TY - CONF A1 - Wosniok, Aleksander A1 - Schukar, Marcus A1 - Breithaupt, Mathias A1 - Kriegsmann, Andreas T1 - Distributed Fibre Optic Monitoring of Hydrogen Storage Composite Pressure Vessels for Automotive Use N2 - We present our research work on the condition monitoring of hydrogen storage composite pressure vessels using distributed fibre optic sensors. The sensing fibres are integrated into the composite structure by wrapping them over the polymer liner in the helical and circumferential direction during the manufacturing process of the carbon fibre reinforced polymer. The following use of optical backscatter reflectometry allows for continuous condition monitoring and precise detection and localization of structural damages during the entire service life. To account for the time-dependent strength degradation of the composite pressure vessels, both slow burst and ambient hydraulic cycling tests, respectively, were conducted on five 70 MPa pressure vessels with integrated fibre optic sensors. The results achieved via distributed fibre optic strain sensing demonstrate a near linear strain response to pressure suitable for sensitive condition monitoring and confirm the required robustness of the selected sensor solution. T2 - DGZfP-Jahrestagung 2025 CY - Berlin, Germany DA - 26.05.2025 KW - Distributed fibre optic sensor (DFOS) KW - Composite pressure vessel KW - Optical backscatter reflectometry KW - Slow burst test KW - Ambient hydraulic cycling test PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-653067 DO - https://doi.org/10.58286/32344 SP - 1 EP - 8 PB - NDT.net AN - OPUS4-65306 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Popiela, Bartosz A1 - Schukar, Marcus A1 - Breithaupt, Mathias A1 - Günzel, Stephan A1 - Mair, Georg W. A1 - Krebber, Katerina A1 - Seidlitz, Holger T1 - Embedding of Fiber Optic Sensors Under Industrial Conditions and Distributed Strain Sensing in Type 4 Composite Pressure Vessels N2 - The number of in-operation composite pressure vessels is increasing, partly due to their attractiveness for on-board compressed gas storage and transport applications. A possible way to maintain the highest safety levels is through the structural health monitoring of the composite cylinders. Here, the use of fiber optic sensors appears to be a promising approach. However, the integration of the optical fibers into the composite structure of a pressure vessel has been shown to be challenging. In this study, insights on the embedding of optical fibers in the composite structure under industrial conditions are provided. A protection concept for the ingress and egress of the optical fibers is presented. Finally, the results from destructive slow burst tests are evaluated, showing no clear trend in the impact of the embedded optical fibers on the performance of composite pressure vessels. T2 - 24th International Conference on Composite Materials CY - Baltimore, Maryland, USA DA - 04.08.2025 KW - Composite KW - Pressure vessel KW - Filament winding KW - Fiber optic sensors PY - 2025 SP - 3710 EP - 3717 AN - OPUS4-63886 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Wang, Kun A1 - Lu, Xin A1 - Schukar, Marcus A1 - Hicke, Konstantin T1 - Water absorption effects on distributed temperature sensing using polyimide-coated optical fiber N2 - Polyimide-coated fibers are becoming more popular for distributed temperature sensing (DTS) because this coating can withstand much higher temperatures than the standard acrylate coating. As a hygroscopic material, polyimide can absorb water from the air, changing its properties, which may result in a modified temperature response of the sensing fiber. This study investigates the effect of water absorption on the performance of polyimide-coated optical fibers with different sizes and properties. The thermal response of these fibers was determined experimentally from 20°C to 90°C at a broad relative humidity level ranging from 10% to 90%. The results show that all the fibers experienced a decrease in temperature sensitivity as humidity increased, with the most noticeable non-linear spectral shift observed at higher humidity levels. These findings highlight the importance of optimizing fiber design and coating properties to balance stability and sensitivity, ensuring the reliable performance of DTS systems under extreme environmental conditions. T2 - 