2013 12-05-sirris-materials-workshop-smart-composites-luyckx-kinet
DESCRIPTION
Sirris Materials Workshop - 5 december 2013 - Monitoring composite structures with fibre optic sensors - Geert Luyckx, UGent and Damien Kinet, MultitelTRANSCRIPT
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Smart CompositesMonitoring composite structures with optical fibers
Geert Luyckx
Damien Kinet
15.12.13© sirris | www.sirris.be | [email protected] |
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1. Objective2. Rationale
A. Production and assembly monitoringB. Operation/Health monitoring
3. Sensor technologies4. Envisaged applications5. Research consortium6. Research approach7. Industrial user consortium
� Life cycle of a composite structure
� Production and assembly monitoring
� Application monitoring
� Opportunities
� Novel technologies
� Applications
� Health monitoring in marine environment
Overview
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Life cycle of a composite structure
“Life cycle monitoring of large-scale CFRP VARTM structure by fiber-optic-based distributed sensing,”
S. Minakuchi, et. al., Composites Part A, 42(6),669-676 (2011)
MA
NU
FA
CT
URIN
GM
AN
UFA
CT
URIN
GM
AN
UFA
CT
URIN
GM
AN
UFA
CT
URIN
G
Assem
bly
Assem
bly
Assem
bly
Assem
bly
UseUseUseUse PhasePhasePhasePhase
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Life cycle monitoring: Wind turbine
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Assembly
Exploitation
DesignProductionProductionProductionProduction
Life cycle monitoring: Wind turbine
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Production monitoring & opportunities
ProductionProductionProductionProduction Today
� Thermocouples
� Pressure sensors
� Ultrasonic inspection
No sensor able to predict initial strain state!
Opportunities
� Initial strain state (residual strains)
e.g. with embedded sensors (Fiber optics, Polymer waveguides,…)
� In-situ Cure monitoring e.g. with ultrasonic transducers, Fresnel reflection, capacitive sensing,…
� NECESSITY FOR MULTI-INSTRUMENTATION
ProductionProductionProductionProduction
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Technology: Fiber Bragg Gratings
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Optical fiberOptical fiberOptical fiberOptical fiberOptical fiberOptical fiberOptical fiberOptical fiber
Combination of Optical fibers and Ultrasound
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Combination of Optical fibers and Ultrasound
2 regions:1. Composite does not exist! Resin in a fluid state2. Composite exist � strain transfer
1111 2222Gelation
Ultrasound
Temperature
FBG�strain
Residual strain magnitude
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Assembly monitoring & opportunities
Assembly+
Finishing
Today
� Visual inspection
Opportunities
� Embed sensors in adhesive zone
� Use finishing layer as sensor (coating)?
� Ageing sensors?
� Impact damage, tool drop
� Speed of monitoring
� event measurement or offline monitoring
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Follow-up of bonded structures
Initiated cracks reach sensor
Safety level
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Exploitation
Design
Application monitoring & opportunities
Today� Visual inspection
� Load monitoring (edge, flap, combined)
� External strain gauges
No information from the inside
Opportunities� Pitch control (blade deformation)
� predict life time blades
� Use material as sensor (CNT, CB,…), Digital Image Correlation?
� Design support tool
� Reduce costly inspection
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Pitch control monitoring
� MOOG inc: System to Adjust Windmill Wing Pitch Angle
www.moog.com/markets/energy/wind-turbines/
� Provide edgewise and flap wise bending moment data to the individual pitch control system.
� 10-20% of load reduction in the blades
� 20-30% in the main shaft
� Life time ↑↑
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� Read-out and integration
� Cost and size of interrogator system
� Go for less performing system?
� More dedicated?
� Cheaper?
� Number of sensors needed to monitor structure?
� The least possible (design or exploitation)
� Reparability: Sensor should survive the structure with 100% certainty or possibility for repair
� Prediction of Eigenfrequenciesvia online strain date
� Relation of the sensor signal with the real situation
Composite life cycle monitoring: DifficultiesOpportunities
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� Micro-structured optical fibers
� Polymer waveguides
� Deformable electronics
Novel sensor technologies
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Structural Health Monitoringapplied to Marine Applications
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Structural Health Monitoringapplied to Marine Applications
� Development of FBG sensors based on silica & plastic optical fibres
� Investigating sensor embedding processes and positioning the optical fibres at different layers according to the strains to monitor
� Developing a complete catamaran in carbon fibre reinforced polymer which will be used for further investigation and embedding of smart components
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Structural Health Monitoringapplied to Marine Applications
� Developing low cost optical interrogator
� Physical validation for finite element simulation
• Real-time strain monitoring• Composite material properties investigation• Broken down and failure detection
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Simulation
SensorFabrication
SensorEmbedding
SensorInterrogation
SensorEvolution
Structural Health Monitoringapplied to Marine Applications
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8.90m
9.25m
15.25m
17.75m
1.10m
0.70m
0.70m
Spreader
Fibre Bragg gratings
Location of the future housing connectors
Shrouds
Front view: Schematic representation
Preliminary tests
• More then 60 FBGs were glued on the catamaran mast
• FBGs realized by the phase mask technique.
• Chirped phase mask: 15nm/cm, length of each FBG: 1mm
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Location of the future housing connectors
Fibre n°1
Fibre n°2Fibre n°3
Fibre n°4
Fibre n°5
Fibre n°7
Fibre n°6
Fibre n°8Fibre n°9
190 mm
35
0 m
m
Shape of the mast base
Base of the mast
Fibres n°1, 4 and 7
Fibres n°3, 6 and 9
Fibres n°2, 5 and 8
Preliminary tests
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Naked mast
Preliminary tests
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Fibre maintained on themast with tape
Preliminary tests
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FBGs are glued on the mastwith epoxy resin
Preliminary tests
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Mast with FBGs
Preliminary tests
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Mast is let free and is only maintained at both extremities
Preliminary tests
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Schematic representation of the mast during this test
Preliminary tests
� We follow the evolution of the Bragg wavelength of the FBGs. As expected:
� The Bragg wavelength shifts of the FBGs of the fibres n°1, 3, 4, 6, 7 and 9 are very small
� The FBGs of the fibres n° 2, 5 and 8 are under compression
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y=-3E-10x4+1E-06x3-0.0012x2-0.078x-19.343
R²=0.92681
-500
-400
-300
-200
-100
0
0 500 1000 1500
Bra
ggw
avele
ngth
shif
t(p
m)
Position(cm)
Preliminary tests
This figure presents the shift of the Bragg wavelength of the FBGs of the fibres n° 2, 5, 8 with an attempt to adjust a curve of the 4th order
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Mast is let free and is only maintained at both extremities but turned on its side
Preliminary tests
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-600
-400
-200
0
200
400
600
1 3 5 7
Bra
ggw
avele
ngth
shif
t(p
m)
N°oftheFBG
Fibre n°4 Fibre n°6
Preliminary tests
� We follow the evolution of the Bragg wavelength of the FBGs. As expected:
� The Bragg wavelength shifts of the FBGs of the fibres n°1, 4 and 7 are under traction.
� The Bragg wavelength shifts of the FBGs of the fibres n°3, 6 and 9 are under compression.
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2nd phase: Embedding
- Realisation of smallgrooves- Optical fibers embedding- Filling of the grooves and protection of the sensorswith epoxy glue
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2nd phase: Embedding
Ingress/egressof the optical fibers
Splicing of the optical fibers
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MPO (Multi-fiber Push-On) connectorbetween the mast and the interrogator
Rapid prototyping of a waterproof housing for the connection. This one will be attached to the mast
2nd phase: Embedding
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Interrogator set-up
…
e-LED
Photodiode &
Data processing
Tunable filter
Optical circulator
FBG 1 FBG x
FBG 1 FBG x
FBG 1 FBG x
Light, small size, low power consuming
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Interrogator set-up
Light, small size, low power consuming
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SBO Self sensing composites
Structural health
monitoring
Production monitoring
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� 2 optical fibers, 10 sensors
� Designed and manufactured by
and
12/5/2013 39
Case: control arm
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5.12.13© sirris | www.sirris.be | [email protected] |
� http://www.sirris.be
� #sirris
� http://www.linkedin.com/company/sirris
� http://techniline.sirris.be