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

Stuttgart Lake Constance Region

Status Quo - Composites Source: Lamborghini Source: BMW

Material Competition steel 400 aluminium today 300 aluminium ] - 30 % dy Weight [kg CFRP today target 200 area CFRP: CFRP: CFRP: CFRP: CFRP 30 €/kg 40 €/kg - 60 % 15 €/kg 20 €/kg Bod 100 100 1000 2000 3000 4000 5000 6000 7000 C Costs [€] t [€]

Lightweight Design + added Value Lightweight Functional Design Integration Sensors Composites Manufacturing Composites Process Parameters Industry 4.0 Use Cases „ Smart Part “ Functional Parameters

Lightweight Design + added Value Chassis HVAC Vandalism Vandalism Accident Accident E M bilit E-Mobility D i Drive train t i Structural Health Monitoring 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) Vac H Inj t0 t1 t2 t3 R [ Ω ] t [s] t3 3 t1 t2 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 t A =1.8804s t B =1.8841s t C =1.9100s

Impact detection: Parking Accident Rear t C =1.6551s t B =1.6598s t A =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 root ‐ mean ‐ square According to  Broadband value Configuration:  structural ‐ borne maximum absolut  Stream of Full Data Bearings induced  Sound Sensor K(t) ‐ Value value and Analysis Vibration Analysis   Low Signal ‐ Noise crest factor  Condition  Ratio kurtosis factor Detection  K(t) value 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 A Sensor

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

Composites 4.0: Lightweight Design & Intelligence embedded Flame Retardancy Structural Integrity Onboard Intelligence SHM / NVH Sensorics Wireless Energy Transfer Wireless Data Transfer Thermala Management Package Package Assembly / Service

Composites 4.0: Lightweight Design & Intelligence embedded Fire Protection Textiles / Resins/ Coatings Data Transfer Data Transfer Blutooth / WLAN Energy Transfer Onboard Intelligence wireless/ inductive Sensorics e.g. H 2 Detection Struktural Integrity Leakage.... Crash Sensorics Thermomanagement Predictive Maintenance Predictive Maintenance Heater/ Thermocouples H t / Th l 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)

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