Why does moving from a lab prototype to an industrial product require solving numerous packaging issues?
Moving a shape sensor from a laboratory prototype to an industrial product indeed presents numerous engineering challenges, particularly concerning packaging. While lab prototypes often operate in controlled environments with minimal stress, industrial applications expose sensors to a wide range of harsh conditions and demands.
Here are the key reasons why packaging becomes critical for industrial shape sensors:
- Environmental Protection: Industrial environments can involve extreme temperatures, high humidity, corrosive chemicals, dust, water ingress, and electromagnetic interference (EMI). Packaging must provide robust protection against these elements to ensure the sensor’s long-term functionality and accuracy.
- Mechanical Robustness and Durability: Industrial applications typically involve vibrations, impacts, bending, and abrasive forces. The packaging must be designed to withstand these mechanical stresses without compromising the fragile optical fibers or the sensor’s measurement capabilities. This includes securing the fiber, protecting connection points, and preventing fatigue.
- Installation and Integration: Industrial products need to be easily installed, mounted, and integrated into complex systems. Packaging influences the mounting options, cable routing, connector types, and overall form factor, which must be compatible with existing infrastructure and installation procedures.
- Long-Term Reliability and Stability: Industrial sensors are expected to operate reliably for extended periods without drift or failure. Packaging plays a crucial role in maintaining the sensor’s calibration and structural integrity over its operational lifespan, minimizing maintenance and replacement costs.
- Cost-Effectiveness and Manufacturability: For mass production, the packaging design must be cost-effective to manufacture while meeting all performance and reliability requirements. This involves selecting appropriate materials and manufacturing processes.
- Adherence to Standards and Certifications: Many industrial sectors have specific safety, performance, and environmental standards that products must meet. Packaging often needs to comply with these regulations (e.g., IP ratings for dust and water protection, ATEX for hazardous environments).
OFSCN® offers OFSCN® Fiber Bragg Grating Shape Sensor solutions that address these industrial challenges through robust and customizable packaging. These sensors have iterated to their third generation, emphasizing highly customized designs suitable for diverse industrial requirements. Our shape sensors typically feature a multi-fiber string design (e.g., 3 FBG strings at 120-degree intervals) enclosed within protective structures, with customizable diameters and lengths to match specific application needs.
Here are some standard images of our shape sensors:
You can learn more about its detailed parameters on our website.