IOC: Internet of Composites IOC: Internet of Composites IOC: - - PowerPoint PPT Presentation

IOC: Internet of Composites IOC: Internet of Composites IOC: Internet of Composites IOC: Internet of Composites

Robert Bjekovic, University of applied sciences Ravensburg‐ Weingarten, Weingarten, Germany Michael Elwert, University of applied sciences Ravensburg‐ Weingarten, Weingarten, Germany g , g , y Bronwyn Fox, Swinburne University of Technology, Melbourne, Australia Boris Eisenbart Swinburne University of Technology Melbourne Boris Eisenbart, Swinburne University of Technology, Melbourne, Australia

Lake Constance Region

Stuttgart

Status Quo - Composites

Source: BMW Source: Lamborghini

Material Competition

] 300 400

steel

aluminium

aluminium today

dy Weight [kg 100 200

• 30 %
• 60 %

CFRP

CFRP: 40 €/kg CFRP: 30 €/kg CFRP: 20 €/kg CFRP: 15 €/kg target area CFRP today

Bod 100 1000 2000 3000 4000 5000 6000 7000 C t [€] Costs [€]

Lightweight Design + added Value

Lightweight Design

Composites

Functional Integration

Sensors

Manufacturing

Composites

Industry 4.0

Process Parameters „ Smart Part “ Functional Parameters

Use Cases

Lightweight Design + added Value

Chassis Vandalism Accident HVAC Vandalism E M bilit D i t i Accident Structural Health Monitoring E-Mobility Drive train g Predictive Maintenance

Composites + embedded Fibre-Sensors

Composites + Glass Fibre Epoxy Composite with embedded Sensors Sensors

Composites + embedded Sensors: Infiltration with Resin (Humidity Sensor) (Humidity Sensor)

H

Inj Vac t0 t1 t2 t3

R [Ω] t [s]

3 t1 t2 t3

Source: Florian Ritter, IFB

Preform production + Sensor integration

Structural Tapes Smart Tapes

Preform production + Sensor integration

Source: www.fill.co.at

iMPact XS: Piezoelectric Sensor

high-performance acoustic emission and dynamic load sensor especially for structural health monitoring applications of lightweight structures

Impact Localization Carbon Composite

Impact Localization User Frontend

Impact Localization: Mercedes-Benz S-Class AMG: Multi- functional Carbon Spare Wheel Pan functional Carbon Spare Wheel Pan

Impact detection: Placement of iMPact XS Sensors C A B Sensors

Impact detection: Placement of iMPact XS Sensors C A B Sensors

Impact detection: Parking Accident Front

tA=1.8804s tB=1.8841s tC=1.9100s

Impact detection: Parking Accident Rear

tC=1.6551s tB=1.6598s tA=1.6778s

Impact detection: Parking Accident Side

Possible Real Life Scenario

Predictive Maintenance: Condition Monitoring for Bearings according to VDI 3832 according to VDI 3832

• root‐mean‐square

Bearings induced Vibration Analysis

• root‐mean‐square

value

• maximum absolut

value

• crest factor
• kurtosis factor
• K(t) value
• Broadband

structural‐borne Sound Sensor

• Low Signal‐Noise

Ratio

• K(t)‐Value

According to Configuration:

• Stream of Full Data

and Analysis

• Condition

Detection Advantages of iNDTact System:  Precise Information of Acceleration, Vibration and structural‐borne Sound  Detection and Analysis of all VDI 3832 Parameters

Source: iNDTact

Predictive Maintenance: Condition Monitoring for Bearings according to VDI 3832 according to VDI 3832

Procedure: Analysis of the structural-borne sound of a new and a defatted bearing using iMPactXS. Result: Result: Clear distinction of bearing condition possible. Forecast: With the help of several p measurements over lifetime and self-learning algorithms a reliable prediction of bearing conditions can be made

Placement of iMPact XS Sensor for Tire Pressure measurement Sensor A

Data Acquisition during online Tire Pressure measurement

• 1 Sensors iMpact XS

1 Sensors iMpact XS

• 1 Amplifiers
• Picoscope 6404 C
• MatLab 2015a

Tire Pressure measurement

Sensor attached to Axle Arm Test-bench Setup Sensor attached to Axle Arm Test-bench Setup Sensor attached to Axle Arm Sensor attached to Axle Arm Test bench Setup Sensor attached to Axle Arm Test bench Setup Sensor attached to Axle Arm

Composites 4.0: Lightweight Design & Intelligence embedded

Flame Retardancy Onboard Intelligence Structural Integrity SHM / NVH Sensorics Wireless Energy Transfer Wireless Data Transfer Thermala Management Package Assembly / Service Package

Composites 4.0: Lightweight Design & Intelligence embedded

Data Transfer Fire Protection Textiles / Resins/ Coatings Onboard Intelligence Energy Transfer wireless/ inductive Data Transfer Blutooth / WLAN Thermomanagement H t / Th l Sensorics e.g. H2 Detection Leakage.... Struktural Integrity Crash Sensorics Predictive Maintenance Heater/ Thermocouples Predictive Maintenance Quality Control

Mercedes-Benz S-Class AMG: Multi-functional Composite Spare Wheel Pan Spare Wheel Pan

Mercedes-Benz S-Class AMG: Multi-functional Composite Spare Wheel Pan (Aidme) Spare Wheel Pan (Aidme)

Thank you for your attention