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Overcoming Conflicts of Objectives Between sensory and Mechanical Domain in the Development of sensor-Integrating Machine Elements Using the Example of Bolts

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IEEE ACCESS 2024年 12卷 93975-93992页

作者： Peters, Julian Mirbach, Nathanael Herbst, Felix Riehl, David Kupnik, Mario Hofmann, Klaus Matthiesen, Sven Karlsruhe Inst Technol KIT Inst Prod Engn D-76131 Karlsruhe Germany Tech Univ Darmstadt Measurement & Sensor Technol Grp D-64289 Darmstadt Germany Tech Univ Darmstadt Integrated Elect Syst Lab D-64289 Darmstadt Germany

Comprehensive data on machines is essential for digitization in the industry. Since standardized machine elements are used in most machines, integrating them with sensors provides the opportunity to acquire data comprehensively from in-situ. The sensor integration must not change the element's core function and the standardized mechanical interfaces. Hence, sensors must be fully integrated and self-sufficient. Regarding bolts as widely used machine element, a solution that combines all the aforementioned requirements does not yet exist. A main problem in developing sensor-integrating machine elements and especially bolts is to overcome the conflicting objectives in defining design space for mechanical and sensory functions. There is a lack of an approach to model the effects of the design space parameters on the mechanical and sensory functions. This paper proposes an optimization function to aid mechanical and electrical engineers in resolving conflicting objectives by balancing function fulfillment when determining design space parameters. Therefore, the effects of the parameters on the mechanical and sensory functions are modelled using FE-analysis and composing an optimization function with weights. This function provides optimal design space parameters. With respect to mountability boundary conditions the optimum for equal weights is at diameters 13.2mm both, increasing v. Mises stress by 29% and strain at sensor position by 80%. The location of the optimum is very dependent on proper weighting, which resembles a prioritization of the mechanical versus the sensory function fulfillment. This enables engineers to find optimal parameters by balancing the mechanical and the sensory function fulfillment.

关键词： Bolt conflicting objectives design space finite element analysis mechanical domain optimization sensing sensor sensory domain sensor integration strain gauges finite element analysis mechanical domain optimization sensing sensor sensory domain sensor integration strain gauges

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An integrated temperature and humidity dual-parameter triboelectric sensor

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JOURNAL OF MATERIALS CHEMISTRY C 2024年第30期12卷 11640-11647页

作者： Si, Jiawei Yang, Jin Chen, Yiqi Hu, Ningxin Yang, Yurui Wu, Yuxuan Huang, Qing-an Han, Lei Southeast Univ Key Lab MEMS Minist Educ Nanjing 210096 Peoples R China Southeast Univ Sch Elect Sci & Engn Nanjing 210096 Jiangsu Peoples R China Southeast Univ Sch Informat Sci & Engn Nanjing 210096 Jiangsu Peoples R China

Integrated self-powered triboelectric sensors using sensitive materials as the triboelectric layer have the advantages of large signal amplitude, high integration, simple structure, and easy preparation. However, most of the current studies focus on single-parameter sensors. In this work, an integrated decouplable temperature and humidity dual-parameter triboelectric sensor is proposed, which contains a vertical contact-separation mode triboelectric nanogenerator (TENG) and a conductive polyethylene (c-PE) film. The TENG responds to humidity changes from 30%RH to 80%RH through output voltage variations based on the sensitive polyethylene terephthalate (PET) film. The inserted c-PE film realizes temperature sensing from 20 degrees C to 70 degrees C through changes in resistance based on the positive temperature coefficient effect, which is further applied to compensate the TENG for accurate humidity measurements. The compensation algorithm effectively reduces the maximum testing error of the humidity parameter from 31.34% to 7.29%. The proposed dual-parameter sensor provides an innovative strategy for the design and integration of dual-parameter sensors, showing great potential in intelligent sensors. An integrated decouplable temperature and humidity dual-parameter triboelectric sensor is proposed, which contains a triboelectric nanogenerator responding to humidity and an inserted conductive polyethylene film responding to temperature.