29th International Conference on Optical Fiber Sensors CY - Porto, Portugal DA - 26.05.2025 KW - Humidity sensing KW - Distributed temperature sensing KW - Optical fiber sensors KW - Temperature sensing KW - Water absorption KW - Polyimide-coated fiber PY - 2025 SN - 978-1-5106-9187-2 DO - https://doi.org/10.1117/12.3062748 VL - 13639 SP - 136393W-1 EP - 136393W-4 PB - SPIE AN - OPUS4-63642 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Karapanagiotis, Christos A1 - Schukar, Marcus A1 - Breithaupt, Mathias A1 - Hicke, Konstantin T1 - Toward a Digital Twin of Hydrogen Pressure Vessels Enabled by Distributed Fiber Optic Sensors N2 - We present a digital replica of a hydrogen pressure vessel enabled by distributed fiber optic sensors (DFOS). This digital replica dynamically displays and updates the vessel’s structural condition by calculating strain residuals defined as the difference between the measured DFOS strain and the expected strain based on pressure data. As an example, we show the ability of the DFOS to detect and localize damage caused by drilling six holes into the vessel’s body. This digital replica represents a foundational step toward a fully integrated digital twin for predictive maintenance and remaining lifetime prognosis. T2 - Sensor and Measurement Science International (SMSI) 2025 CY - Nuremberg, Germany DA - 06.05.2025 KW - fiber optic sensors KW - digital twin KW - structural health monitoring KW - hydrogen KW - machine learning PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-633885 UR - https://www.ama-science.org/proceedings/details/5962 SN - 978-3-910600-06-5 DO - https://doi.org/10.5162/SMSI2025/C6.1 SP - 165 EP - 166 PB - AMA Service GmbH CY - Wunstorf AN - OPUS4-63388 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Lu, Xin A1 - Schukar, Marcus T1 - Humidity response analysis of optical fibers with hygroscopic coatings based on Lamé’s equations N2 - Optical fibers with hygroscopic coatings are widely used for humidity sensing, where the coating expands upon absorbing water, inducing strain in the fiber. This strain is then used to determine humidity. However, previous studies have oversimplified the strain generation process. A comprehensive three-dimensional model of the mechanical interaction between the coating and the fiber is built based on Lamé’s equations. An analytical expression for the induced strain is derived. The proposed model predicts larger humidity-induced strain compared to the reported ones, given the same Young’s modulus or coefficient of humidity expansion for the coating. Interestingly, the effect of coating thickness on strain response are quite similar for both methods. Experimental validation using fibers with a polyimide coating shows strong agreement with the theoretical predictions. T2 - 29th International Conference on Optical Fiber Sensors CY - Porto, Portugal DA - 26.05.2025 KW - Reflectometry KW - Distributed fiber sensing KW - Humidity sensors KW - Lamé’s equations KW - Optical fiber sensors KW - Structural health monitoring KW - Rayleigh scattering PY - 2025 SN - 978-1-5106-9188-9 DO - https://doi.org/10.1117/12.3060891 VL - 13639 SP - 1 EP - 4 PB - SPIE AN - OPUS4-63257 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Karapanagiotis, Christos A1 - Schukar, Marcus A1 - Breithaupt, Mathias A1 - Krebber, Katerina T1 - Monitoring of composite pressure vessels using surface applied distributed fiber optic sensors N2 - In this paper, we report on surface-applied distributed fibre optic sensors for monitoring composite pressure vessels designed for hydrogen storage. Previous reports have revealed that integrating optical fibres within vessel composite structures effectively enables the monitoring of structural behavior throughout their lifetime. However, integrating optical fibres during the manufacturing process is complex and time-consuming. Therefore, we aim to simplify this process by attaching the optical fibres to the vessel’s surface. This method is significantly more timeefficient than the integration process and can be applied to any vessel. Our results demonstrate that surface-applied fibre optic sensors can detect and precisely localise damage. Additionally, signs of damage can be recognised even before the damage occurs. Predictive maintenance using fibre optic sensors could reduce premature maintenance costs and periodic