coils.">FBG Thermal Sensing Features for Hot Spot Monitoring in Random Wound Electric Machine Coils.</a> IEEE Sensors Journal. 17 (10), 3058-3067 (2017).</li><li>IEEE. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=IEEE+standard+test+procedure+for+thermal+evaluation+of+systems+of+insulating+materials+for+random-wound+AC+electric+machinery.">IEEE standard test procedure for thermal evaluation of systems of insulating materials for random-wound AC electric machinery.</a> IEEE Std 117-2015. , 1-34 (2016).</li><li>IEC. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Rotating+electrical+machines+-+Part+1:+Rating+and+performance.">Rotating electrical machines - Part 1: Rating and performance.</a> IEC. , (2010).</li><li>Mohammed, A., Djurovi&#263;, S., Smith, A. C., Tshiloz, K. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=FBG+sensing+for+hot+spot+thermal+monitoring+in+electric+machinery+random+wound+components.">FBG sensing for hot spot thermal monitoring in electric machinery random wound components.</a> 2016 XXII International Conference on Electrical Machines (ICEM). , 2266-2272 (2016).</li></ol>

The authors have nothing to disclose.

The paper has demonstrated the procedure required to design, calibrate and test in situ FBG thermal sensors in low voltage wound coils. These sensors offer a number of advantages for in situ sensing applications within current carrying wound coil structures: they are fully EMI immune, are flexible and can conform to an arbitrary desired geometry to deliver arbitrary desired sensing point locations with high accuracy, and can provide a large number of sensing points on a single sensor. While thermal sensing within wound coils can be achieved with conventional thermal monitoring techniques employing thermocouple or resistance temperature detectors, the application of FBGs is shown to provide a number of attractive functional advantages.
Appropriate packaging of the FBG array sensor is key to its effective utilization. It is important that individual sensing heads or the entire sensing area of the fiber be appropriately packaged to ensure isolation of FBG heads from mechanical excitation in a rigid yet flexible thermally conductive capillary. It is desirable for the capillary to be designed of non-electrically conductive material as this ensures optimal performance in the EMI rich environment characteristic of current carrying coils.
Care needs to be taken during the process of packaging capillary installation into the coil to accurately position the package segments in their corresponding sensing locations. It is also essential to optimize the capillary geometry in case highly dynamic thermal conditions are to be observed.
It is vital to ensure accurate characterization of the coil embedded sensor. This is best done by performing free packaged sensor calibration before its installation within the wound coil geometry. While a high degree of protection from mechanical excitation is provided by the in situ packaging, the installation process can result in wavelength shift due to strain sensitivity. If performed carefully this can be negligible; however, it is good practice for this to be ascertained in in situ calibration tests where possible.
This application of FBGs within wound coils is relatively new and opens a number of opportunities for improved design, utilization, monitoring and health diagnosis of electrical machines. Further work is needed to reduce cost of these and make them a credibly viable option for large scale application in electric machinery.