关键词： Temperature

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Highly Sensitive Biomimetic Crack Pressure sensor with Selective Frequency Response

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ACS sensors 2024年第6期9卷 3057-3065页

作者： Li, Yan Zhang, Zongzheng Du, Songlin Zong, Sicheng Ning, Zijun Yang, Fuling China Univ Min & Technol Beijing Sch Mech & Elect Engn Beijing 100083 Peoples R China

High-sensitivity sensors in practical applications face the issue of environmental noise interference, requiring additional noise reduction circuits or filtering algorithms to improve the signal-to-noise ratio (SNR). To address this issue, this study proposes a biomimetic crack pressure sensor with selective frequency response based on hydrogel dampers. The core of this research is to construct a biomimetic crack pressure sensor with selective frequency response using the high-pass filtering characteristics of gelatin-chitosan hydrogels. This design, inspired by the slit sensilla and stratum corneum structure of spider legs, delves into the material properties and principles of hydrogel dampers, exploring their application in biomimetic crack pressure sensors, including parameter selection, structural design, and performance optimization. By delving into the nuanced characteristics and working principles of hydrogel dampers, their integration in biomimetic crack pressure sensors is examined, focusing on aspects like parameter selection, structural engineering, and performance enhancement to selectively sieve out low-frequency noise and transmit target vibrational signals. Experimental results demonstrate that this innovative sensor, while suppressing low-frequency vibration signals, can selectively detect high-frequency signals with high sensitivity. At different vibration frequencies, the relative change in resistance exceeds 200%, and the sensor sensitivity is 7 x 10(4) kPa(-1). Furthermore, this sensor was applied to human voice detection, and the corresponding results verified its frequency-selective performance evidently. This study not only proposes a new design for pressure sensors but also offers fresh insights into the application of biomimetic crack pressure sensors in intricate environments.

关键词： biomimetic crack pressure sensor frequency hydrogel SNR

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Recent progress in high-resolution tactile sensor array: From sensor fabrication to advanced applications

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Progress in Natural Science:Materials International 2023年第1期33卷 55-66页

作者： Rui Wang Shaoxiong Hu Wei Zhu Yue Huang Wenhao Wang Ying Li Yuchen Yang Jiajie Yu Yuan Deng Research Institute for Frontier Science Beihang University School of Materials Science and Engineering Beihang University Key Laboratory of Intelligent Sensing Materials Chip Integration Technology of Zhejiang Province(2021E10022) Hangzhou Innovation Institute of Beihang University

Tactile sensors can transform the environmental stimuli into electrical signals to perceive and quantify the environmental information, which show huge application prospects. The development of bionic robots and wearable devices towards intelligence has put high demands on the performance of tactile sensor arrays. Herein,the current state-of-the-art tactile sensor arrays over recent years have been summarized, from sensor array fabrication to advanced applications. The main preparation methods of patterned array including screen printing,3D printing, laser microprocessing, and textile technology are discussed in detail. Strategies to optimize the signal crosstalk caused by flexible high-density sensor arrays are systematically introduced from the perspective of structure design and circuit design. Furthermore, advanced tactile sensors are not limited to a single pressure sensing function, and hence the development of multimodal detection for sensors has been discussed. In order to promote the adaptability in applications, stretchable and self-powered versatile integration scheme for advanced sensing are briefly described. Then, by means of machine learning and neural networks, it is possible to deeply explore the information embedded in the tactile acquisition signal with enriched application scenarios. Finally,the current challenges and the future perspectives for flexible tactile sensor arrays towards practical use are provided.

