
Failure Analysis and Engineering Optimization of an In-vessel Fiber-optic Current Sensor Routing Structure in the EXL-50U Spherical Tokamak
Jia Li, Dong Guo, Liu Shuo, Lombroni Riccardo, Zhixin Wang, Renyi Tao, Yumin Wang, Yuejiang Shi
Plasma current measurement is essential for tokamak equilibrium, control, and machine protection. Fiber-optic current sensors (FOCS) provide electrical isolation and immunity to electromagnetic interference, while their metallic in-vessel protective routes remain subject to electromagnetic loads and vacuum-boundary constraints. An annealed-copper FOCS protective tube in EXL-50U developed a vacuum leak, and inspection found localized flattening, rubbing, blackened surfaces, and fracture-like damage near center-column supports. Possible failure mechanisms were assessed using the assembly geometry, inspection evidence, electromagnetic estimates, and an idealized ring-compression reference. A representative normal toroidal-field (TF) ramp gives a loop current scale of approximately 1.4 kA and a distributed line load of 3.2 N/mm. A representative 500 kA vertical displacement event yields a toroidal-flux change of about 0.0639 Wb over a 0.1 ms output interval, corresponding to a finite-difference voltage scale of 639 V. An ideal impulse calculation gives currents of 1.6–12.8 kA for the assumed coupling and inductance range. The estimates show the scale of possible electromagnetic loading, but do not determine the local flattening threshold or the exact cause of failure. The observations suggest that tube motion against relatively rigid surrounding structures contributed to local deformation and possible electrical or thermal damage. The revised design uses a 316L stainless-steel tube, additional supports, polyimide insulation at support interfaces, and improved seals. We also discuss the design limitations and a ceramic electrical break as an alternative.