Random wound coils are a key design element of most electric apparatus in modern industrial systems and are commonly used in low voltage electric machinery. A major barrier to improved usage of wound coils in these applications is their sensitivity to in-service electro-thermal stress. Thermal overloads are particularly pertinent in this regard as these can cause insulation coil insulation system breakdown and ultimately its total failure1; this can arise due to excessive coil current levels, or other causes such as a coil electrical fault or a cooling system malfunction, where localized hot spots are induced in the coil structure leading to insulation breakdown. Enabling operative in situ distributed thermal monitoring of an in-service coil&#8217;s internal structure allows for development of improved utilization and condition based maintenance routines; it would allow for advanced understanding and identification of the coils&#8217; operating status and any degradation process, and thus condition based corrective action to maintain the operating status and prevent or slow down further damage2,3.
The presented method is aimed at enabling in situ monitoring of electric coil structure embedded thermal conditions through use of flexible and electromagnetic interference immune (EMI) fiber Bragg grated optical thermal sensors. The method offers a number of functional advantages over existing thermal monitoring techniques used in electric coils: these almost invariably rely on usage of thermocouple (TCs) or resistance temperature detectors (RTDs) that are not EMI immune; they are made of conductive materials; and they are generally reasonably bulky hence not ideally suited for sensing applications within the structure of wound electric coils. The usage of robust and flexible fiber optic FBG thermal sensors provides a number of considerable improvements in this respect, not solely due to sensor EMI immunity but also its small size, multiplexing ability and its flexibility, which enables them to be embedded into and conform to an arbitrary wound coil architecture to achieve thermal sensing with pinpoint accuracy in desired structural locations4. These features are especially attractive in electrical machine (EM) applications where device thermal limits are defined by electric coil thermal conditions and are particularly pertinent in the light of the expected considerable growth in EM usage with proliferation of electric transport.
This paper presents the methodology of instrumenting a typical low voltage random wound coil structure with thermal FBG sensors to enable on-line monitoring of internal hotspots. A detailed protocol of the FBG sensor choice, design, packaging, instrumentation, calibration and usage is reported. This is presented on an IEEE standard random wound coil motorette system. The paper also reports the obtained in situ thermal measurements under static and non-uniform thermal operating condition of the examined test coil.
FBGs are formed by the process of &#8216;grating&#8217; the optical fiber core to create periodic longitudinal imprints (usually referred to as sensing heads in FBG sensing applications); when the fiber containing FBGs is exposed to ultraviolet light each existing FBG head will cause its refractive index to be periodically modulated5. The sensing head reflected wavelengths will be affected by the thermal and mechanical conditions that the fiber is exposed to, and thus enable the grated fiber to be applied as a thermal or mechanical sensor assuming adequate design and application.
The FBG technology is especially attractive for distributed sensing applications: it allows for a single optical fiber to be grated to contain multiple FBG sensing heads, where each head is coded with a distinct Bragg wavelength and acts as a distinct sensing point. This type of FBG based sensing device is known as an FBG array sensor6 and its operating concept is illustrated in Figure 1. Broadband light is used to excite the array resulting in distinct reflected wavelengths from each contained FBG head; here, each head reflects a defined wavelength (i.e., Bragg wavelength) that matches its grating design and is also dependent on the prevailing thermal and mechanical conditions at the head (i.e., sensing) location. An interrogator device is needed to enable array fiber excitation with light and the inspection of the reflected spectra for distinct Bragg wavelengths containing information on localized thermal and/or mechanical conditions.
A particularly important aspect of FBG thermal sensor implementation is the mitigation of thermo-mechanical cross sensitivity effects to obtain as close as possible to exclusively thermal readings7. The FBG inherent feature of thermo-mechanical cross-sensitivity requires careful design of FBG sensors aimed at thermal only or mechanical only sensing applications. Where thermal sensing is concerned an effective method of mitigation FBG mechanical excitation sensitivity is to isolate the sensing head with a packaging capillary made of material suitable for a given application; in the coil embedded thermal sensing application examined in this work this not only reduces cross-sensitivity problems but also serves to protect the fragile sensing fiber structure from underside and potentially destructive mechanical stress8.
Figure 2A shows the random wound electric coil test specimen used as a demonstration vehicle in this paper. The coil is designed according to IEEE standards9 for thermal evaluation procedures of random wound coils&#8217; insulation system; the resulting test system shown in Figure 2B is known as a motorette system and is representative of a winding and its insulation system in a low voltage electrical machine. In the presented case study, the motorette will be instrumented with an FBG array thermal sensor consisting of four thermal sensing points, to emulate typical thermal sensing hot spots of interest in practical machine applications that tend to be localized in coil end winding and slot sections. For calibration and performance evaluation, the FBG embedded motorette will be thermally excited using a commercial thermal chamber and a DC power supply.

