Segmentation of piezoelectric layers based on the numerical study of normal strain distributions in bimorph cantilevers vibrating in the second transverse mode/normaliniu deformaciju pasiskirstymo optimalios formos bimorfinese gembese, zadinamose antruoju rezonansiniu dazniu, tyrimas ir pjezoelektriniu sluoksniu segmentavimas.
Zizys, D. ; Gaidys, R. ; Dauksevicius, R. 等
1. Introduction
Nowadays energy harvesting is becoming an increasingly important
issue for low-power micro-systems (for e.g. wireless node systems,
seismic sensors, etc.). Progress in modern ultra-low-power
microelectronics demand a promote progress in micro-energy harvesting
from ambient energy sources to create self-powered microsystems. Since
usual locations for such systems are hardly accessible it is natural
that it is required that these sensors or systems would be self-powered,
would satisfy certain size and mass requirements, and would assure
continuous, longterm, uninterrupted power supply without replacement of
batteries or other elements. Several ambient energy sources could be
harnessed for this purpose such as thermal gradients, photonic energy,
various forms of radiation though the biggest potential is seen in
mechanical energy and vibrational energy in particular since low and
medium frequency vibrations are all around us and may offer a constant
and reliable power supply if harnessed correctly. During recent years
energy harvesting from vibration sources has attracted a lot of
interest, particularly as micro energy sources. The main application for
these are wireless sensor nodes, communication modules, etc. Supply
powers of < 100 [mu]W are sufficient to operate wireless nodes in
silent mode. The duty cycle can be quite small so that mW supply levels
already enable some autonomy. Motion and vibrations are the most
versatile and ubiquitous ambient energy source available [1]. The
mechanical to electrical energy transformation is most efficiently done
by piezoelectric materials [2].
Among numerous advantages of vibration energy harvesting there are
some drawbacks too. The most significant of those is their low
efficiency and the fact that their maximum power output is reached only
when the frequency of ambient vibrations matches the resonant frequency
of the harvester device. When the vibration of the environment passes
resonant frequency of the harvesters its efficiency drops significantly.
There are numerous solutions offered to overcome these drawbacks such as
widening the broadband frequency of the harvesters by changing the
shape, mass or parameters of the harvesters or introducing arrays of
different harvesters for harvesting different resonant frequencies.
The paper focuses on increasing the efficiency of rectangular and
optimal shape of the second and third mode transverse vibration
cantilever harvesters by optimal segmentation of the piezoelectric
materials of different polarization on the face of the cantilever. To
utilize this goal the rectangular cantilever is investigated at its
second resonant frequency of 541 Hz at settled vibration state as well
as two optimal shape cantilevers at their second resonant frequency of
534 Hz. The optimal shape cantilever means that the cantilever is
designed to match the rectangular cantilevers resonant frequency (second
and third resonant frequencies in this case) but to have minimal mass.
The normal strain along the length of cantilever is assumed to be
directly proportional to the power output of the piezoelectric layer of
corresponding sign. The results are assumed to be universal for any
cantilever harvester of such type. Fig. 1 illustrates the distribution
of utilization of different vibration frequencies and accelerations by
different kinds of vibrational energy harvesters.
[FIGURE 1 OMITTED]
1.1. Cantilever type harvester setup
Various forms and shapes of the cantilevers have been proposed to
increase the power output from strains in cantilver type generators.
Glynne-Jones proposed and modeled a tapered beam generator. The tapered
beam setup is different from normal rectangular cantilever harvester
that the constant strain is assured along the whole length of the
cantilver for given displacements. The device was manufactured from 0.1
mm thick AISI 316 stainless steel. The piezoelectric material used was
PZT-5H powder mixed with Corning 7575 glass and a suitable thick-film
vehicle to form a screen printable thixotropic paste. Both faces of the
cantilever were coated to cancel the uneven thermal expansion of the
cantilever and to maximize the power output. The structure was excited
at its first natural resonant frequency of 80.1 Hz and generated 3 [mu]W
at 333 k[OMEGA] [2].
There is also wide range of active materials to choose since the
deposition techniques are well developed for both thin and thick films
[3]. This was a constant width steel bar with two layers of PZT-5A on
top and bottom of the bar. The drawback of this design was that the
strain was distributed unequally along the bar; the mathematical models
describing this phenomenon are presented in [4]. A cubic mass made of
tin and bismuth composite was attached on the tip of the cantilever. The
designed resonant frequency for the structure was 120 Hz. The maximum
output value reached was 80 [mu]W into a 250 k[OMEGA] load resistance
with 2.5 m/[s.sup.2] input acceleration and the results showed a
reasonable level of agreement with the analytical models. Using these
models as reference the structure was optimized to overall size
constraint of 1 c[m.sup.3]. Two further designs were developed, each
using two PZT-5H layers attached to a 0.1 mm central brass. The paper
[5] provides results of dynamic numerical analysis of piezoelectric
cantilever-type microgenerator intended for wireless MEMS applications.
