Fibre Optic Coupled, Infrared Thermometers For
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FIBRE OPTIC COUPLED, INFRARED THERMOMETERS FOR PROCESSES INCURRING HARSH CONDITIONS Andrew David Heeley Registration Number 150143161 This thesis is submitted in partial fulfilment of the requirements for the degree of Doctor of Philosophy The University of Sheffield Faculty of Engineering Department of Electronic and Electrical Engineering 18th December 2019 The template used to compile this thesis was produced by Malcolm Morgan and Kayla Friedman for the Centre for Sustainable Development, University of Cambridge, UK ⁘ “The socialism I believe in isn’t really politics. It is a way of living. It is humanity. I believe the only way to live and to be truly successful is by collective effort, with everyone working for each other, everyone helping each other and everyone having a share in the rewards at the end of the day. That might be asking a lot but it is the way I see football, the way I see life.” Bill Shankly ⁘ There are those who sow divisions and those who grow visions. Wisdom teaches us to live in the shelter of each other. ⁘ i DECLARATION I, Andrew David Heeley, confirm that this thesis is my own work and includes nothing that is the outcome of work done in collaboration except where specifically indicated in the text. I am aware of the University’s Guidance on the Use of Unfair Means (www.sheffield.ac.uk/ssid/unfair-means). This work has not been previously submitted, in part or whole, to any university for any degree or other qualification. Signed: A D Heeley Date: 18th December 2019 Andrew David Heeley Sheffield, UK ii FIBRE OPTIC COUPLED, INFRARED THERMOMETERS FOR PROCESSES INCURRING HARSH CONDITIONS ANDREW D HEELEY, DECEMBER 2019 ABSTRACT This study undertook the development and testing of fibre optic coupled infrared thermometers (IRTs) that could substitute for thermocouples in harsh conditions that would affect contact temperature measurements deleteriously. The IRTs have been configured without photodiode cooling and signal chopping but achieved low minimum measurable temperatures, fast responses and good sensitivities. IRTs were configured with mid-wave infrared (MWIR) and short-wave infrared (SWIR) photodiodes, to measure over different temperature ranges. The thermometers had small footprints, therefore could be installed into constrained spaces and not cause interference with the process. The MWIR thermometers were substituted for thermocouples in high temperature conditions in end milling tool temperature measurements and reactive electrochemical conditions in Lithium-ion cell temperature measurements. The conditions into which the fibre optics were embedded would lead to inaccurate measurements from thermocouples, whereas the fibre optic and remotely positioned IRT offered immunity against these errors. Calibration drift is a major problem that afflicts thermocouple temperature measurements. There has been progress towards addressing this weakness with improved thermocouples. The SWIR thermometer used a zero drift operational amplifier to minimise offset voltage, drift and noise. The IRT was coupled to a sapphire fibre optic probe that had tin deposited onto the core to form an integral fixed point temperature calibration cell. This low drift IRT provided an increment towards creating a drift-free, self-calibrating IRT that would substitute for thermocouples with integral calibration capabilities. The feasibility of substituting thermocouples with embedded fibre optics coupled to IRTs has been demonstrated and potential improvements of these thermometers have been identified. iii ACKNOWLEDGEMENTS First and foremost, I owe the biggest thank-you to my fiancée, Sally for supporting and encouraging me in taking the opportunity to study for a PhD that presented itself back in 2015 and putting up with my humour for so many years, besides. I am grateful for having had the chance to pursue a PhD somewhat later in life than most students come to this level of study and to Dr. Jon Willmott as my academic supervisor for enabling that chance. I wish to acknowledge the help and friendship offered by all those whom I have met and discussed: work, life, politics, philosophy and football with and shared lunchtime conversations with throughout The Electronic and Electrical Engineering Department and Sensor Systems Group. In no particular order: Dr. Matt Hobbs (particularly for introducing the Wednesday lunch), Dr. Nick Boone, Dr. Chengxi Zhu (Todd), Steve Dorward, Mary Stuart, Leigh Stanger, Dr. Akeel Auckloo, Matt Davies, Dr. Tom Rockett, Matt Grainger, Dr. Richard Hodgkinson and Dr. Jeng-Shui Cheong. Outside of the research group, my thanks go to Dr. Mark Sweet and Dr. Ben White particularly for sharing some of their experience and engaging with interesting lunchtime conversations. Thank-you also to Dr. Jaime Maravi Nieto for joining me in forming ‘Ohm and Away’ back in 2016 and the many EEE postgraduates who played alongside us. You have all added something to my experience here. I wish to thank and acknowledge Dr. Hatim Laalej, Dr. Jon Stammers, Stephen Mann and Dr. Sabino Ayvar-Soberanos at The University of Sheffield, Advanced Manufacturing Research Centre for their assistance in testing the thermometer on an end milling machine. I wish to thank and acknowledge Dr. Denis Cumming, Laurie Middlemiss, Josie-May Whitnear, Nikko Talplacido, Laura Wheatcroft, Megan Hoyle and Jagoda Cieslik of the University of Sheffield, Chemical and Biological Engineering department for their assistance in testing the battery cell fibre optic thermometer. iv Thank you to Kayla Friedman and Malcolm Morgan of the Centre for Sustainable Development, University of Cambridge, UK for producing the Microsoft Word template used to produce this thesis. Finally, I am truly thankful for the volunteers of Edale Mountain Rescue Team and Yorkshire Air Ambulance for rescuing me after a fall from White Edge in Derbyshire (please support these dedicated people, if you are reading this thesis) and all of the staff at Sheffield’s Northern General Hospital major trauma centre & intensive care unit for achieving what “all of the King’s horses and all of the King’s men” could not and putting me back together in 2017, enabling me to complete this PhD. Funding. This research was funded by the UK Engineering and Physical Sciences Research Council under doctoral training grant scholarship numbers EP/K503149/1 and EP/L505055/1 and grant number EP/M009106/1 Optimised Manufacturing Through Unique Innovations in Quantitative Thermal Imaging. v CONTENTS 1 INTRODUCTION .................................................................................................................. 1 1.1 INDUSTRIAL TEMPERATURE MEASUREMENT ................................................................... 5 1.2 INFRARED RADIATION THERMOMETER CONFIGURATIONS .............................................. 7 1.2.1 Photodiode junction operation ..................................................................................... 7 1.2.2 Transimpedance amplifier configuration ..................................................................... 9 1.2.3 Thermometer detector and optical configuration ....................................................... 12 1.3 FIBRE OPTIC MATERIALS ................................................................................................... 13 1.4 OBJECTIVES OF INFRARED THERMOMETER DEVELOPMENT. ......................................... 14 1.5 SPECIFICATION FOR PROTOTYPE INFRARED THERMOMETER ........................................ 15 1.6 RAISON D’ETRE OF THIS THESIS. ...................................................................................... 16 1.7 ARRANGEMENT OF THESIS .............................................................................................. 18 1.8 PAPERS PUBLISHED .......................................................................................................... 19 2 PRINCIPLES AND THEORY APPLICABLE TO RADIATION THERMOMETRY 26 2.1 RADIOMETRY DEFINITIONS ............................................................................................. 28 2.2 BLACKBODY RADIATION CURVES ................................................................................... 29 2.3 NUMERICAL INTEGRATION OF PLANCK’S LAW ............................................................. 31 2.4 WIEN’S APPROXIMATION OF PLANCK’S LAW ................................................................ 34 2.5 SAKUMA-HATTORI EQUATION. ....................................................................................... 39 2.6 FIBRE OPTIC COUPLING ................................................................................................... 41 2.6.1 Fibre optic materials .................................................................................................. 42 2.6.2 Fibre optic transmission equations. ........................................................................... 44 2.7 MODELLING OF INFRARED TRANSMISSION AND POWER INCIDENT UPON DETECTOR . 48 2.8 MINIMUM TEMPERATURE MEASURABLE WITH PROTOTYPE FIBRE OPTIC THERMOMETER ................................................................................................................................................. 50 2.9 TRANSIMPEDANCE AMPLIFIER AND BOOTSTRAPPING CONFIGURATIONS .................... 53 3 EXPERIMENTAL AND ANALYTICAL METHODS DEPLOYED ............................. 59 3.1 INFRARED THERMOMETER CONFIGURATION .................................................................. 59 3.2 MODELLING OF OP-AMP NOISE AND INPUT OFFSET VOLTAGE .....................................