<table><tbody><tr><td>Cletop-S</td><td>Fujikura</td><td>14110601</td><td>Commercial optic connector cleaner</td></tr><tr><td>Copper wire AWG24</td><td>RS</td><td>357-744</td><td>Commercial insulated copper wire</td></tr><tr><td>DC power supply</td><td>TTi</td><td>CPX400SP</td><td>Commercial 420W DC power supply</td></tr><tr><td>FBG sensors</td><td>ATGratings</td><td>NA</td><td>Commerically manufactured FBG array to design spec</td></tr><tr><td>Heat Shrink Tubing</td><td>RS</td><td>700-4532</td><td>Heat Shrink Tubing 3mm Sleeve Dia. x 10m</td></tr><tr><td>Kapton masking tape</td><td>RS</td><td>436-2762</td><td>Orange Masking Tape Tesa 51408</td></tr><tr><td>PEEK tubing</td><td>Polyflon</td><td>4901000060</td><td>Commercial PEEK tubing</td></tr><tr><td>SmartScan04</td><td>Smartfibres UK</td><td>S-Scan-04-F-60-U-UK</td><td>Commercial interrogator system</td></tr><tr><td>Thermal Oven</td><td>Lenton</td><td>WHT6/30</td><td>Commercial thermal oven</td></tr><tr><td>Winder machine</td><td>RS</td><td>244-2636</td><td>Commercial winder machine</td></tr></tbody></table>

design, instrumentation and usage protocols for distributed in situ thermal hot spots monitoring in electric coils using fbg sensor multiplexing

Random wound coils are a key operational element of most electric apparatus in modern industrial systems, including low voltage electric machines. One of the major current bottlenecks in improved exploitation of electrical devices is the high sensitivity of their wound components to in-service thermal stress. The application of conventional thermal sensing methods (e.g., thermocouples, resistance temperature detectors) for thermal condition monitoring of current carrying random wound coils can impose considerable operational limitations due to sensor size, EMI sensitivity and the existence of electrically conductive material in their construction. Another substantial limitation exists in distributed sensing applications and is caused by what is often a considerable length and volume of conventional sensor wiring leads.
This paper reports the design of a fiber optic FBG&#160;sensing system&#160;intended for enabling real-time distributed internal thermal&#160;condition monitoring within random wound coils. The procedure of random wound coil instrumentation with the FBG sensing system is reported in a case study on an IEEE standard wound coil representative of those utilized in electrical machines. The reported work also presents and discusses important practical and technical aspects of FBG sensing system implementation and application, including the FBG array geometry design, sensing head and fiber packaging, the sensor array installation and calibration procedure and the use of a commercial interrogation system for obtaining thermal measurements. Finally, the in situ multiplexed FBG sensing system thermal monitoring performance is demonstrated in representative static and dynamic thermal conditions.&#160;

