Cost-Effective, Contactless Optical Vibration Sensor for Rotating Machinery Based on Fiber-Optic Telecommunication Components and a Cross-Correlation Method

Vibration measurements are essential for the early detection of faults in rotating machinery and are particularly important for hydrogenerators in hydro power plants. Industrial applications of vibration measurements typically rely on displacement, velocity, and acceleration sensors, each offering distinct advantages and limitations. This paper discusses and proposes a cost-effective, contactless optical vibration sensing system based on standard fiber-optic telecommunication components, enabling its integration into existing fiber-optic networks. The proposed system utilizes interferometric sensing principles, providing inherent immunity to electromagnetic interference and galvanic effects while achieving micrometer-scale resolution. The key advancement of the proposed sensor lies in the relatively simple and cost-effective configuration—the realization of the Michelson interferometer. It facilitates a combination of standard optical communication hardware, including a 3 × 3 fiber-optic coupler and two photodetectors for reliable discrimination of vibration displacement directions. The associated signal processing platform is based on a cross-correlation algorithm by which both the direction and the magnitude of displacement are determined. The optical sensor was experimentally validated using a realistic-scenario laboratory setup, which demonstrates the feasibility and performance of the proposed approach.