Carbon nanotube/polymer-based composites have led to studies that enable the realization of low-cost, high-sensitivity piezoresistive strain sensors. This study investigated the characteristics of piezoresistive multi-walled carbon nanotube (MWCNT)/epoxy composite strain sensors subjected to tensile and compressive loads in one direction at relatively small amounts of strain. A patterned sensor was designed to overcome the disadvantage of the load direction sensitivity differences in the existing sensors. The dispersion state of the MWCNTs in the epoxy polymer matrix with the proposed dispersion process was verified by scanning electron microscopy. An MWCNT/epoxy patterned strain sensor and a patch-type strain sensor were directly attached to an acrylic cantilever beam on the opposite side of a commercial metallic strain gauge. The proposed patterned sensor had gauge factors of 2.52 in the tension direction and 2.47 in the compression direction. The measured gauge factor difference for the patterned sensor was less than that for the conventional patch-type sensor. Moreover, the free-vibration frequency response characteristics were compared with those of metal strain gauges to verify the proposed patch-type sensor. The designed drive circuit compensated for the disadvantages due to the high drive voltage, and it was confirmed that the proposed sensor had higher sensitivity than the metallic strain gauge. In addition, the hysteresis of the temperature characteristics of the proposed sensor is presented to show its temperature range. It was verified that the patterned sensor developed through various studies could be applied as a strain sensor for structural health monitoring.
The strong aerodynamic drag under a railroad vehicle in motion causes the track ballast to fly up and around. The flying ballast can collide with the underside of the coach, damaging the electronics installed there. There are even cases wherein the aerodynamics of fast-moving train causes the gravel to hit the side of the coach and break the windows. Extensive and numerous studies are underway to reduce the damage caused by such phenomena. In this study, a “smart paint sensor” for impact monitoring was fabricated using piezoelectric nano powder and commercial paint for railroad vehicles, and the application of impact monitoring to railroad vehicles was analyzed. The process was simplified because the use of commercial paint eliminated the need to apply an additional layer of functionalized paint. Furthermore, the fact that the paint can be evenly sprayed on a large surface made it suitable for use on large and intricate objects such as a railroad vehicle bogie. Because railroad vehicles are exposed to thermal stress for a long period of time, a thermal fatigue test was conducted in order to figure out the stability of the polymer-based material, which is relatively vulnerable to temperature variations. The test results were used to analyze the impact sensitivity of the piezoelectric paint sensor. For the analysis, a full-size mock-up of the railroad vehicle bogie and an impact monitoring system with piezoelectric paint sensor were implemented in order to visualize the impact signals from differently shaped objects with large surfaces.
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