Smart Composite Conductor With Embedded Fiber Sensing
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Solution Overview
Problem
The electrical grid faces inefficiencies and reliability issues due to outdated conductor technology, leading to significant energy losses and greenhouse gas emissions, with conventional conductors failing to effectively monitor operating parameters or withstand extreme weather conditions.
Innovation Solution
The development of smart composite conductors featuring a strength member with a composite core and encapsulation layer, integrated with an optical fiber assembly that senses operating parameters, providing real-time monitoring and enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional conductors are used for electrical transmission, then the electrical grid can operate with existing infrastructure, but energy losses increase and real-time monitoring capability is lost
Solution Approach 1:
The patent combines multiple functions into a single conductor structure: electrical conduction through aluminum/conductor layers, mechanical strength through composite core, and real-time monitoring through integrated optical fiber sensors. This merging allows the conductor to simultaneously transmit electricity and provide diagnostic data, eliminating the need for separate monitoring infrastructure.
Solution Approach 2:
The conductor is designed as a multi-functional component that performs electrical transmission, mechanical support, and sensing operations. The optical fiber assembly embedded in the composite core enables the conductor to serve as both a power transmission medium and a distributed sensing system, providing universal functionality across multiple operational requirements.
2Loss of information
If standard optical fiber assembly is embedded in composite core during manufacturing, then the optical fiber may be damaged due to high processing temperatures, but without embedding real-time sensing capability is lost
Solution Approach 1:
The patent modifies the thermal parameters of the optical fiber assembly by selecting materials with appropriate glass transition temperatures. The fiber encapsulation layer uses materials that maintain structural integrity at the composite core's processing temperature, allowing the optical fiber to withstand manufacturing heat cycles without damage while remaining embedded in the final product.
Solution Approach 2:
The patent employs composite material structures both in the strength member (carbon fiber reinforced polymer) and in the optical fiber encapsulation (temperature-resistant materials). These composite constructions provide the necessary thermal resistance to protect the optical fiber during high-temperature processing while maintaining mechanical properties.
3Measurement precision
If optical fiber assembly has small bend radius to fit in conductor, then micro-bending losses increase, but without proper bend control sensing accuracy deteriorates
Solution Approach 1:
The patent uses a flexible encapsulation layer around the optical fiber that can accommodate the small bend radius required for conductor integration while protecting the fiber from excessive micro-bending stresses. This flexible protection allows the fiber to follow the conductor's geometry without suffering prohibitive optical losses.
Solution Approach 2:
The patent optimizes the bend radius parameter to balance two competing requirements: small enough to fit within the conductor structure and large enough to minimize micro-bending losses. By carefully controlling this geometric parameter and using appropriate encapsulation, the system achieves acceptable optical transmission while maintaining compact form factor.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces energy losses, enhances conductor strength, and enables real-time fault detection, improving grid efficiency and resilience against extreme weather, while reducing environmental impact.
Implementation Method 1
An optical fiber assembly is disposed in the composite core or in the encapsulating layer around the composite core and is configured to sense one or more operating parameters of the conductor
Implementation Method 2
the fiber encapsulation layer has a second glass transition temperature or melting temperature that is greater than the first glass transition temperature or melting temperature or the processing temperature of the strength member
Implementation Method 3
the optical fiber assembly may have a bend radius of equal to or less than 250 mm and/or have a cladding having a thickness of greater than 80 microns such that the optical fiber assembly has a micro-bending induced optical energy transmission loss of equal to or less than about 5 dB/km
Data Source
AI summary
An apparatus includes a strength member including a core formed of a composite material, and having a first glass transition or melting temperature. An encapsulation layer is disposed around the core. An optical fiber assembly is disposed in the core and includes a fiber core and a fiber encapsulation layer disposed therearound that has a second glass transition or melting temperature that is greater than the first glass transition or melting temperature. A conductor layer is disposed around the strength member. A coupler may be coupled to an axial end of the apparatus. The coupler may define an aperture through a wall thereof and a portion of the optical fiber assembly is routed therethrough. A system may include a control unit configured to receive a sensing signal from the fiber assembly and transmit the signal or determine a value of the operating parameter and transmit the value to the receiver.