This work presents the manufacturing and testing of active composite panels (ACPs) with embedded piezoelectric sensors and actuators. The composite material employed here is a plain weave carbon/epoxy prepreg fabric with 0.30 mm ply thickness. A cross-ply type stacking sequence is employed for the ACPs. The piezoelectric flexible patches employed here are Active Fiber Composite (AFC) piezoceramics with 0.33 mm thickness. Composite layers with openings are used to fill the space around the embedded piezo patches to minimize the problems associated with ply drops in composites. The AFC piezoceramic patches were embedded inside the composite laminate. High-temperature wires were soldered to the piezo leads, insulated from the carbon substructure by high-temperature materials, and were taken out of the composite laminates employing cutout hole, molded-in hole, and embedding techniques. The laminated ACPs with their embedded piezoelectric sensors and actuators were vacuum bagged and co-cured inside an autoclave employing the cure cycle recommended by the composite material supplier. The Curie temperature of the embedded piezo patches should be well above the curing temperature of the composite materials as was the case here. The capacitance of the piezoelectric patches was measured before and after cure for quality control. The manufactured ACPs were trimmed and then tested for their functionality. A finite element analysis (FEA) model was developed to verify the free expansion of the AFC FEA. Next, the FEA model of the manufactured ACP was developed based on the AFC FEA free expansion model and was employed to test the functionality of the AFCs embedded within the ACPs. Both static and dynamic FEA results of the modeled ACPs showed very good agreements with their corresponding experimental results. Finally, vibration suppression as well as simultaneous vibration suppression and precision positioning tests, using Hybrid Adaptive Control (HAC), were successfully conducted on the manufactured ACP beams and their functionality was further demonstrated. The advantages and disadvantages of ACPs with embedded piezoelectric sensor and actuator patches manufactured employing the abovementioned three wires out techniques are also presented in terms of manufacturing and performance.
This article employs a finite element method to introduce Displacement-Load-Sensor voltage-Actuator voltage (DLSA) Design Charts and associated vibration suppression schemes; namely, Constant Voltage (CV), Optimum Voltage (OV), Corresponding Voltage (COV), and Truncated Corresponding Voltage (TCOV), to develop actuator control voltages with amplitude and phase information for the design of smart structures with piezoelectric sensors and actuators for active vibration suppression. These techniques can be used to (a) design the location, size, and number of actuators without resorting to complex control strategies or formal optimization techniques, (b) investigate the actuation effectiveness of surface-mounted versus embedded piezoelectric patches in similar composite structures, and (c) determine actuator control voltages analogous to a feedforward open-loop control technique. Guidelines are presented for the development of DLSA Design Charts. In addition, closed form analytical equations that can replace DLSA Design Charts, are developed and presented due to their ease of use. An Active Composite Panel (ACP) with a surface-mounted piezoelectric patch actuator for lateral vibration suppression and an Active Composite Strut (ACS) with a piezoelectric stack actuator for axial vibration suppression are considered. The ACP and ACS are employed to demonstrate the applications of the introduced DLSA Design Charts and the vibration suppression schemes for vibration suppression and actuator placement optimization. The vibration suppression of both ACP and ACS is significant over a frequency range encompassing several resonances, and is indicated by the Suppressed Vibration Energy (SVE) index. This investigation shows that the optimum location of the actuator depends on the structural mode shape, based on the criteria of maximum SVE and minimum actuator power. In general, the actuator should be placed on the panel on a sub-area, where the sum of normal strains is maximum. However, a preferred location can be determined over a range of frequencies that encompass more than one natural frequency.
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