A Flexible Integrated Optical Chip Based Sensor Network for Aircraft Leak Detection

ABSTRACT: To address Air Force needs for a networked sensor system for detecting aircraft leaks and environmental contaminants that cause corrosion, Physical Optics Corporation (POC) proposes to develop a micro-miniature, flexible integrated optical chip (FlexOChip) sensor for aircraft leak detection. This proposed sensor could be cemented to the aircraft to detect chemical leaks from fluid lines and tank surfaces without affecting its performance characteristics. These sensors are suitable for hard to reach or remotely located points around the body of the aircraft. FlexOChip comprises an array of D-shaped fiber optic sensors with half-polished fiber cores integrated on a flexible substrate. The sensor consists of edge-mounted vertical cavity surface-emitting laser chips and ultra-thin photodiodes integrated with the chip. The innovation in flexible optical chip sensing will enable precise monitoring of leaks and inform about possible subsystem failures. POC"s FlexOChip sensor network will be a novel, low-cost solution with high detection sensitivity and specificity, which is highly desirable for routine aircraft maintenance. In Phase I, POC will demonstrate the feasibility of detection of hydraulic fluids, aircraft fuel, humidity, and oxidizers. In Phase II, POC plans to build a prototype of FlexOChip sensor modules wirelessly integrated with a central command station. BENEFIT: The FlexOChip sensor technology will enable the Air Force to enhance its existing aircraft maintenance capability. The proposed micro-miniature, flexible integrated optical chip sensor can be used to automatically collect, store, and manage, and be intelligently exploited, for monitoring the structural health status of the aircraft. The sensor system can take advantage of new computing and software technologies for leak detection at hard to access places around the body of the aircraft. Once the project is successful and carried over into Phases II and III, the resulting product will be highly marketable. FlexOChip sensors could be used in a wide range of applications, from monitoring of leaks in cargo planes and commercial aircraft to monitoring power plants, oil rigs, chemical plants, vehicle engines, and pipe lines.