Vibrational energy harvesting for sensors in vehicles

The miniaturization of semiconductor technology and reduction in power requirements have begun to enable wireless self-sufficient devices, powered by ambient energy. To date the primary application lies in generating and transmitting sensory data. The number of sensors and their applications in automotive vehicles has grown drastically in the last decade, a trend that seems to continue still. Wireless self-powered sensors can facilitate current sensor systems by removing the need for cabling and may enable additional applications. These systems have the potential to provide new avenues of optimization in safety and performance.This thesis delves into the topic of vibrations as ambient energy source, primarily for sensors in automotive vehicles. The transduction of small amounts of vibrational, or kinetic, energy to electrical power, also known as vibrational energy harvesting, is an extensive field of research with a plethora of inventions. A short review is given for energy harvesters, in an automotive context, utilizing transduction through either the piezoelectric effect or magnetic induction. Two practical examples, for ambient vibration harvesting in vehicles, are described in more detail. The first is a piezoelectric beam for powering a strain sensor on the engines rotating flexplate. It makes combined use of centrifugal force, gravitational pull and random vibrations to enhance performance and reduce required system size. The simulated power output is 370 \ub5W at a rotation frequency of 10.5 Hz, with a bandwidth of 2.44 Hz. The second example is an energy harvesting unit placed on a belt buckle. It implements magnetic induction by the novel concept of a spring balance air gap of a magnetic circuit, to efficiently harvest minute vibrations. Simulations show the potential to achieve 52 \ub5W under normal road conditions driving at 70 km/h. Theoretical modeling of these systems is also addressed. Fundamental descriptions of the lumped and distributed models are given. Based on the lumped models of the piezoelectric energy harvester (PEH) and the electromagnetic energy harvester (EMEH), a unified model is described and analyzed. New insights are gained regarding the pros and cons of the two types of energy harvester run at either resonance or anti-resonance. A numerical solution is given for the exact boundary of dimensionless quality factor and dimensionless intrinsic resistance, at which the system begins to exhibit anti-resonance. Regarding the maximum achievable power, the typical PEH is favored when running the system in anti-resonance and the typical EMEH is favored at resonance. The described modeling considers all parameters of the lumped model and thus provides a useful tool for developing vibrational energy harvester prototypes

SOLID-SHELL FINITE ELEMENT MODELS FOR EXPLICIT SIMULATIONS OF CRACK PROPAGATION IN THIN STRUCTURES

Crack propagation in thin shell structures due to cutting is conveniently simulated using explicit finite element approaches, in view of the high nonlinearity of the problem. Solidshell elements are usually preferred for the discretization in the presence of complex material behavior and degradation phenomena such as delamination, since they allow for a correct representation of the thickness geometry. However, in solid-shell elements the small thickness leads to a very high maximum eigenfrequency, which imply very small stable time-steps. A new selective mass scaling technique is proposed to increase the time-step size without affecting accuracy. New ”directional” cohesive interface elements are used in conjunction with selective mass scaling to account for the interaction with a sharp blade in cutting processes of thin ductile shells

Advances in Micro- and Nanomechanics

This book focuses on recent advances in both theoretical and experimental studies of material behaviour at the micro- and nano-scales. Special attention is given to experimental studies of nanofilms, nanoparticles and nanocomposites as well as tooth defects. Various experimental techniques were used. Magneto- and thermoelastic coupling were considered, as were nonlocal models of thin structures

Characterization of Mechanical Properties at the Micro/Nano Scale: Stiction Failure of MEMS, High-Frequency Michelson Interferometry and Carbon NanoFibers

Different forces scale differently with decreasing length scales. Van der Waals and surface tension are generally ignored at the macro scale, but can become dominant at the micro and nano scales. This fact, combined with the considerable compliance and large surface areas of micro and nano devices, can leads to adhesion in MicroElectroMechanical Systems (MEMS) and NanoElectroMechanical Systems (NEMS) - a.k.a. stiction-failure. The adhesive forces between MEMS devices leading to stiction failure are characterized in this dissertation analytically and experimentally. Specifically, the adhesion energy of poly-Si μcantilevers are determined experimentally through Mode II and mixed Mode I&II crack propagation experiments. Furthermore, the description of a high-frequency Michelson Interferometer is discussed for imaging of crack propagation of the μcantilevers with their substrate at the nano-scale and harmonic imaging of MEMS/NEMS. Van der Waals forces are also responsible for the adhesion in nonwoven carbon nanofiber networks. Experimental and modeling results are presented for the mechanical and electrical properties of nonwoven (random entanglements) of carbon nanofibers under relatively low and high-loads, both in tensions and compression. It was also observed that the structural integrity of these networks is controlled by mechanical entanglement and flexural rigidity of individual fibers as well as Hertzian forces at the fiber/fiber interface

On-chip electrochemical capacitors and piezoelectric energy harvesters for self-powering sensor nodes