关键词： Tactile sensor arrays Fabrication Anti-crosstalk design integration strategy Advanced application

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Multifaceted classification and integration of time-varying complex signals using analog neuromorphic UV phototransistors

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JOURNAL OF MATERIALS CHEMISTRY C 2024年第47期12卷 19035-19048页

作者： Kumar, Mohit Lee, Suwan Dang, Hyunmin Seo, Hyungtak Ajou Univ Dept Energy Syst Res Suwon 16499 South Korea Ajou Univ Dept Mat Sci & Engn Suwon 16499 South Korea

Human vision encompasses a sophisticated sensory and computational system capable of analyzing complex attributes such as color, intensity, duration, and nature (linear or non-linear) of light exposure, along with storing its termination details. Inspired by this, neuromorphic vision sensors have been developed to enhance real-time data processing and decision-making, surpassing conventional sensors. However, they fall short in accurate multifaceted classification, integration of complex and temporal patterns, and secure storage of outcomes, which are critical for precise monitoring, security, and forecasting of dynamic natural phenomena. Here, we present a generic approach to developing a neuromorphic optical sensor adept at multifaceted classification and integration of non-linear inputs. Leveraging the heterogeneity in UV response of two-dimensional electron gas-based thin-film transistors and robust persistent photoconductivity, our sensor precisely discriminates between 310, 365, and 395 nm wavelengths, mixed wavelengths, while tracking both the duration and termination of illumination. The sensor offers highly secure, in-sensor multibit data processing and storage with a high on/off ratio exceeding 107. Furthermore, it adeptly handles real-time dynamic sensing, integration, and revelation of both linear and non-linear optical inputs as dictated by differential equations, including logistic maps, and is capable of monitoring complex dynamic phenomena such as those caused by water vortices.

关键词： Thin film transistors

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A soft sensor open-source methodology for inexpensive monitoring of water quality: A case study of NO3-concentrations

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JOURNAL OF COMPUTATIONAL SCIENCE 2025年 85卷

作者： Chaves, Antonio Jesus Martin, Cristian Torres, Luis Llopis Diaz, Manuel Fernandez-Ortega, Jaime Barbera, Juan Antonio Andreo, Bartolome Univ Malaga ITIS Software Malaga 29071 Spain Univ Malaga Dept Geol CEHIUMA Malaga 29071 Spain Univ Malaga Ctr Hydrogeol CEHIUMA Malaga 29071 Spain

Nitrate (NO3-) concentrations in aquifers constitute a global problem affecting environmental integrity and public health. Unfortunately, deploying hardware sensors specifically for NO3- measurements can be expensive, thereby, limiting scalability. This research explores the integration of soft sensors with data streams through an use case to predict nitrate NO3- levels in real time. To achieve this objective, a methodology based on Kafka-ML is proposed, a framework designed to manage the pipeline of machine learning models using data streams. The study evaluates the effectiveness of this methodology by applying it to a real-world scenario, including the integration of low-cost sensor devices. Additionally, Kafka-ML is extended by integrating MQTT and other IoT data protocols. The methodology benefits include rapid development, enhanced control, and visualisation of soft sensors. By seamlessly integrating IoT and data analytics, the approach promotes the adoption of cost-effective solutions for managing NO3- pollution and improving sustainable water resource monitoring.

关键词： Soft sensors Internet of Things Machine learning Nitrate Water monitoring

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SmartLVEnergy: An AIoT Framework for Energy Management Through Distributed Processing and sensor-Actuator integration in Legacy Low-Voltage Systems

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IEEE sensors JOURNAL 2024年第13期24卷 20726-20741页

作者： Fernandes, Rubens de Andrade da Costa Jr, Carlos Tavares Gomes, Raimundo Claudio S. Vilaca, Neilson Luniere Amazonas State Univ Embedded Syst Lab BR-69050020 Manaus Brazil Fed Univ Para Inst Technol BR-66075110 Belem Brazil