Figure 5 presents the temperatures measured by the array sensor in the static thermal test. The four internal temperature readings, taken by respective array FBG heads in corresponding coil locations, are observed to be closely similar as is generally expected for the examined test conditions; there is a slight variation between the reported individual measurement of less that &#8776;1.5 &#176;C between the observed average hotspot temperatures of &#8776;75.5 &#176;C.
Figure 6 reports the array sensor measurements obtained in the non-uniform thermal condition test. These are shown first for the period where there is no excitation in the external coil (first &#8776;75s) indicating closely uniform measured thermal levels, as would be expected. The external coil is then excited resulting in additional localized thermal excitation: this results in a clear change in the observed measurements, with the sensing point in closest proximity to the external coil (i.e., FBG4) measuring the highest thermal level (&#8776;128.6 &#176;C) and that furthest away the lowest (&#8776;117.6 &#176;C); the FBG temperature sensors located between these report intermediate and closely similar temperature levels (&#8776;122.7 and &#8776;121.6 &#176;C). The observed readings clearly relate to individual sensing head distribution in the examined test coil geometry. Furthermore, the results clearly demonstrate the functional capability of the coil embedded array sensor for monitoring and identification of internal distributed thermal hotspot distribution in random wound coils.
<img alt="Figure 1" class="xfigimg" src="/files/ftp_upload/59923/59923fig1.jpg" /> 
Figure 1. The FBG array sensor operating concept. This figure has been modified from a previous publication4. <a href="https://www-jove-com.bdigitaluss.remotexs.co/files/ftp_upload/59923/59923fig1large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>
<img alt="Figure 2" class="xfigimg" src="/files/ftp_upload/59923/59923fig2.jpg" /> 
Figure 2. IEEE standard motorette coil assembly. (A) Random wound electric coil; see IEEE standards9. (B) Assembled and varnished IEEE standard motorette. <a href="https://www-jove-com.bdigitaluss.remotexs.co/files/ftp_upload/59923/59923fig2large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>
<img alt="Figure 3" class="xfigimg" src="/files/ftp_upload/59923/59923fig3.jpg" /> 
Figure 3. FBG thermal sensor array design. (A) FBG array fiber length, (B) FBG head locations in the array structure, (C) FBG array packaging design. <a href="https://www-jove-com.bdigitaluss.remotexs.co/files/ftp_upload/59923/59923fig3large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>
<img alt="Figure 4" class="xfigimg" src="/files/ftp_upload/59923/59923fig4.jpg" /> 
Figure 4. The packaged array sensor FBG heads calibration characteristics. The characteristics are derived from the data obtained in the array free thermal calibration tests. This figure has been modified from a previous publication4. <a href="https://www-jove-com.bdigitaluss.remotexs.co/files/ftp_upload/59923/59923fig4large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>
<img alt="Figure 5" class="xfigimg" src="/files/ftp_upload/59923/59923fig5.jpg" /> 
Figure 5. FBG array thermal measurements obtained in steady state thermal condition test. The individual head thermal measurements reported by the FBG array sensor are shown with an inset detail steady-state measurement view. This figure has been modified from a previous publication4. <a href="https://www-jove-com.bdigitaluss.remotexs.co/files/ftp_upload/59923/59923fig5large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>
<img alt="Figure 6" class="xfigimg" src="/files/ftp_upload/59923/59923fig6.jpg" /> 
Figure 6. Thermal measurements in the non-uniform thermal condition test. This figure has been modified from a previous publication4. <a href="https://www-jove-com.bdigitaluss.remotexs.co/files/ftp_upload/59923/59923fig6large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>
<table border="1" fo:keep-together.within-page="1">
	<tbody>
		<tr>
			<td></td>
			<td colspan="2">Intercept</td>
			<td colspan="2">B1</td>
			<td colspan="2">B2</td>
			<td>Statistics</td>
		</tr>
		<tr>
			<td></td>
			<td>Value</td>
			<td>Standard Error</td>
			<td>Value</td>
			<td>Standard Error</td>
			<td>Value</td>
			<td>Standard Error</td>
			<td>Adj. R-Square</td>
		</tr>
		<tr>
			<td>FBG1</td>
			<td>1555.771</td>
			<td>0.0137</td>
			<td>0.00855</td>
			<td>2.85E-04</td>
			<td>1.50E-05</td>
			<td>1.34E-06</td>
			<td>0.99978</td>
		</tr>
		<tr>
			<td>FBG2</td>
			<td>1547.669</td>
			<td>0.0112</td>
			<td>0.00851</td>
			<td>2.34E-04</td>
			<td>1.41E-05</td>
			<td>1.10E-06</td>
			<td>0.99985</td>
		</tr>
		<tr>
			<td>FBG3</td>
			<td>1539.852</td>
			<td>0.0101</td>
			<td>0.00871</td>
			<td>2.11E-04</td>
			<td>1.30E-05</td>
			<td>9.90E-07</td>
			<td>0.99988</td>
		</tr>
		<tr>
			<td>FBG4</td>
			<td>1531.768</td>
			<td>0.0131</td>
			<td>0.00808</td>
			<td>2.72E-04</td>
			<td>1.67E-05</td>
			<td>1.28E-06</td>
			<td>0.9998</td>
		</tr>
	</tbody>
</table>
Table 1: Calculated polynomial qudratic fit curve parameters. The calculated parameters standard error and individual head correction coefficientsare included; good linearity and a coorection factor coefficient in excess of 0.999 was observed for the four tested FBG heads. This table has been modified from a previous publication4.

