To achieve data-driven intelligence in engineering applications, the key requirements for distributed optical fiber sensor networks are large capacity, long distance, dense distribution, fast response, and high signal-to-noise ratio (SNR). Combining the traditional optical reflectometry techniques with the large-scale fiber Bragg grating (FBG) array fabricated on-line by a fiber drawing tower, multiplexing and demodulation of thousands of FBG sensors is successfully demonstrated, which greatly expands the application of FBG sensors to the field of distributed sensing. In this work, the fabrication, demodulation, and applications of large-scale FBG arrays are reviewed. Firstly, the on-line fabrication technology and process of large-scale FBG arrays are introduced. Secondly, the demodulation techniques including wavelength demodulation based on optical time-domain reflectometry (OTDR) and optical frequency-domain reflectometry (OFDR), as well as phase demodulation based on phase-sensitive OTDR are reviewed, where we mainly focus on the key parameters such as multiplexing capacity, demodulation speed, spatial resolution, and SNR. Last, the applications of the large-scale FBG arrays are briefly discussed.

In this paper, to develop a high-performance fiber-optic hydrophone for large-scale hydrophone arrays, a general sensing model is theoretically built from mandrel-wound structures of fiber-optic hydrophones. By analyzing and optimizing the structural parameters of the model, a high-performance fiber-optic hydrophone is designed from two aspects. First, the structure of the mandrel is optimized by elastic theory and finite element analysis approach, and the structural design of fiber-optic hydrophone with high acoustic pressure sensitivity and wide frequency response range is realized. Then, the winding ratio of the fiber is optimized by mathematical simulation to realize an Omni-directivity fiber optic hydrophone design. The feasibility of the designed fiber-optic hydrophone is further experimentally demonstrated. The results indicate that the proposed hydrophone achieves a high average acoustic pressure sensitivity of $-$ 113 dB ( $re$ 1 rd / $\mu$ Pa) within the flatness of $\pm$ 1.5 dB from 10 Hz to 1000 Hz, and a horizontal directivity of $\pm$ 1 dB at 1 kHz. Moreover, the average minimum detectable acoustic pressure is achieved as low as 14.1 $\mu$ Pa. The capability of weak acoustic signal detection and large-scale multiplexing offers great potential for application in underwater faint target detection.

Under realistic scenarios, more fiber Bragg gratings (FBGs) are always expected to be multiplexed in one sensor array to share the expensive optical components and electrical devices. However, either the sensing number or the interrogation frequency is limited in previous works due to the huge amount of data generated from large-scale sensing arrays. This paper presents a field-programmable gate array (FPGA)-based dynamic wavelength interrogation system for thousands of identical FBGs. With the advantages of parallel controlling and pipeline processing, FPGA can accelerate the data-processing rate of the wavelength interrogation, realizing a continuous-running and real-time sensing system. The signal-processing system precisely synchronizes the generation of interrogation pulses, the acquisition of reflected signals, and the processing of the wavelength-related data, making the interrogation frequency fundamentally limited by the round-trip time of light pulses traveling in the fiber. Multiple sensing arrays can be independently carried out simultaneously, affecting hardly the interrogation frequency. Experimental results show that over 4000 FBGs with a 3-m spatial resolution in four channels are interrogated with a 150-Hz sensing frequency, 3-nm dynamic range, and ±5.9-pm sensing precision, greatly improving the interrogation frequency while ensuring the multiplexing number.

Crack generation starts at the crack tip, which bears the highest stress concentration. Under further stress, the crack propagates and leads to severe structural damage. To avoid such damage, the identification of the crack tips, and monitoring of the surrounding stress and strain fields, are very important. In this work, the location of, and strain distribution monitoring around, the crack tip are achieved using a dense ultra-short (DUS) fiber Bragg grating (FBG) array together with an improved optical frequency domain reflectometry (OFDR) interrogator. The adjacent grating interference correlation algorithm helps overcome the limitation on the demodulation precision, which is imposed by the inherently broad reflection spectra of individual ultra-short gratings. High spatial resolution measurement of the strain profile around the crack tip is performed at different levels of induced strain. Furthermore, the vertical-crossed layout is adopted to avoid the omission of cracks, which usually occurs in the case of the one direction layout. We achieve 1 mm spatial resolution and 7.5 m detection distance. Location of a single crack, multiple cracks, and an oblique crack was realized experimentally by locating the crack tips. The experimental results are consistent with the theoretical analysis, verifying the feasibility of the DUS-FBG system for high-density distributed crack tip sensing.

In order to ensure the effective vibration–reduction and vibration–isolation of the steel spring floating plate rail and meet the safe operation requirements of the subway, a Fiber Bragg Grating (FBG) displacement sensor for the deformation monitoring of the subway floating plate is proposed. The sensor adopts double FBGs to realize temperature self-compensation. The elastic ring is used as the elastic conversion structure after the fiber grating is pre-stretched; the two ends are pasted and fixed in the groove in the diameter direction of the ring, which avoids the waveform distortion caused by the full pasting of the fiber grating. The combination of linear bearing and displacement probe rods can increase stability and reduce friction loss so that the sensor has the advantages of high sensitivity and accurate measurement results. The test results and error analysis show that in the range of 0~20 mm, the sensitivity of the sensor is 164.2 pm/mm, the accuracy reaches 0.09% F.S, and the repeatability error and hysteresis error are only 1.86% and 0.99%, respectively. The thermal displacement coupling experiment proves that the sensor has good temperature self-compensation performance. It provides a new technical scheme for the effective monitoring and condition assessment of the built-in steel spring floating plate rail.