This analysis constitutes an initial phase of ongoing research work
aimed at microgenerator optimal design. It is based on beneficial
utilization of higher vibration modes, which may offer significant
benefits in terms of dynamic performance. Here we report preliminary
results of simulations that were performed with a developed 3D finite
element model of the microgenerator that constitutes a bilayer
cantilever structure with proof mass at the free end. The structure was
subjected to harmonic base excitation by applying vertical acceleration
through body load. The resulting characteristics reveal strong
dependence of magnitude of generated voltage on design and excitation
parameters (frequency, acceleration). Initial findings indicate the
necessity to develop microgenerator design with self-tuning of the
resonance frequency, i.e. the device should adapt to varying excitation
frequency so as to be driven in resonance thereby achieving maximal
electrical power output. Paper [6] reports on numerical modeling and
simulation of a generalized contact-type MEMS device having large
potential in various microsensor/actuator applications, which are
currently limited because of detrimental effects of the contact bounce
phenomenon that is still not fully explained and requires comprehensive
treatment. The proposed 2D finite element model encompasses cantilever
microstructures operating in a vacuum and impacting on a viscoelastic
support. The presented numerical analysis focuses on the first three
flexural vibration modes and their influence on dynamic characteristics.
Simulation results demonstrate the possibility to use higher modes and
their particular points for enhancing MEMS performance and reliability
through reduction of vibro-impact process duration. In [7] a
piezoelectric generator composed from a beam and a proof mass of is
designed and installed on a bicycle handlebar; the first experiments
have shown that the few mW that produced the piezoelectric generator is
able to power LED-lamp. Under ideal conditions such as pure sinusoidal
vibrations at 5 m[s.sup.2] and 12.5 Hz, the power harvestable measured
achieved 3.5 mW for an optimal resistive load of 100 kW, power that is
sufficient to recharge a battery, or to power low consumption devices.
These types of generators are the simplest while the mechanical
motion is directly converted into a voltage output via electrode active
material. This type of device can be used for both impact and vibration
energy harvesting without need for numerous additional components. This
type of generators is particularly well suited for micro-engineering. On
the other hand PZT is known to provide high output voltage but low
output currents. The piezoelectric materials are required to be strained
directly and therefore their mechanical properties will limit the
overall performance and lifetime. Also the transduction efficiency is
ultimately limited by piezoelectric properties of materials employed.
The output impedance of piezoelectric generators is typically very high
(> 100 k[OMEGA]) [8].
These and other sources were used to analyze the normal strain
distribution in direction along of the cantilever. Normal strain is
analyzed because there is a direct relation between normal strains
appearing on the face of the cantilever and thus in the layer of
piezoelectric material, and energy output of piezoelectric material
placed on that cantilever. Measuring and understanding the dynamic
effects appearing in the cantilever will help to optimize the energy
output from these strains.
Segmentation of the piezoelectric material on the face of the
cantilever is extremely important if the cantilever is going to be used
at its second or higher resonant frequency since at the regions of nodes
areas of uncertainty appear, where strains of both negative and positive
sign appear at the same moment and thus it is important to place the
piezoelectric materials of different polarizations so that the maximum
of the strains would be harnessed.
In normal conditions one would segment the piezoelectric material
at the middle of such region, but in this paper optimization of such
regions will be done and strain, or energy output gain of such
optimization will be calculated.
The objectives of this paper are to investigate normal strain
distribution along length of cantilever, then the cantilever is excited
at its second mode of transverse vibrations. The investigation was done
for three different shape cantilevers: rectangular, optimal shape of the
second mode transverse vibration and optimal shape of the third mode
transverse vibration. The eigenfrequencies have the same value. After
conducting the investigation optimal segmentation boundaries were
calculated where tensile deformations change compression deformations
and vice versa.
1.2. Derivation of characteristics
Modal analysis. Since the investigated cantilever systems are
considered to be undampped that is there is no element present that is
consuming the vibration energy of the cantilever the system may be
considered to be undergoing free vibrations and the governing
differential equation may be written as shown in (1):
Mu + Ku=Q. (1)
Internal elastic forces Ku act as an offset to the internal forces
Mu. In this case K is the stiffness matrix and M is the mass matrix.