Watch this Scientific Journal Video about Design, Instrumentation and Usage Protocols for Distributed In Situ Thermal Hot Spots Monitoring in Electric Coils using FBG Sensor Multiplexing at JoVE.com

Design, Instrumentation and Usage Protocols for Distributed In Situ Thermal Hot Spots Monitoring in Electric Coils using FBG Sensor Multiplexing

This paper presents a protocol that enables instrumentation of random wound electric coils with fiber Bragg grating (FBG) thermal sensors for the purpose of distributed condition monitoring of internal thermal hot spots.

Random wound coils are a key operational element of most electric apparatus in modern industrial systems, including low voltage electric machines. One of ...

design-instrumentation-usage-protocols-for-distributed-situ-thermal

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Engineering

5.8K Views.  University of Manchester. This paper presents a protocol that enables instrumentation of random wound electric coils with fiber Bragg grating (FBG) thermal sensors for the purpose of distributed condition monitoring of internal thermal hot spots.

Video: Design, Instrumentation and Usage Protocols for Distributed In Situ Thermal Hot Spots Monitoring in Electric Coils using FBG Sensor Multiplexing

Method for Simultaneous fMRI/EEG Data Collection during a Focused Attention Suggestion for Differential Thermal Sensation

In the present work, we demonstrate a method for concurrent collection of EEG/fMRI data. In our setup, EEG data are collected using a high-density 256-channel sensor net. The EEG amplifier itself is contained in a field isolation containment system (FICS), and MRI clock signals are synchronized with EEG data collection for subsequent MR artifact characterization and removal. We demonstrate this method first for resting state data collection. Thereafter, we demonstrate a protocol for EEG/fMRI data recording, while subjects listen to a tape asking them to visualize that their left hand is immersed in a cold-water bath and referred to, here, as the cold glove paradigm. Thermal differentials between each hand are measured throughout EEG/fMRI data collection using an MR compatible temperature sensor that we developed for this purpose. We collect cold glove EEG/fMRI data along with simultaneous differential hand temperature measurements both before and after hypnotic induction. Between pre and post sessions, single modality EEG data are collected during the hypnotic induction and depth assessment process. Our representative results demonstrate that significant changes in the EEG power spectrum can be measured during hypnotic induction, and that hand temperature changes during the cold glove paradigm can be detected rapidly using our MR compatible differential thermometry device.

We present a protocol for concurrent collection of EEG/fMRI data, and synchronized MR clock signal recording. We demonstrate this method using a unique paradigm whereby subjects receive &#x2018;cold glove&#x2019; instructions during scanning, and EEG/fMRI data are recorded along with hand temperature measurements both before and after hypnotic induction.

In the present work, we demonstrate a method for concurrent collection of EEG/fMRI data. In our setup, EEG data are collected using a high-density ...

Behavior

Surface Renewal: An Advanced Micrometeorological Method for Measuring and Processing Field-Scale Energy Flux Density Data

Advanced micrometeorological methods have become increasingly important in soil, crop, and environmental sciences. For many scientists without formal training in atmospheric science, these techniques are relatively inaccessible. Surface renewal and other flux measurement methods require an understanding of boundary layer meteorology and extensive training in instrumentation and multiple data management programs. To improve accessibility of these techniques, we describe the underlying theory of surface renewal measurements, demonstrate how to set up a field station for surface renewal with eddy covariance calibration, and utilize our open-source turnkey data logger program to perform flux data acquisition and processing. The new turnkey program returns to the user a simple data table with the corrected fluxes and quality control parameters, and eliminates the need for researchers to shuttle between multiple processing programs to obtain the final flux data. An example of data generated from these measurements demonstrates how crop water use is measured with this technique. The output information is useful to growers for making irrigation decisions in a variety of agricultural ecosystems. These stations are currently deployed in numerous field experiments by researchers in our group and the California Department of Water Resources in the following crops: rice, wine and raisin grape vineyards, alfalfa, almond, walnut, peach, lemon, avocado, and corn.