On-chip sensing and communications in the Internet of things platform have benefited from the miniaturization of faster and low power complementary-metal-oxide semiconductor (CMOS) microelectronics. Micro-electromechanical systems technology (MEMS) and development of novel nanomaterials have further improved the performance of sensors and transducers while also demonstrating reduction in size and power consumption. Integration of such technologies can enable miniaturized nodes to be deployed to construct wireless sensor networks for autonomous data acquisition. Their longevity, however, is determined by the lifetime of the power supply. Traditional batteries cannot fully fulfill the demands of sensor nodes that require long operational duration. Thus, we require solutions that produce their own electricity from the surroundings and store them for future utility. Furthermore, manufacturing of such a power supply must be compatible with CMOS and MEMS technology. In this thesis, we will describe on-chip electrochemical capacitors and piezoelectric energy harvesters as components of such a self-powered sensor node. Our piezoelectric microcantilevers confirm the feasibility of fabricating micro electro-mechanical-systems (MEMS) size two-degree-of-freedom systems which can address the major issue of small bandwidth of piezoelectric micro-energy harvesters. These devices use a cut-out trapezoidal cantilever beam, limited by its footprint area i.e. a 1 cm$^2$ silicon die, to enhance the stress on the cantilever\u27s free end while reducing the gap remarkably between its first two eigenfrequencies in the 400 - 500 Hz and in the 1 - 2 kHz range. The energy from the M-shaped harvesters could be stored in rGO based on-chip electrochemical capacitors. The electrochemical capacitors are manufactured through CMOS compatible, reproducible, and reliable micromachining processes such as chemical vapor deposition of carbon nanofibers (CNF) and spin coating of graphene oxide based (GO) solutions. The impact of electrode geometry and electrode thickness is studied for CNF based electrodes. Furthermore, we have also demonstrated an improvement in their electrochemical performance and yield of spin coated electrochemical capacitors through surface roughening from iron and chromium nanoparticles. The CVD grown CNF and spin coated rGO based devices are evaluated for their respective trade-offs. Finally, to improve the energy density and demonstrate the versatility of the spin coating process, we manufactured electrochemical capacitors from various GO based composites with functional groups heptadecan-9-amine and octadecanamine. The materials were used as a stack to demonstrate high energy density for spin coated electrochemical capacitors. We have also examined the possibility of integrating these devices into a power management unit to fully realize a self-powering on-chip power supply through survey of package fabrication, choice of electrolyte, and device assembly

Dynamic analysis and fabrication of a bi-stable structure designed for MEMS energy harvesting applications.

Thanks to the rapid growth in demand for power in remote locations, scientists’ attention has been drawn to vibration energy harvesting as an alternative to batteries. Over the past ten years, the energy harvesting community has focused on bistable structures as a means of broadening the working frequency range and, by extension, the effective efficiency of vibration-based power scavenging systems. In the current study, a new method is implemented to statically and dynamically analyze a bistable buckled, multi-component coupled structure designed specifically for low-frequency vibration energy harvesting systems in both macro and MEMS-scale sizes. Furthermore, several micro-fabrication steps using advanced manufacturing technology methods were applied to design and fabricate a micro-scale version of the energy harvester at the University of Louisville Micro/Nano Technology Center. First, previously efforts performed on different aspects of vibration energy harvesting systems are reviewed to show the current challenges associated with such devices. The coupled structure proposed in this project is then introduced and its equations of motion are developed based on nonlinear Euler-Bernoulli beam theory. These governing equations are discretized and solved using a Galerkin method in two different approaches: with some known shape functions which only satisfies the geometrical boundary conditions; with the exact shape functions obtained from solving the linearized coupled structure as a one single system. An experimental setup is also used to verify the advantages of designed structure in capturing bistable motion at low-frequency range. To validate the modeling approaches, the obtained results are compared with the ones captured from both FEA model and the experimental setup, which shows the superiority of the proposed approach in which exact shape functions of the system are used as the basis in the discretization process. After the validation of the proposed approach, it is applied on a micro-scale version of the system in which structural, piezoelectric, and electrode layers are all considered as they exist in an actual device. Furthermore, a different bistable system, which was previously studied by other researchers in the area, is analyzed by this method to show the reliability of the proposed model. For all these cases, the amplitude-frequency response of the system and snap-through regime with the variation of various parameters, including exciting frequency, base vibration, and buckling loads are investigated based on the developed model. It is shown that bisatble motion and other nonlinear phenomena such as super-harmonic behavior in the system can be captured under certain circumstances, which can significantly impact major system functionalities such as output voltage response and is crucial for the performance of energy harvesting devices. As mentioned above, various micro-fabrication techniques were also used to design and fabricate a micro-scale version of the proposed system, which eventually led to the successful fabrication of a MEMS device as a result of experimental efforts performed to overcome the challenges and issues associated with the designed manufacturing process

Numerical modelling of additive manufacturing process for stainless steel tension testing samples