Digital integration is essential for efficient and sustainable management of energy resources, especially in modernizing outdated infrastructures. This involves embedding sensor and actuator devices for precise energy monitoring and control, supported by distributed computing from edge to cloud, necessary for tailored analytical and predictive decisions. Retrofit strategies incorporate these resources into older systems, enhancing existing infrastructures while adapting to technological progress. Nevertheless, systematic methodologies for sensor-actuator integration are lacking in the literature. Therefore, this article introduces the SmartLVEnergy framework, designed to modernize legacy low-voltage systems with a retrofitting approach, integrating decentralized sensing, control, distributed processing, and predictive analytics. The framework was employed to retrofit the energy distribution panel of a legacy manufacturing plant with sensor devices, which support remote monitoring and decentralized predictive analysis using 15-min energy demand forecast models based on two-layer long-short-term memory (LSTM) networks, adhering to Artificial Intelligence of Things (AIoT) and tiny machine learning (TinyML) principles. Benchmarked against nonquantized and single-layer LSTM models for the installation energy demand forecast between May 8 and July 11, 2023, our approach showed reduced prediction latency and memory consumption. The main circuit breaker exhibited a 96.67% R-squared score ( R-2 ) and 7.23 kW root mean squared error (RMSE), with the associated sensor showing a prediction latency of 54.55 ms and using 58.45 KB of FLASH memory. These metrics for the best-performing sensor were 97.33%, 0.39 kW, 5.55 ms, and 10.20 KB. This AIoT framework marks a significant advancement in sensor-actuator retrofitting, blending digital technology with legacy systems for intelligent energy management.

关键词： Energy management Internet of Things Buildings Predictive models Cloud computing Low voltage Long short term memory Artificial Intelligence of Things (AIoT) demand forecasting retrofit sensor-actuator system integration SmartLVEnergy Framework SmartLVGrid Metamodel tiny machine learning (TinyML)

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A Noncontact Passive Temperature-Vibration Multiparameter sensor

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IEEE sensors JOURNAL 2025年第3期25卷 5438-5445页

作者： Li, Chen Zheng, Miaomiao Bi, Kun Zhang, Wenping Hong, Yingping Zhang, Huixin Miao, Jing Xiong, Jijun North Univ China Key Lab Instrumentat Sci & Dynam Measurement Minist Educ Taiyuan 030051 Peoples R China Suzhou Univ Sci & Technol Sch Mech Engn Suzhou 215009 Peoples R China North Univ China Key Lab Instrumentat Sci & Dynam Measurement Minist Educ Taiyuan 030051 Peoples R China

As crucial rotating elements in mechanical apparatuses, the health condition of bearings is directly correlated with the dependability and safety of the entire system. Consequently, an integrated monitoring framework integrating bearing temperature and vibration sensors is imperative for the implementation of predictive maintenance tactics. To accomplish real-time surveillance of the temperature and vibration state of the inner ring of the bearing, a wireless passive inductive-capacitance (LC) multiparameter sensor based on thick-film integration and high-temperature sintering technology was advocated. This wireless passive sensor enables in situ precise measurement of temperature and vibration parameters without reliance on an external power supply, furnishing pivotal data support for the reliability and safety of large-scale equipment. The silver paste for the fabrication of the functional layer of the sensor was integrated in situ on the surface of the inner ring of the bearing via screen printing and high-temperature sintering technology. The temperature-vibration signals of the inner ring were gauged through a wireless RF transmission method. The feasibility and accuracy of the sensor for the synchronous measurement of the temperature-vibration parameters of the inner ring of the bearing within the temperature range of 35 degrees C-130 degrees C and under 2-10-g vibration circumstances were verified on the constructed temperature-vibration composite test platform. The results disclose that the sensor has a temperature sensitivity of 0.00586 MHz/degrees C and a maximum nonlinearity error of 0.013%. The vibration sensitivity is 0.05272 V/g with a maximum nonlinearity error of 0.2714%.

