Contactless Low-Cost Position Sensor Using a D-Shaped Polymer Optical Fiber

This article describes a contactless fiber-optic position sensor. It comprises a Polymer Optical Fiber that is grinded to form a D-shaped cross-section with an exposed fiber core. This sensor has two photodiodes at both fiber ends to measure the emitted light intensity. Light is coupled using a red LED at the side face into the exposed core of the fiber at a defined position. The position of the LED at the length of the fiber is measured by calculating the optical power quotient measured by both photodiodes. To test this sensor, Polymer Optical Fibers with different side surface roughness are produced and qualified. Measurements show that the optical power quotient is reproducible and nearly linear over the length of the fiber. It is also seen that the fiber attenuation increases when grinding the fiber side-face with rougher sandpaper. Position measurements show an absolute position error of this sensor in the range of a few millimeters. Microscope images show surface defects along the polished side face of the fiber that are expected to lead to a nonuniform attenuation along the fiber and cause the position errors. Overall, it is proven that this sensor principle works as a contactless low-cost position sensor for short distances with an absolute position standard deviation error lower than 1 mm.