Surface renewal is a micrometeorological method that is being used increasingly to determine energy fluxes, but its technical complexity makes it inaccessible to a broad audience. We describe the steps needed to set up and calibrate a surface renewal field station, to acquire and process data, and to correctly interpret results.

Advanced micrometeorological methods have become  increasingly important in soil, crop, and environmental sciences.  For many scientists without formal ...

Environment

Thermal Measurement Techniques in Analytical Microfluidic Devices

Thermal measurement techniques have been used for many applications such as thermal characterization of materials and chemical reaction detection. Micromachining techniques allow reduction of the thermal mass of fabricated structures and introduce the possibility to perform high sensitivity thermal measurements in the micro-scale and nano-scale devices. Combining thermal measurement techniques with microfluidic devices allows performing different analytical measurements with low sample consumption and reduced measurement time by integrating the miniaturized system on a single chip. The procedures of thermal measurement techniques for particle detection, material characterization, and chemical detection are introduced in this paper.

Here, we present three protocols for thermal measurements in microfluidic devices.

Thermal measurement techniques have been used for many applications such as thermal characterization of materials and chemical reaction detection. ...

High-resolution Thermal Micro-imaging Using Europium Chelate Luminescent Coatings

Micro-electronic devices often undergo significant self-heating when biased to their typical operating conditions. This paper describes a convenient optical micro-imaging technique which can be used to map and quantify such behavior. Europium thenoyltrifluoroacetonate (EuTFC) has a 612 nm luminescence line whose activation efficiency drops strongly with increasing temperature, due to T-dependent interactions between the Eu3+ ion and the organic chelating compound. This material may be readily coated on to a sample surface by thermal sublimation in vacuum. When the coating is excited with ultraviolet light (337 nm) an optical micro-image of the 612 nm luminescent response can be converted directly into a map of the sample surface temperature. This technique offers spatial resolution limited only by the microscope optics (about 1 micron) and time resolution limited by the speed of the camera employed. It offers the additional advantages of only requiring comparatively simple and non-specialized equipment, and giving a quantitative probe of sample temperature.

Europium thenoyltrifluoroacetonate (EuTFC) has an optical luminescence line at 612 nm, whose activation efficiency decreases strongly with temperature. If a sample coated with a thin film of this material is micro-imaged, the 612 nm luminescent response intensity may be converted into a direct map of sample surface temperature.

Micro-electronic devices often undergo significant self-heating when biased to their typical operating conditions. This paper describes a convenient ...

Fiber Optic Distributed Sensors for High-resolution Temperature Field Mapping

The reliability of computational fluid dynamics (CFD) codes is checked by comparing simulations with experimental data. A typical data set consists chiefly of velocity and temperature readings, both ideally having high spatial and temporal resolution to facilitate rigorous code validation. While high resolution velocity data is readily obtained through optical measurement techniques such as particle image velocimetry, it has proven difficult to obtain temperature data with similar resolution. Traditional sensors such as thermocouples cannot fill this role, but the recent development of distributed sensing based on Rayleigh scattering and swept-wave interferometry offers resolution suitable for CFD code validation work. Thousands of temperature measurements can be generated along a single thin optical fiber at hundreds of Hertz. Sensors function over large temperature ranges and within opaque fluids where optical techniques are unsuitable. But this type of sensor is sensitive to strain and humidity as well as temperature and so accuracy is affected by handling, vibration, and shifts in relative humidity. Such behavior is quite unlike traditional sensors and so unconventional installation and operating procedures are necessary to ensure accurate measurements. This paper demonstrates implementation of a Rayleigh scattering-type distributed temperature sensor in a thermal mixing experiment involving two air jets at 25 and 45 &#176;C. We present criteria to guide selection of optical fiber for the sensor and describe installation setup for a jet mixing experiment. We illustrate sensor baselining, which links readings to an absolute temperature standard, and discuss practical issues such as errors due to flow-induced vibration. This material can aid those interested in temperature measurements having high data density and bandwidth for fluid dynamics experiments and similar applications. We highlight pitfalls specific to these sensors for consideration in experiment design and operation.