关键词： Synchronous measurement temperature sensors temperature sensors vibration sensors vibration sensors wireless passive wireless passive wireless passive

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Development of a Miniature Photometric Vision-Based Tactile sensor

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IEEE sensors JOURNAL 2024年第20期24卷 32053-32064页

作者： Gao, Yuan Zhang, Shixin Wan, Weiwei Fang, Bin Sun, Fuchun Harada, Kensuke Osaka Univ Grad Sch Engn Sci Toyonaka 5600043 Japan China Univ Geosci Beijing Sch Engn & Technol Beijing 100190 Peoples R China Beijing Univ Posts & Telecommun Sch Artificial Intelligence Beijing 100876 Peoples R China Tsinghua Univ Dept Comp Sci Beijing 100084 Peoples R China Natl Inst Adv Ind Sci & Technol Tsukuba 1008921 Japan

This study presents the design of a miniature vision-based tactile sensor (VTS) for compact integration with robotic grippers. VTSs have become a significant research area in the past decade known for their high-resolution capabilities. However, a common challenge faced by the VTS is their large size, which significantly limits the application scenarios. To solve this problem, in this article, we formulate the sensor structure design as an optimization problem constrained by the limitations of the camera and acrylic board and develop an optimally small sensor structure by solving the problem. Meanwhile, we use white LED lights paired with multicolor fluorescent pigment paintings for illumination. The pigment paintings were a more efficient and compact replacement for the traditional multicolor LED lights. The optimization, in conjunction with the pigment paintings, helps reduce the sensor size while maintaining the high-resolution characteristics of VTSs. The sensor has a low cost and can be easily integrated into existing robotic systems. For verification, we installed two such sensors on a two-finger parallel robotic gripper to perform various grasping tasks. The results show that the sensors could satisfactorily reconstruct the depth map of the contact surface. We also compared the proposed design with variations that have different lighting, camera, or mirror setups. The comparison results highlighted the importance of the various components and the effectiveness of the optimization.

关键词： sensors Robot sensing systems Cameras Tactile sensors Lighting Elastomers Mirrors GelSight sensor sensor miniaturization tactile sensing vision-based tactile sensors (VTSs)

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Directly Deposited Thin-Film Strain Gauges for Force Measurement at Guide Carriages

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IEEE sensors JOURNAL 2024年第24期24卷 40471-40484页

作者： Ottermann, Rico Kowalke, Dennis Denkena, Berend Korbacher, Michael Mueller, Matthias Wurz, Marc Christopher Leibniz Univ Hannover Inst Micro Prod Technol Micro & Nano Integrat Dept D-30823 Hannover Germany Leibniz Univ Hannover Inst Prod Engn & Machine Tools D-30823 Hannover Germany Bosch Rexroth AG Res & Dev Dept D-97424 Schweinfurt Germany Fooke GmbH Res & Dev Dept D-46325 Borken Germany Leibniz Univ Hannover Inst Micro Prod Technol D-30823 Hannover Germany

Many industrial production processes use sensors to generate information about the manufacturing process. In this way, monitoring machine tools ensures the proper functionality of the system and detects unexpected behavior due to, for example, material inhomogeneity, incorrect data input, temperature influence, or tool wear. In large production machines, such as portal milling machines, the sensor equipment of guide carriages can be an important possibility since they are a standardized component and can be easily integrated into existing machines. Here, conventional polymer foil-based strain gauges show several disadvantages due to reproducibility and reliability of the sensor connection via adhesive. Thus, this article addresses the manufacturing of directly deposited chromium thin-film strain gauges on a guide carriage with integrated programmable data preamplification. Tests with different sensor materials on steel substrates showed that chromium was the most suitable sensor material with a high k-factor. Then, one end face of the carriage was polished before sputtering an Al2O3 insulation layer and a chromium sensor layer that was laser-structured afterward to produce two Wheatstone full bridges at previously simulated sensor positions. In a tensile test stand, the calibration of the sensors took place in the two spatial directions perpendicular to the guide rail direction. With an additional sensor data fusion for the final interpretation of measured forces, it is shown that this sensor technology is suitable for force measurement at guide carriages.

关键词： sensors Strain Strain measurement Metals Sensitivity Production Temperature sensors sensor phenomena and characterization Semiconductor device measurement Conductivity Condition monitoring direct deposition force measurement guide carriages K-factor machine tool sensor integration strain gauges temperature coefficient of resistance (TCR) thin-film sensors

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