Nowadays additive manufacturing (AM) technologies including 3D printing grow rapidly and they are expected to replace conventional subtractive manufacturing technologies to some extents. During a selective laser melting (SLM) process as one of popular AM technologies for metals, large amount of heats is required to melt metal powders, and this leads to distortions and/or shrinkages of additively manufactured parts. It is useful to predict the 3D printed parts to control unwanted distortions and shrinkages before their 3D printing. This study develops a two-phase numerical modelling and simulation process of AM process for 17-4PH stainless steel and it considers the importance of post-processing and the need for calibration to achieve a high-quality printing at the end. By using this proposed AM modelling and simulation process, optimal process parameters, material properties, and topology can be obtained to ensure a part 3D printed successfully

Dynamics of Ultrasonic Consolidation

Ultrasonic consolidation (UC) is a solid state rapid manufacturing process derived from ultrasonic welding of thin metal foils coupled with contour milling to achieve functional accurate components. The bonding of metal is accomplished by the local application of high frequency vibration energy under pressure producing a metallurgical bond without melting the base material. Its unique nature allows the design and fabrication of structural panels for satellites, production of injection molding tools, functionally graded structures, metal-matrix composites, embedded sensors, armor, and fiber embedded adaptive structures. It is commonly theorized that interfacial motion and friction at the bonding interface play a prominent role in the bonding process by removing surface contaminants, allowing direct metal to metal contact, and producing sufficient stress to induce plastic flow. The substrate\u27s geometry is also crucial in the bonding process. Researchers have experimentally observed that as the height of build specimen approaches its width, the bonding process degrades, and no further foils may be welded. This work explores the process as the dimensions of the build specimen modeled as a standard parallelepiped, approaches the critical geometry through a combination of numerical, analytical and experimental analysis. We examine the resonances of a build feature due to a change in geometry and material properties using a three dimensional Rayleigh-Ritz model. A simple nonlinear dynamic model of the Ultrasonic Consolidation Process examines how the geometry change may influence the overall process dynamics. This simple model is use to provide estimates of how changes is substrate geometry affect the differential motion at the bonding interface and the amount of changing friction force due to build height. The trends of changes in natural frequency, and differential motion, are compared to experimental limits on build height. These analyses lead to several predictions on build height that are verified experimentally. Finally, the work examines the effectiveness of using support material to extend the build height limit of the process. The results show that a proximity to a resonance excitation is clearly responsible for bonding degradation at features built with the nominal tape width of 0.9375 inches. However, for small widths other factors such as surface topography, and contact area may play an important role in bonding degradation

Advance in Energy Harvesters/Nanogenerators and Self-Powered Sensors

This reprint is a collection of the Special Issue "Advance in Energy Harvesters/Nanogenerators and Self-Powered Sensors" published in Nanomaterials, which includes one editorial, six novel research articles and four review articles, showcasing the very recent advances in energy-harvesting and self-powered sensing technologies. With its broad coverage of innovations in transducing/sensing mechanisms, material and structural designs, system integration and applications, as well as the timely reviews of the progress in energy harvesting and self-powered sensing technologies, this reprint could give readers an excellent overview of the challenges, opportunities, advancements and development trends of this rapidly evolving field

Development of non-prestressed fibre-reinforced concrete sleepers

Railway sleepers are one of the essential parts of the ballasted railway tracks that provide support to the rails, retain the track gauge, and transfer the rail-seat loads uniformly to the underlying ballast layer. Prestressed concrete (PSC) sleepers are currently the most well-known railway sleepers used by the railway industry. It is estimated that there are around 400 billion prestressed concrete sleepers used in railway tracks worldwide and this number is increasing rapidly. The manufacturing process of the PSC sleeper requires relatively spacious indoor area with expensive machinery. Additionally, this manufacturing process needs heat curing and, therefore, is energy-consuming and pollutes the atmosphere due to the emission of greenhouse gases. This research proposes the application of non-prestressed concrete sleepers as an alternative to the currently used PSC railway sleepers. For manufacturing non-prestressed concrete sleepers, ultra-high tensile strength concrete is needed to resist the significant flexural tensile stresses generated within the sleeper under the design wheel load. In this research study, the reactive powder concrete (RPC) material, also called ultra-high performance fibre-reinforced concrete (UHP-FRC), is utilised for manufacturing the proposed non-prestressed concrete sleeper. In the first stage, the optimal UHP-FRC mix design is determined through experimental testing of trial concrete mixes and a mathematical optimisation algorithm. Then, the standard rail-seat positive moment and the cyclic/fatigue tests are carried out for the prototype UHP-FRC sleepers. The prototype sleeper satisfies the criterion to pass the standard rail-seat static test. However, the fatigue performance of the UHP-FRC sleeper needs further improvements. Indeed, the prototype UHP-FRC sleeper sample failed under fatigue (cyclic) loading after around 200,000 load cycles, while according to the Australian Standard, concrete sleepers are expected to resist at least 3 millions of load cycles