We demonstrate use of a fiber optic distributed sensor for mapping the temperature field of mixing air jets. The Rayleigh scattering-based sensor generates thousands of data points along a single fiber to provide exceptional spatial resolution that is unattainable with traditional sensors such as thermocouples.

The reliability of computational fluid dynamics (CFD) codes is checked by comparing simulations with experimental data. A typical data set consists ...

A Random-displacement Measurement by Combining a Magnetic Scale and Two Fiber Bragg Gratings

Long-distance displacement measurements using optical fibers have always been a challenge in both basic research and industrial production. We developed and characterized a temperature-independent fiber Bragg grating (FBG)-based random-displacement sensor that adopts a magnetic scale as a novel transferring mechanism. By detecting shifts of two FBG center wavelengths, a full-range measurement can be obtained with a magnetic scale. For identification of the clockwise and counterclockwise rotation direction of the motor (in fact, the direction of movement of the object to be tested), there is a sinusoidal relationship between the displacement and the center wavelength shift of the FBG; as the anticlockwise rotation alternates, the center wavelength shift of the second FBG detector shows a leading phase difference of around 90&#176; (+90&#176;). As the clockwise rotation alternates, the center wavelength shift of the second FBG displays a lagging phase difference of around 90&#176; (-90&#176;). At the same time, the two FBG-based sensors are temperature independent. If there is some need for a remote monitor without any electromagnetic interference, this striking approach makes them a useful tool for determining the random displacement. This methodology is appropriate for industrial production. As the structure of the whole system is relatively simple, this displacement sensor can be used in commercial production. In addition to it being a displacement sensor, it can be used to measure other parameters, such as velocity and acceleration.

A protocol to create a full-range linear displacement sensor, combining two packaged fiber Bragg grating detectors with a magnetic scale, is presented.

Long-distance displacement measurements using optical fibers have always been a challenge in both basic research and industrial production. We developed ...

A Silicon-tipped Fiber-optic Sensing Platform with High Resolution and Fast Response

In this article, we introduce an innovative and practically promising fiber-optic sensing platform (FOSP) that we proposed and demonstrated recently. This FOSP relies on a silicon Fabry-Perot interferometer (FPI) attached to the fiber end, referred to as Si-FOSP in this work. The Si-FOSP generates an interferogram determined by the optical path length (OPL) of the silicon cavity. Measurand alters the OPL and thus shifts the interferogram. Due to the unique optical and thermal properties of the silicon material, this Si-FOSP exhibits an advantageous performance in terms of sensitivity and speed. Furthermore, the mature silicon fabrication industry endows the Si-FOSP with excellent reproducibility and low cost toward practical applications. Depending on the specific applications, either a low-finesse or high-finesse version will be utilized, and two different data demodulation methods will be adopted accordingly. Detailed protocols for fabricating both versions of the Si-FOSP will be provided. Three representative applications and their according results will be shown. The first one is a prototype underwater thermometer for profiling the ocean thermoclines, the second one is a flow meter to measure flow speed in the ocean, and the last one is a bolometer used for monitoring exhaust radiation from magnetically confined high-temperature plasma.

This work reports an innovative silicon-tipped fiber-optic sensing platform (Si-FOSP) for high-resolution and fast-response measurement of a variety of physical parameters, such as temperature, flow, and radiation. Applications of this Si-FOSP span from oceanographic research, mechanical industry, to fusion energy research.

