sensor and actuator functions are integrated into structures to control their mechanical properties in a. âsmartâ way. Adaptronics is inspired by nature ...
Actuator & Sensor Integration for Adaptronic Applications
CIMTEC 2012
Archivierungsangaben
Prof. Dr.-Ing. Thilo Bein
Montecatini Terme, Tuscany, Italy June 10 - 14, 2012
Outline
Die Kunst
der Anpassung
Brief Introduction to Adaptronics Adaptronics Selected Applications
Actuators & Sensors for Adaptronics
Requirements and Challenges
Actuator & Sensor development within the LOEWE-Center AdRIA
Selected Applications
Summary
Die Kunst
Adaptronics ... inspired by nature
der Anpassung
... sensor and actuator functions are integrated into structures to control their mechanical properties in a „smart“ way. Adaptronics is inspired by nature
Adaptronics ... inspired by nature
Die Kunst
der Anpassung
Technical application areas
Customer‘s advantages
Active vibration control (AVC)
Active structural acoustic control (ASAC)
structural loadings, durability,
Active shape control
lightweight design,
Structural Health Monitoring (SHM)
functions
Structural Health Control (SHC)
Optimization of
Increase of comfort and safety
On-demand maintenance
Die Kunst
The basic smart (multifunctional) material
der Anpassung
Electric Field Magnetic Field Heat Light
Electric Charge Resistance, Inductivity Resistance Light Intensity
Actuator Piezoceramics Piezopolymere Electrostrict. ceramics Electroviskose Fluids Polymergele
LPA
Quelle: EMK, TU Darmstadt
Magnetostrict. Alloys Magnetoviskose Fluids
Mechanical force, deformation, etc…
Shape Memory Alloys Memorypolymere Hybrid material systems Polymergele Polymergele Electrostrictive materials Photomechanic Materials Optical Fibres
Quelle: mNemoScience
Sensor ETREMA
Basic working principle
Die Kunst
der Anpassung
Brain
Nerves
a) FS
Actuator
Control of the structureborne sound path Sensor
Controller
c)
Muscels
b)
Die Kunst
Most prominent active structure solutions from market view
der Anpassung
discrete interfaces to isolate / damp motors, aggregates, etc. distributed flat transducers to damp plate-like structures e.g. for oil pan, door,
housing
add-on systems e.g. for active or adaptive absorption or broad band vibration
reduction with proof mass absorbers, inertial exciters / compensators
new actuators e.g. for switching / modification of the load situation in structures
e.g. for crash applications and load control, substitution of conventional drives (electric flap drives), smart fluid dampers
Structure integrated damage (health) monitoring (vibration based) Systems for energy harvesting
via active, semi-active or passive approaches – both adaptronic and mechatronic
Die Kunst
Application of Intelligent Material Systems - Examples
der Anpassung
Concept • AVC – Active Vibration Control - Vibrations • ASAC – Active Structural Acoustic Control – Vibro-Acoustics • SHM – Structural Health Monitoring • Safety
discrete active mountings e.g. suspension strut AVC / ASAC
Vibration-based condition monitoring e.g. tie rod SHM
planar actuators e.g. damping of side-door ASAC switching systems e.g. variable stiffness for side-crash Safety
The LOEWE-Center AdRIA
Die Kunst
der Anpassung
Establishing Darmstadt as leading center for Adaptronics in Europe
Competences h_da
Competences FhG-LBF
Cornerstones beyond LOEWE: FhE Adaptronics Research focal point Adaptronics at the TUD
h_da – function integrated lightweight design
Competences TU Darmstadt (6 faculties with 22 professors)
complemented by four additional LOEWE-Professorships
Die Kunst
der Anpassung
The LOEWE-Center AdRIA
Outline
Die Kunst
der Anpassung
Brief Introduction to Adaptronics Adaptronics Selected Applications
Actuators & Sensors for Adaptronics
Requirements and Challenges
Actuator & Sensor development within the LOEWE-Center AdRIA
Selected Applications
Summary
Requirements and challenges - Actuators
Die Kunst
der Anpassung
• positioning of the load application
load application
• design of the load application • operational conditions (interdependency)
actuator
• actuating principle / transducer material • efficiency / sensitivity / performance • controllability / reproducibility
power electronics control
• power requirements • amplifier
Requirements and challenges - Sensors
Die Kunst
der Anpassung
New sensors acceleration velocity displacement strain force impedance sound power or intensity corrosion others Performance / Constraints sensitivity sensor range frequency range power consumption multiple sensing harsh environment transparency
“new” physical values or new ways of sensing
miniaturization / sensitivity
collocated sensor (force & velocity in one unit) without microphone
e.g. speed of fluids
“new” applications (ASAC, SHM, ….)
widened spectrum due to new applications
energy efficiency different type of sensor information from one unit high temperature, aggressive media,… acoustic applications
Die Kunst
Requirements and challenges – Actuators & Sensors
der Anpassung
System integration miniaturization integration powering (battery vs. self-sustaining) weight data processing & communication wired vs. wireless data preprocessing re-configurable self-calibration large number of sensors Reliability & Life-Cycle life-time environmental conditions data quality & security manufacturability & costs
research topics within Adaptronics
Example - towards sensor modules
Die Kunst
der Anpassung
smart sensor module communication (wired/wireless) signal processing input
sensor element
signal conditioning
self-calibrating data preprocessing re-configurable
self-sustaining powering non-sensorial functions
smart information
Outline
Die Kunst
der Anpassung
Brief Introduction to Adaptronics Adaptronics Selected Applications
Actuators & Sensors for Adaptronics
Requirements and Challenges
Actuator & Sensor development within the LOEWE-Center AdRIA
Selected Applications
Summary
Die Kunst
der Anpassung
Materials & Design: seismic sensor for active mounts Direct pulsed-laser deposition of PZT on spring steel (transparent thin layers)
design of the seismic sensor
Frequency range: 0,7 – 100 Hz Eigenfrequency: >500 Hz) Sensitivity: 1 V / m/s² Dimension: 68 x 40 x 33,5 mm³
Source: TUD-MaWi, L. Alff & LBF
Die Kunst
der Anpassung
Materials & Design: piezoelectret accelerometer for ASAC piezoelectret, stable up to 90°C
12 mm 40 mm shielded sensor with a seismic mass
Source: TUD-MaWi & TUD-SzM J. Hillenbrand, P. Pondrom
Die Kunst
Materials & Design: piezoelectret accelerometer for ASAC
der Anpassung
10
15 Wandler LP01 - Frequenz: 100 Hz Wandler LP01 - Frequenz: 200 Hz Wandler LP01 - Frequenz: 500 Hz Wandler LP01 - Frequenz: 1000 Hz Wandler LP01 - Frequenz: 1500 Hz Wandler LP01 - Frequenz: 2000 Hz
14 13 1 10
100
1000
frequency [Hz]
sensitivity [pC/g]
sensitivity [pC/g]
100
12 11 10 9 8 7 6 5
0,1
1
acceleration [g]
Source: TUD-MaWi & TUD-SzM J. Hillenbrand, P. Pondrom
Die Kunst
Miniaturisation & Manufacturing: piezoresistive strain sensors
der Anpassung
Si-Chips high degree of miniaturisation (A = 0,25 mm2) high sensitivity (50x higher than conventional DMS) Printed Low-Cost-Sensors integrated in the manufacturing process sensitivity similiar conventional DMS
Si-Chips
printed
characteristics under static loading
Source: TUD-EMK, Werthschützky & Rausch TUD-IDD, Dörsam & Griesheimer
Integration & Manufacturing
Die Kunst
der Anpassung
Use of screen printing and Inkjet to produce functional structures Silberstruktur
2. Schicht Iso 1. Schicht Iso Blech
Maintaining the functionality of the sensor after forming processes
Functionality up to 20 % strain maintained
Silver: up to 33 % strain
Isolation: up to 35 % strain
Source: TUD-IDD, TUD-PTW & TUD-PtU Dörsam, Abele, Groche, et.al.
Integration & Manufacturing
Die Kunst
der Anpassung
Smart (curved) panels for active structural acoustic control (ASAC) Embedded circuit pathes
Printed circuit pathes Printed sensors
embedded actuators
Source: TUD-IDD, TUD-PTW & TUD-PtU Dörsam, Abele, Groche, et.al.
Selective laser melting of active struts
der Anpassung
Dehnung [µm]
Die Kunst
36 50 V 100 V 150 V 200 V
30 24 18
CAD-Modell
12 6 0
integration of actuator
0
300
600
900
1200 Kraft [N]
active strut
Source: TUD-PTW & LBF
Adaptive lightweight absorbers
Die Kunst
der Anpassung
design
manufacturing F F
Amplitude
Sum FRF Kontakte kurzgeschlossen 1.00 Sum FRF Kontakte offen
dB
Transmissibilität [(m/s²)/N] Unknown ()
30.00
testing
70.70 72.54
-20.00 0.00
0.00 Hz
Frequenz [Hz]
300.00
Source: h_da & LBF
Die Kunst
High performing active mounts
der Anpassung
hybrid, active mount with parallel load application
Source: LBF
Outline
Die Kunst
der Anpassung
Brief Introduction to Adaptronics Adaptronics Selected Applications
Actuators & Sensors for Adaptronics
Requirements and Challenges
Actuator & Sensor development within the LOEWE-Center AdRIA
Selected Applications
Summary
Die Kunst
Active engine mount for a passenger car
der Anpassung
piezo based active engine mount for 2nd order attenuation
design of an actuator module
active engine mount
control system
test at chassis dyna
results for acceleration control (z)
results for SPL control
Die Kunst
Smart actuators for side impact crashworthiness
der Anpassung
Release time < 70 ms / 100 mm stroke
Implemented locking device, integrated electronics with CAN-link, compatible with the board net
Die Kunst
der Anpassung
Smart actuators for side impact crashworthiness
Die Kunst
der Anpassung
Active noise abatement - active façades
Die Kunst
Structural health monitoring - vibration analysis
der Anpassung
automated determination of modal parameters
Operational Modal Analysis
smart sensor networks
long term data acquisiton
developement of hardware and algorithms
Die Kunst
Energy Harvesting
der Anpassung
Numerical und experimental system optimization – mechanical structure, piezo transducers, electronics System integration of transducers, power management electronics and storage Development of resonant energy converters Energy harvesting with dielectric polymers Integration of energy harvesting into vibration absorbers for combined absorber-monitoring systems
Self-sustaining absorber-sensor-modules
Die Kunst
der Anpassung
Combination of absorber and sensor function into a self-sustaining module
sensor- and/or communication module
sensor
mass energy
EAP
excitation
spring, damper
excitation
Self-sustaining absorber-sensor-modules
Die Kunst
der Anpassung
absorber passive
centralised control centralised monitoring Control of excitation
excitation (Shaker)
a [dB]
Network of adaptive absorbers
Frequenz [Hz]
mounting (passive)
absorber with mit local control (SSAP) local monitoring(SSP)
a [dB]
absorber adaptiv
Frequenz [Hz]
Outline
Die Kunst
der Anpassung
Brief Introduction to Adaptronics Adaptronics Selected Applications
Actuators & Sensors for Adaptronics
Requirements and Challenges
Actuator & Sensor development within the LOEWE-Center AdRIA
Selected Applications
Summary
Summary
Die Kunst
der Anpassung
• Adaptronics is an innovative technology for •
active noise and vibration control
•
form and position control
•
energy harvesting and structure health monitoring
• In the past, the R&D focus was more on multifunctional materials, actuator design, control and design methodologies • whereby today system integration including sensors, manufacturing and reliability is being more and more considered • Adaptronics requires •
new types of actuators & sensors
•
a very high degree of integration
•
multifunctionality of actuator & sensor modules
Special thanks to my colleagues
LOEWE-Center AdRIA Institute for Electromechanical Design EMK, Prof. R. Wertschützky, J. Rausch Department of Materials and Earth Sciences, Prof. L. Alff Institute of System Reliability and Machine Acoustics, J. Bös, P. Pondrom Institute of Printing Science Technologies, Prof. E. Dörsam, S. Griesheimer Institute of Production Management, Technology and Machine Tools (PTW), Prof. E. Abele, J. Fischer Institute of Production Engineering and Forming Machines (PtU), Prof. P. Groche, M. Ibis Research Group Embedded Systems and Applications, Prof. A. Koch, A. Engel Research Group Microelectronical Systems, Prof. M. Glesner, F. Samman University of Applied Sciences Darmstadt, Prof. A. Büter Fraunhofer LBF, M. Kauba, M. Koch, T. Bartel
Thank you for your attention! AdRIA
Adaptronik - Research, Innovation, Application
