The detection method based on FBG sensor network can be used for three-dimensional shape sensing of flexible snake shaped instruments. The main goal of this paper is to design a packaging process of miniature shape sensor which can be integrated into flexible medical instruments. In this paper, a novel fiber Bragg grating (FBG) sensor (diameter 1mm, length 260mm) is proposed to measure the shape of flexible robot. The sensor uses four evenly distributed fiber arrays, each of fiber contains three FBG nodes to obtain discrete curvature for shape sensing. First, the sensor packaging positioning device, the optical fiber positioning device, the glue injection method, and the glue type and packaging process of the sensor package are all improved to not only reduce the diameter of the shape sensor but also ensure the success rate of the sensor package and the accuracy of the package positioning. Secondly, the sensor network is designed, and encapsulated by the new encapsulation method. The packaged sensor has six measuring points. Finally, an experimental platform is established to experiment verification. The experimental results of shape reconstruction show that the measurement accuracy of the sensor is about 2.92%, which verifies the practicability of the sensor and the feasibility of the proposed packaging method.
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