In this article, we introduce an innovative and practically promising fiber-optic sensing platform (FOSP) that we proposed and demonstrated recently. This ...

Optimized Sealing Process and Real-Time Monitoring of Glass-to-Metal Seal Structures

Residual stress is an essential factor to keeping the hermeticity and robustness of a glass-to-metal seal structure. The purpose of this report is to demonstrate a novel protocol to characterize and measure residual stress in a glass-to-metal seal structure without destroying the insulation and hermeticity of sealing materials. In this research, a femto-laser inscribed fiber Bragg grating sensor is used. The glass-to-metal seal structure that is measured consists of a metal shell, sealing glass, and Kovar conductor. To make the measurements worthwhile, the specific heat treatment of metal-to-glass seal (MTGS) structure is explored to obtain the model with best hermeticity. Then, the FBG sensor is embedded into the path of sealing glass and becomes well-fused with the glass as the temperature cools to RT. The Bragg wavelength of FBG shifts with the residual stress generated in sealing the glass. To calculate the residual stress, the relationship between Bragg wavelength shift and strain is applied, and the finite element method is also used to make the results reliable. The online monitoring experiments of residual stress in sealing glass are carried out at different loads, such as high temperature and high pressure, to broaden functions of this protocol in harsh environments.

Key procedures to optimize the sealing process and achieve real-time monitoring of the metal-to-glass seal (MTGS) structure are described in detail. The embedded fiber Bragg grating (FBG) sensor is designed to achieve online monitoring of temperature and high-level residual stress in the MTGS with simultaneous environmental pressure monitoring.

Residual stress is an essential factor to keeping the hermeticity and robustness of a glass-to-metal seal structure. The purpose of this report is to ...

In Situ Surface Temperature Measurement in a Conveyor Belt Furnace via Inline Infrared Thermography

Measuring the surface temperature of objects that are processed in conveyor belt furnaces is an important tool in process control and quality assurance. Currently, the surface temperature of objects processed in conveyor belt furnaces is typically measured via thermocouples. However, infrared (IR) thermography presents multiple advantages compared to thermocouple measurements, as it is a contactless, real-time, and spatially resolved method. Here, as a representative proof-of-concept example, an inline thermography system is successfully installed into an IR lamp powered solar firing furnace, which is used for the contact firing process of industrial Si solar cells. This protocol describes how to install an IR camera into a conveyor belt furnace, conduct a customer correction of a factory calibrated IR camera, and perform the evaluation of spatial surface temperature distribution on a target object.

This protocol describes how to install an infrared camera into a conveyor belt furnace, conduct a customer correction of a factory calibrated IR camera, and evaluate the spatial surface temperature distribution of an object of interest. The example objects are industrial silicon solar cells.

Measuring the surface temperature of objects that are processed in conveyor belt furnaces is an important tool in process control and quality assurance. ...

Optimizing Brillouin Optical Time-Domain Analyzers Based on Gain Spectrum Engineering

Demonstrated is a unique method for sensing performance enhancement in Brillouin optical time-domain analyzers (BOTDA). A Brillouin gain spectrum (BGS) is superimposed with two symmetric Brillouin loss spectra (BLS). This leads to a complex engineered spectrum shape that is more resistant to the sensing system noise. Instead of only one pump and probe interaction as in the conventional BOTDA setup, three optical probe waves are exploited, with one probe located in the BGS and the other two symmetrically in the BLS. Due to the resistance and insensitivity of the engineered spectrum shape to the noise, the sensing performance is enhanced by 60% and the measurand resolution is doubled.

A protocol for Brillouin optical time-domain analyzers based on gain spectrum engineering is presented. Enhancements in the sensing performance, including sensing range and measurand resolution are achieved and the excess Brillouin intensity noise is studied. The protocol introduces a new way to enhance distributed Brillouin sensing performance.

Demonstrated is a unique method for sensing performance enhancement in Brillouin optical time-domain analyzers (BOTDA). A Brillouin gain spectrum (BGS) is ...