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C entre for C omputational S tructural and M aterials M echanics A multiscale approach to the smart deployment of micro-sensors over flexible plates Giovanni Capellari, Francesco Caimmi, Matteo Bruggi, Stefano Mariani Politecnico di Milano

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Centre for Computational Structural and Materials Mechanics

A multiscale approach to the smart deployment

  • f micro-sensors over flexible plates

Giovanni Capellari, Francesco Caimmi, Matteo Bruggi, Stefano Mariani Politecnico di Milano

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

Damage (delamination) in composite structures

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Syntactic foam/glass fibre composite sandwich delamination

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

after Kousourakis et al., Composites (2008)

Effects of embedded monitoring systems

3 inner (embedded) piezo surface mounted piezo after Tang et al., JIM (2011) effects of embedded fiber sensors

SHM modifies the stress-carrying capacity of the structural component

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

Surface-mounted MEMS-based sensing

4 MEMS evaluation board

Features of 3-axis, digital output MEMS (micro electro-mechanical sensor) accelerometer LIS3LV02DQ (STM):

  • full scale Β±2𝑕
  • bandwidth 640 Hz
  • sensitivity 1,000 LSb(Least_Significant_bit)/𝑕
  • resolution 1 m𝑕
  • weight 0.2 grams
  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

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Validation of the SHM scheme Optimal sensor placement

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

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Validation test: DCB test under cyclic loading

Sinusoidally varying imposed displacement u (at increasing )

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

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Validation test: test results and MEMS output

Load P varies smoothly MEMS output shows high-order frequency fluctuation

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

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Validation test: theoretical model (Bernoulli-Euler beam bending)

Specimen compliance: a: delamination length Acceleration-load relation: : assumed constant (geometry dependent) In case of sinusoidal load: Moving to the frequency domain, through FFT: At the driving frequency:

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

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Validation test: theoretical model (Bernoulli-Euler beam bending)

𝛿 = | 𝑣| βˆ†π‘£ = πœ’ 2𝐷 Ξ΄ 𝑔 βˆ’ 𝑔

𝑣

= 𝜈 𝑏3 Ξ΄ 𝑔 βˆ’ 𝑔

𝑣

We obtained a delamination length-sensing SHM system

(Mariani et al., MEJ 2013, IEEE Sensors 2014)

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

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Validation of the SHM scheme Optimal sensor placement

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

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Optimal sensor placement

DCB test Thin square, simply supported plate: Isotropic material: (dimensionless) Young modulus E=10.92 Poisson ratio n=0.3 examples of localized damaged regions

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

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Optimization approach (coupling FEA and MMA)

In case of a single damaged region (of known position), to maximize the sensitivity to the effects of damage: undamaged plate solution damaged plate solution max allowed number of sensors penalization term to approach pure 0-1 distributions (p>1) number of possible sensor locations (FE)

(Mariani-Bruggi et al., EO, JIM 2013)

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

β€œsensor density” at the i-th position

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

13

Optimization approach (coupling FEA and MMA)

In case of a multiple damaged regions (of known positions), to maximize the sensitivity to the magnitude of the effects of damage [FORM-1]: number of damaged areas

  • r, to maximize the sensitivity to

damage [FORM-2]:

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

To be adopted at each length-scale (two concatenated analyses in the cases to follow)

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

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Square plate: optimal sensor placement – damage anywhere at the macroscale simply supported plate

[FORM-1] [FORM-2]

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

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Rectangular plate: optimal sensor placement – damage anywhere at the macroscale simply supported plate

[FORM-1] [FORM-2]

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

16

Square plate: optimal sensor placement – damage anywhere at the macroscale simply supported plate

[FORM-1] [FORM-2]

damaged area

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

17

Square plate: optimal sensor placement – damage anywhere at the macroscale clamped plate

[FORM-1] [FORM-2]

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

18

Square plate: optimal sensor placement – damage anywhere clamped plate, distributed load

[FORM-2],

Multi-scale analysis: L=1 m (side length, or structural size) s=5 cm (element, or damaged area size) l=2.5 mm (sensor size)

  • bjective function

sensor macro-placement sensor micro-placement

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

19

Square plate: optimal sensor placement – damage anywhere clamped plate, concentrated load

[FORM-2],

Multi-scale analysis: L=1 m (side length, or structural size) s=5 cm (element, or damaged area size) l=2.5 mm (sensor size)

  • bjective function

sensor macro-placement sensor micro-placement

  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI

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DTIP 2011 - S. Mariani, S.E. Azam, A. Ghisi, A. Corigliano, B.Simoni

20

Conclusions Ongoing activities and future work Acknowledgments

  • We proposed a MEMS-based SHM system,

sensitive to damage (delamination) extent in composite

  • We proposed a multi-scale topology
  • ptimization-like procedure to deploy MEMS,

so as to maximize sensitivity to damage

  • robustness of the SHM system
  • networking of (possibly self-powered) MEMS sensors
  • real-time damage detection and identification for flexible (composite) plates
  • Application: engineered bike and ski helmets, to understand links between

impacts and brain injuries

  • Italian MIUR-PRIN project Mechanics of microstructured materials: multi-scale identification, optimization

and active control

  • Italian Consorzio Interuniversitario Nazionale per la Scienza e la Tecnologia dei Materiali (INSTM)
  • Regione Lombardia and CILEA Consortium, grant M2-MEMS
  • Fondazione Cariplo, project Safer Helmets
  • G. Capellari, F. Caimmi, M. Bruggi, S. Mariani

POLIMI