Lessons learned from real-world implementations
Distributed fiber optic sensing (DFOS) has rapidly moved from a niche research tool to a vital technology in aerospace, energy, civil infrastructure, and beyond. With the ability to provide continuous, high-resolution strain and temperature data along the entire length of an optical fiber, DFOS offers insights that conventional single point sensors simply can’t match.
However, as with any advanced technology, the path from initial concept to successful deployment is rarely straightforward. Based on years of experience supporting customers around the globe, Sensuron has identified a few common pitfalls that can derail fiber optic sensing applications – and, more importantly, how to avoid them.
- Overlooking Application-Specific Requirements
The pitfall: One of the most common mistakes is assuming that “any fiber optic sensing system will do” for a given project. In reality the performance of a fiber optic sensing application depends on factors such as required spatial resolution, sensing length, and sampling frequency. Using the wrong technology can add unnecessary costs or compromise results.
How to avoid it: Define the application goals clearly at the outset. Are you monitoring microstrain changes in an aircraft component, or detecting thermal hot spots along an energy pipeline? Different applications call for different sensing strategies. Sensuron’s OFDR-based systems, for instance, excel when ultra-high spatial resolution and accuracy are critical.
- Neglecting Best Practices for Sensing Fiber Installation
The pitfall: Even the most advanced interrogator can’t compensate for a poor sensing fiber installation. Common issues include improper bonding, excessive bending, or exposing the fiber to environmental stresses that distort readings.
How to avoid it: Treat the optical fiber as the core sensing element it is. Follow established installation guidelines: ensure proper surface preparation, use adhesives compatible with the host material, and avoid sharp bends or mechanical stress. Sensuron often recommends small-scale preliminary tests before large rollouts to validate installation techniques in real-world conditions.
- Underestimating Data Management Challenges
The pitfall: DFOS generates an enormous amount of data—typically orders of magnitude more than conventional sensing systems. Without a clear strategy, users can quickly become overwhelmed, leading to slow analysis and missed insights.
How to avoid it: Plan for data management as part of the sensing system design. Consider how often you’ll need measurements, how you’ll store them, and what level of processing will be required in real time. Many Sensuron customers integrate their DFOS output into existing monitoring platforms, using analytics to focus on actionable trends rather than raw data overload.
- Failing to Account for Environmental Factors
The pitfall: Fiber optic sensors are sensitive to both strain and temperature. Without careful design, it’s easy to misinterpret temperature-induced shifts as strain events—or vice versa.
How to avoid it: Use appropriate compensation and calibration strategies. For some applications, this may mean installing reference sensors that only measure temperature; in others, it may involve advanced modeling. Sensuron’s OFDR technology offers the precision needed to separate and account for these effects, ensuring measurement accuracy.
- Treating DFOS as an Equivalent Replacement for Traditional Sensors
The pitfall: Engineers sometimes assume that distributed fiber optic sensing can be deployed in the same way as traditional point sensors. This leads to mismatched expectations and underutilization of the technology’s capabilities.
How to avoid it: Reframe how you think about measurement. DFOS provides continuous profiles rather than isolated data points. This opens up entirely new approaches to structural monitoring, system validation, and predictive maintenance. By designing your monitoring program around DFOS’s strengths, you can maximize return on investment.
Turning Challenges into Opportunities
When implemented thoughtfully, distributed fiber optic sensing delivers game-changing insights that improve safety, efficiency, and reliability. The key is to anticipate the challenges before they arise.
At Sensuron, we’ve helped customers across a variety of industries overcome these pitfalls—transforming ambitious sensing projects into reliable, long-term solutions. If you’re considering DFOS for your next application, our team can help you avoid these common mistakes and design a system that meets your project requirements and business goals.
Ready to get started? Contact Sensuron to discuss your application and learn how OFDR-based DFOS can deliver the insights you need.