In the automotive industry, there has been considerable focus on developing various sensors for engine oil monitoring. However, when it comes to monitoring the condition of brake fluid, which is crucial for ensuring safety, there has been a lack of a secure online method for this monitoring. This study addresses this gap by developing a hybrid silica nanofiber mat, or an aerogel integrated with an optical fiber sensor, to monitor brake fluid condition. The incorporation of silica nanofibers in this hybrid enhances the sensitivity of the optical fiber glass surface by at least 3.75 times. Furthermore, creating an air gap between the glass surface of the optical fiber and the nanofibers boosts sensitivity by at least 5 times, achieving a better correlation coefficient (R2 = 0.98). In the case of silica aerogel, the sensitivity is enhanced by 10 times, but this enhancement relies on the presence of the established air gap. The air gap was adjusted to range from 0.5 mm to 1 mm, without any significant change in the measurement within this range. The response time of the developed sensor is a minimum of 15 min. The sensing material is irreversible and has a diameter of 2.5 mm, making it easily replaceable. Overall, the sensor demonstrates strong repeatability, with approximately 90% consistency, and maintains uncertainty levels below 5% across specific ranges: from 3% to 6% for silica aerogel and from 5% to 6% for silica nanofibers in the presence of an air gap. These findings hold promise for integrating such an optical fiber sensor into a car's electronic system, enabling the direct online monitoring of brake fluid quality. Additionally, the study elucidates the effect of water absorption on the refractive index of brake fluid, as well as on the silica nanomaterials.
Keywords: air gap; electrospinning; humidity; intensity modulated optical fiber sensor; moisture sensors; optical fiber sensor; optical properties of nanofibers and aerogel; refractive index of nanofibers; sensitivity; silica aerogel; silica nanofibers.