inspections while increasing safety and extending the vessel’s useful service life. The role of machine learning in predictive maintenance is also discussed. T2 - 20th Sensors & their Applications Conference CY - Limerick, Ireland DA - 11.08.2024 KW - Hydrogen KW - Fiber optic sensors KW - Composites KW - Machine learning KW - Structural health monitoring PY - 2024 SP - 1 EP - 4 AN - OPUS4-60911 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Wosniok, Aleksander A1 - Schukar, Marcus A1 - Woody, Paul A1 - Wang, Bin A1 - Breithaupt, Mathias A1 - Kriegsmann, Andreas T1 - Distributed fiber optic strain sensing for structural health monitoring of 70 MPa hydrogen vessels N2 - We report on the development and testing of 70 MPa hydrogen pressure vessels with integrated fiber optic sensing fibers for automotive use. The paper deals with the condition monitoring of such composite pressure vessels (CPVs) using the optical backscatter reflectometry (OBR) applied for a distributed fiber optic strain sensing along fully integrated polyimide-coated single-mode glass optical fiber (SM-GOF). The sensing fibers were embedded into the vessel structure by wrapping them over the polymer liner during the manufacturing process of the carbon fiber reinforced polymer (CFRP). Detecting local strain events by the integrated fiber optic sensors can be an opportunity for monitoring the material degradation of CPVs under static and cyclic loading. T2 - 11th European Workshop on Structural Health Monitoring CY - Potsdam, Germany DA - 10.06.2024 KW - Fiber optic sensor KW - Distributed strain sensing KW - Composite pressure vessel KW - Structural health monitoring KW - Fiber-reinforced plastics PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-603105 SP - 1 EP - 8 PB - NDT.net AN - OPUS4-60310 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Karapanagiotis, Christos A1 - Heimann, Jan A1 - Duffner, Eric A1 - Charmi, Amir A1 - Schukar, Marcus A1 - Hashemi, Seyedreza A1 - Prager, Jens T1 - Towards predictive maintenance of hydrogen pressure vessels based on multi-sensor data fusion and digital twin modeling N2 - Hydrogen pressure vessels are among the most essential components for reliable hydrogen technology. Under current regulations, a mostly conservative strategy is employed, restricting the usage time of hydrogen pressure vessels without providing information on the real remaining lifetime. During the service life, pressure vessels are inspected periodically. However, no established method that can provide continuous monitoring or information on the remaining safe service life of the vessel. In this paper, we propose a sensor network for Structural Health Monitoring (SHM) of hydrogen pressure vessels where data from all sensors are collected and centrally evaluated. Specifically, we integrate three different SHM sensing technologies namely Guided Wave ultrasonics (GW), Acoustic Emission testing (AT), and distributed Fiber Optic Sensing (FOS). This integrated approach offers significantly more information and could therefore enable a transition from costly and time-consuming periodic inspections to more efficient and modern predictive maintenance strategies, including Artificial Intelligence (AI)-based evaluation. This does not only have a positive effect on the operational costs but enhances safety through early identification of critical conditions in the overall system in real-time. We demonstrate an experimental set-up of a lifetime test where a Type IV Composite Overwrapped Pressure Vessel (COPV) is investigated under cyclic loading instrumented with AT, FOS, and GW methods. We acquired data from the sensor network until the pressure vessel failed due to material degradation. The data collected using the three different SHM sensor technologies is planned to be evaluated individually, using data fusion, and AI. In the future, we aim to integrate the measurement setup into a hydrogen refueling station with the data stream implemented into a digital signal processing chain and a digital twin. T2 - 11th European Workshop on Structural Health Monitoring CY - Potsdam, Germany DA - 10.06.2024 KW - Acoustic emission KW - Ultrasonic guided waves KW - Fiber optic sensors KW - Hydrogen KW - Pressure vessels KW - Structural health monitoring KW - Machine learning PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-602764 UR - https://www.ndt.net/search/docs.php3?id=29702 SP - 1 EP - 8 PB - NDT.net AN - OPUS4-60276 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Karapanagiotis, Christos A1 - Schukar, Marcus A1 - Breithaupt, Mathias A1 - Duffner, Eric A1 - Ulbricht, Alexander A1 - Prager, Jens A1 - Krebber, Katerina T1 - Structural health monitoring of hydrogen pressure vessels using distributed fiber optic sensing N2 - We report on distributed fiber optic sensing-based monitoring of hydrogen composite overwrapped pressure vessels (COPV) to simultaneously increase the operational lifespan and mitigate maintenance costs. Our approach represents, to the best of our knowledge, the first application of distributed fiber optic sensing for COPV Type IV monitoring, where the sensing fibers are attached to the surface, rather than integrated into the composite material. Specifically, we attach an optical fiber of 50 m to the pressure vessel's surface, covering both the cylindrical and dome sections. We note that our fiber optic sensing technique relies on swept wavelength interferometry providing strain information along the entire length of the optical fiber with high spatial resolution even at the millimeter scale. When the vessel is pressurized, the sensing optical fiber shows a linear strain response to pressure at every position along the fiber. After thousands of load cycles, the vessel finally fails with the optical fiber detecting and precisely localizing the damage in the vessel’s blind dome area. Furthermore, we discuss the potential of state-of-the-art signal processing methods and machine learning for advancing predictive maintenance. This could reduce the number of regular inspections, mitigate premature maintenance costs, and simultaneously increase the vessel’s remaining safe service life. We believe that the structural health monitoring of hydrogen pressure vessels with fiber optic sensors can enhance trust in hydrogen technology contributing to the energy transition in the future. T2 - 11th European Workshop on Structural Health Monitoring CY - Potsdam, Germany DA - 10.06.2024 KW - Hydrogen KW - Fiber optic sensors KW - Composites KW - Machine learning KW - Structural health monitoring PY - 2024 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-602731 UR - https://www.ndt.net/search/docs.php3?id=29701 SP - 1 EP - 7 PB - NDT.net AN - OPUS4-60273 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Schilling, Richard A1 - Oehrl, A. A1 - Wischerhoff, E. A1 - Schukar, Marcus T1 - A fibre optic temperature sensor based on thermoresponsive polymer N2 - We present a temperature sensor based on a polymer exhibiting a Lower Critical Solution Temperature (LCST) in aqueous solution encapsulated in a capillary. Parameters are chosen such that the solution exhibits a cloud point in a temperature range of 30° C to 39°C. The characteristic of thermoresponsive polymers with an LCST, is that above that temperature phase separation of the polymer takes place which leads to a temperature-dependent formation of a cloudy suspension. An optical intensity measurement over the desired temperature range is established by an increase of optical attenuation inside the polymer solution caused by a rising temperature. For our purpose, the polymer capillary is connected to transmitter and receiver via a Polymer Optical Fibre (POF). Our intensity measurement is, to the best of our knowledge, a novel method and can be considered simple when compared to existing fibre-based temperature measurement techniques. Due to the lack of electrical components at the probe, this sensor is suitable for measurements in strong electromagnetic fields and environments for which flying sparks are hazardous, i.e., inflammable fluids or gases. Furthermore, all manufactured sensors share the same temperature dependence and, therefore, are well-suited for comparative measurement, e.g., flow measurement systems. With the given temperature range, a body temperature measurement is also suitable. T2 - European Workshop on Optical Fibre Sensors (EWOFS 2023) CY - Mons, Belgium DA - 23.05.2023 KW - Thermoresponsive polymer KW - Aqueous polymer solution KW - Temperature sensor KW - LCST KW - POF PY - 2023 DO - https://doi.org/https://doi.org/10.1117/12.2678418 SP - 12643-69 PB - SPIE CY - Bellingham, Wash. AN - OPUS4-57735 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -