Electromechanical contact elements for modelling adhesion and interfacial interactions in electrospun nanofibers systems

Abstract The analysis of deformation and interactions during the electromechanical contact between surfaces with non-matching meshes is important for advanced applications such as mechanical energy harvesting and pressure/force sensors using flexible piezoelectric devices made of polymeric nanowires. The node-to-segment (NTs) and the node-to-surface (NTS) algorithms are widely employed discretization techniques despite well known limitations in problems where the identification of the master segment/surface related to a slave-node is ambiguous or impossible. The objectives of this work is to extend the classical formulation to electromechanical interfaces using automatic differentiation technologies to derive and implement the resulting numerical equations. In particular, the contact contributions to the stiffness matrix and to the residual vector are derived and an adhesion behaviour is also added into the constitutive law. Then, some applications to selected practical problems are presented

A two-step hybrid approach for modeling the nonlinear dynamic response of piezoelectric energy harvesters

An effective hybrid computational framework is described here in order to assess the nonlinear dynamic response of piezoelectric energy harvesting devices. The proposed strategy basically consists of two steps. First, fully coupled multiphysics finite element (FE) analyses are performed to evaluate the nonlinear static response of the device. An enhanced reduced-order model is then derived, where the global dynamic response is formulated in the state-space using lumped coefficients enriched with the information derived from the FE simulations. The electromechanical response of piezoelectric beams under forced vibrations is studied by means of the proposed approach, which is also validated by comparing numerical predictions with some experimental results. Such numerical and experimental investigations have been carried out with the main aim of studying the influence of material and geometrical parameters on the global nonlinear response. The advantage of the presented approach is that the overall computational and experimental efforts are significantly reduced while preserving a satisfactory accuracy in the assessment of the global behavior

Phenomenological model for coupled multi-axial piezoelectricity

A quantitative calibration of an existing phenomenological model for polycrystalline ferroelectric ceramics is presented. The model relies on remnant strain and polarization as independent variables. Innovative experimental and numerical model identification procedures are developed for the characterization of the coupled electro-mechanical, multi-axial nonlinear constitutive law. Experiments were conducted on thin PZT-5A4E plates subjected to cross-thickness electric field. Unimorph structures with different thickness ratios between PZT-5A4E plate and substrate were tested, to subject the piezo plates to coupled electro-mechanical fields. Material state histories in electric field-strain-polarization space and stress-strain-polarization space were recorded. An optimization procedure is employed for the determination of the model parameters, and the calibrated constitutive law predicts both the uncoupled and coupled experimental observations accurately

Broadband vibration damping of a non-periodic plate by piezoelectric coupling to its electrical analogue

International audienceSeveral solutions for multimodal vibration damping of thin mechanical structures based on piezoelectric coupling have been developed over the years. Among them, piezoelectric network damping consists in using piezoelectric transducers to couple a structure to an electrical network, where the transferred electrical energy can be dissipated. In particular, the effectiveness of coupling rods, beams and plates to networks which are their electrical analogues has been proven. This work is the first step going towards more complex structures. After defining and experimentally validating a new electrical analogue of a simply-supported plate, the study is extended to the damping of a non-periodic plate. Experiments show that in this case, a broadband damping is achieved once the piezoelectric transducers are coupled to an adequate analogous network. A finite element model of the structure coupled to its analogous network is concurrently developed and validated

Metamodel-assisted design optimization of piezoelectric flex transducer for maximal bio-kinetic energy conversion

Energy Harvesting Devices (EHD) have been widely used to generate electrical power from the bio-kinetic energy of human body movement. A novel Piezoelectric Flex Transducer (PFT) based on the Cymbal device has been proposed by Daniels et al. (2013) for the purpose of energy harvesting. To further improve the efficiency of the device, optimal design of the PFT for maximum output power subject to stress and displacement constraints is carried out in this paper. Sequential Quadratic Programming (SQP) on metamodels generated with Genetic Programming from a 140-point optimal Latin hypercube design of experiments is used in the optimization. Finally, the optimal design is validated by finite element simulations. The simulations show that the magnitude of the electrical power generated from this optimal PFT harvesting device can be up to 6.5 mw when a safety design factor of 2.0 is applied

Study and Development of Mechatronic Devices and Machine Learning Schemes for Industrial Applications

Obiettivo del presente progetto di dottorato è lo studio e sviluppo di sistemi meccatronici e di modelli machine learning per macchine operatrici e celle robotizzate al fine di incrementarne le prestazioni operative e gestionali. Le pressanti esigenze del mercato hanno imposto lavorazioni con livelli di accuratezza sempre più elevati, tempi di risposta e di produzione ridotti e a costi contenuti. In questo contesto nasce il progetto di dottorato, focalizzato su applicazioni di lavorazioni meccaniche (e.g. fresatura), che includono sistemi complessi quali, ad esempio, macchine a 5 assi e, tipicamente, robot industriali, il cui utilizzo varia a seconda dell’impiego. Oltre alle specifiche problematiche delle lavorazioni, si deve anche considerare l’interazione macchina-robot per permettere un’efficiente capacità e gestione dell’intero impianto. La complessità di questo scenario può evidenziare sia specifiche problematiche inerenti alle lavorazioni (e.g. vibrazioni) sia inefficienze più generali che riguardano l’impianto produttivo (e.g. asservimento delle macchine con robot, consumo energetico). Vista la vastità della tematica, il progetto si è suddiviso in due parti, lo studio e sviluppo di due specifici dispositivi meccatronici, basati sull’impiego di attuatori piezoelettrici, che puntano principalmente alla compensazione di vibrazioni indotte dal processo di lavorazione, e l’integrazione di robot per l’asservimento di macchine utensili in celle robotizzate, impiegando modelli di machine learning per definire le traiettorie ed i punti di raggiungibilità del robot, al fine di migliorarne l’accuratezza del posizionamento del pezzo in diverse condizioni. In conclusione, la presente tesi vuole proporre soluzioni meccatroniche e di machine learning per incrementare le prestazioni di macchine e sistemi robotizzati convenzionali. I sistemi studiati possono essere integrati in celle robotizzate, focalizzandosi sia su problematiche specifiche delle lavorazioni in macchine operatrici sia su problematiche a livello di impianto robot-macchina. Le ricerche hanno riguardato un’approfondita valutazione dello stato dell’arte, la definizione dei modelli teorici, la progettazione funzionale e l’identificazione delle criticità del design dei prototipi, la realizzazione delle simulazioni e delle prove sperimentali e l’analisi dei risultati.The aim of this Ph.D. project is the study and development of mechatronic systems and machine learning models for machine tools and robotic applications to improve their performances. The industrial demands have imposed an ever-increasing accuracy and efficiency requirement whilst constraining the cost. In this context, this project focuses on machining processes (e.g. milling) that include complex systems such as 5-axes machine tool and industrial robots, employed for various applications. Beside the issues related to the machining process itself, the interaction between the machining centre and the robot must be considered for the complete industrial plant’s improvement. This scenario´s complexity depicts both specific machining problematics (e.g. vibrations) and more general issues related to the complete plant, such as machine tending with an industrial robot and energy consumption. Regarding the immensity of this area, this project is divided in two parts, the study and development of two mechatronic devices, based on piezoelectric stack actuators, for the active vibration control during the machining process, and the robot machine tending within the robotic cell, employing machine learning schemes for the trajectory definition and robot reachability to improve the corresponding positioning accuracy. In conclusion, this thesis aims to provide a set of solutions, based on mechatronic devices and machine learning schemes, to improve the conventional machining centre and the robotic systems performances. The studied systems can be integrated within a robotic cell, focusing on issues related to the specific machining process and to the interaction between robot-machining centre. This research required a thorough study of the state-of-the-art, the formulation of theoretical models, the functional design development, the identification of the critical aspects in the prototype designs, the simulation and experimental campaigns, and the analysis of the obtained results

MECHANICAL ENERGY HARVESTER FOR POWERING RFID SYSTEMS COMPONENTS: MODELING, ANALYSIS, OPTIMIZATION AND DESIGN

Finding alternative power sources has been an important topic of study worldwide. It is vital to find substitutes for finite fossil fuels. Such substitutes may be termed renewable energy sources and infinite supplies. Such limitless sources are derived from ambient energy like wind energy, solar energy, sea waves energy; on the other hand, smart cities megaprojects have been receiving enormous amounts of funding to transition our lives into smart lives. Smart cities heavily rely on smart devices and electronics, which utilize small amounts of energy to run. Using batteries as the power source for such smart devices imposes environmental and labor cost issues. Moreover, in many cases, smart devices are in hard-to-access places, making accessibility for disposal and replacement difficult. Finally, battery waste harms the environment. To overcome these issues, vibration-based energy harvesters have been proposed and implemented. Vibration-based energy harvesters convert the dynamic or kinetic energy which is generated due to the motion of an object into electric energy. Energy transduction mechanisms can be delivered based on piezoelectric, electromagnetic, or electrostatic methods; the piezoelectric method is generally preferred to the other methods, particularly if the frequency fluctuations are considerable. In response, piezoelectric vibration-based energy harvesters (PVEHs), have been modeled and analyzed widely. However, there are two challenges with PVEH: the maximum amount of extractable voltage and the effective (operational) frequency bandwidth are often insufficient. In this dissertation, a new type of integrated multiple system comprised of a cantilever and spring-oscillator is proposed to improve and develop the performance of the energy harvester in terms of extractable voltage and effective frequency bandwidth. The new energy harvester model is proposed to supply sufficient energy to power low-power electronic devices like RFID components. Due to the temperature fluctuations, the thermal effect over the performance of the harvester is initially studied. To alter the resonance frequency of the harvester structure, a rotating element system is considered and analyzed. In the analytical-numerical analysis, Hamilton’s principle along with Galerkin’s decomposition approach are adopted to derive the governing equations of the harvester motion and corresponding electric circuit. It is observed that integration of the spring-oscillator subsystem alters the boundary condition of the cantilever and subsequently reforms the resulting characteristic equation into a more complicated nonlinear transcendental equation. To find the resonance frequencies, this equation is solved numerically in MATLAB. It is observed that the inertial effects of the oscillator rendered to the cantilever via the restoring force effects of the spring significantly alter vibrational features of the harvester. Finally, the voltage frequency response function is analytically and numerically derived in a closed-from expression. Variations in parameter values enable the designer to mutate resonance frequencies and mode shape functions as desired. This is particularly important, since the generated energy from a PVEH is significant only if the excitation frequency coming from an external source matches the resonance (natural) frequency of the harvester structure. In subsequent sections of this work, the oscillator mass and spring stiffness are considered as the design parameters to maximize the harvestable voltage and effective frequency bandwidth, respectively. For the optimization, a genetic algorithm is adopted to find the optimal values. Since the voltage frequency response function cannot be implemented in a computer algorithm script, a suitable function approximator (regressor) is designed using fuzzy logic and neural networks. The voltage function requires manual assistance to find the resonance frequency and cannot be done automatically using computer algorithms. Specifically, to apply the numerical root-solver, one needs to manually provide the solver with an initial guess. Such an estimation is accomplished using a plot of the characteristic equation along with human visual inference. Thus, the entire process cannot be automated. Moreover, the voltage function encompasses several coefficients making the process computationally expensive. Thus, training a supervised machine learning regressor is essential. The trained regressor using adaptive-neuro-fuzzy-inference-system (ANFIS) is utilized in the genetic optimization procedure. The optimization problem is implemented, first to find the maximum voltage and second to find the maximum widened effective frequency bandwidth, which yields the optimal oscillator mass value along with the optimal spring stiffness value. As there is often no control over the external excitation frequency, it is helpful to design an adaptive energy harvester. This means that, considering a specific given value of the excitation frequency, energy harvester system parameters (oscillator mass and spring stiffness) need to be adjusted so that the resulting natural (resonance) frequency of the system aligns with the given excitation frequency. To do so, the given excitation frequency value is considered as the input and the system parameters are assumed as outputs which are estimated via the neural network fuzzy logic regressor. Finally, an experimental setup is implemented for a simple pure cantilever energy harvester triggered by impact excitations. Unlike the theoretical section, the experimental excitation is considered to be an impact excitation, which is a random process. The rationale for this is that, in the real world, the external source is a random trigger. Harmonic base excitations used in the theoretical chapters are to assess the performance of the energy harvester per standard criteria. To evaluate the performance of a proposed energy harvester model, the input excitation type consists of harmonic base triggers. In summary, this dissertation discusses several case studies and addresses key issues in the design of optimized piezoelectric vibration-based energy harvesters (PVEHs). First, an advanced model of the integrated systems is presented with equation derivations. Second, the proposed model is decomposed and analyzed in terms of mechanical and electrical frequency response functions. To do so, analytic-numeric methods are adopted. Later, influential parameters of the integrated system are detected. Then the proposed model is optimized with respect to the two vital criteria of maximum amount of extractable voltage and widened effective (operational) frequency bandwidth. Corresponding design (influential) parameters are found using neural network fuzzy logic along with genetic optimization algorithms, i.e., a soft computing method. The accuracy of the trained integrated algorithms is verified using the analytical-numerical closed-form expression of the voltage function. Then, an adaptive piezoelectric vibration-based energy harvester (PVEH) is designed. This final design pertains to the cases where the excitation (driving) frequency is given and constant, so the desired goal is to match the natural frequency of the system with the given driving frequency. In this response, a regressor using neural network fuzzy logic is designed to find the proper design parameters. Finally, the experimental setup is implemented and tested to report the maximum voltage harvested in each test execution