Differential Eq. (1) can be reduced further to get (2) through which the
eigen-frequencies or resonant frequencies are found:
Kv = [[omega].sup.2]Mv, (2)
where [[omega].sub.i] is resonant frequency or eigen-frequency and
[v.sub.i] is corresponding vibration mode or eigen-mode vector. Boundary
condition for this cantilever is one fixed and the other end is free.
The impact of ambient forces is imitated by vertical kinematic (base)
excitation of the cantilever.
Equation of motion. The second problem is finding the distribution
of normal strains through the face of the cantilever under
investigation. For this problem differential equation of damped forced
vibration was used (3). The system was subjected to time dependent force
f(t), which is periodic in time:
Mu (t) + Cu (t) + Ku (t) = f(t). (3)
In this case the added C is damping matrix. The time dependent
force f(t) is described as cantilever body load in vertical direction
and defined as force/volume using the thickness:
f (t) = am sin [[omega].sub.n]t, (4)
where a is acceleration and is 1.2 m/[s.sup.2], m is mass of
cantilever and [[omega].sub.n] is the excitation frequency, which
matches the second resonant frequency of the cantilever under
investigation boundary conditions [6].
1.3. Finite element method models
Finite element method (FEM) was chosen to solve these differential
equations numerically.
The cantilevers under investigation are considered to be thin
because they satisfy the condition that thickness of the cantilever
should not be bigger than one tenth of the width of the cantilever, this
is important because in thin cantilevers the shear deformations in
transverse direction are neglected.
Because investigated structure is thick cantilever with no strain
in the out-of-plane direction the plane strain 2D continuum application
mode was used for modeling. The equation of motion (3) was solved during
transient analysis. The load parameters vary dependent on the excitation
frequency con of time dependent force f(t). The element type is
quadratic Lagrange elements with secondorder polynomials.
Adaptive meshing and extruded triangular mesh was used to solve
these problems. COMSOL 3.5a software was used. The investigation was
carried out with cantilever of three different geometries.
One rectangular cantilever, and the shape of other two cantilevers
was obtained by solving the shape optimization problem with the
objective to obtain the cantilever of minimal mass for a given mode of
transverse eigen-frequency, second and third in this case, with
constraints: state Eq. (2) and the value of its eigen-frequency
[[omega].sub.i] must be the same as value of the corresponding
rectangular cantilever eigen-frequency [[omega].sub.i]. Optimal shape
cantilevers are presented in Fig. 2. The cantilevers have been scaled by
a factor of 10 in vertical direction. Mechanical properties of the
material and dynamic characteristics of cantilevers are given in Table
1.
[FIGURE 2 OMITTED]
2. Numerical analysis
Modal analysis with three different shape cantilever harvesters was
performed. Results of modal analysis are presented in Table 1. From the
results it can be seen that values of eigen-frequency are the same or
close to it for all the cantilevers under investigation. The first
vibration mode of these cantilevers in transverse direction is shown in
Fig. 3 along with normal strain through the length of the cantilever,
and Fig. 4 for the second vibration mode.
[FIGURE 3 OMITTED]
[FIGURE 4 OMITTED]
The bimorph rectangular cantilevers was exposed to ambient harmonic
vibrations that matched their second transverse vibration resonant
frequency of 541 Hz at 1.3g acceleration for rectangular cantilever and
534 Hz and 1.3g acceleration for the optimized shape cantilevers. The
vertical displacement of free end of the cantilever for given interval
of time can be seen in Fig. 5. From Fig. 5 it can also be observed that
the interval selected for further investigation of normal strain in
horizontal direction with respect to cantilevers length is at the
settled region of the time interval. The period selected from this
interval is divided into 4 segments, it is assumed that deflections of I
and IV segments are equal in magnitude as well as II is equal to III,
they only differ in sign. The same methodic was used for other two
cantilevers that were excited at their second resonant frequency of 534
Hz. Fig. 6 represents distribution of normal strains in horizontal
direction in upper cantilever edge with respect to cantilevers length in
meters for given interval of time.
[FIGURE 5 OMITTED]
The number of curves represents the number of time steps that the
time interval was divided to. From Fig. 6 it can be seen that positive
strains appear from 0 m to a = 0.0189 m of the cantilever with strains
curve bounded area [A.sup.+], while negative--from b = 0.42 m to 0.1 m
with strains curve bounded area [A.sup.-]. Bounded areas [A.sup.+] and
[A.sup.-] are computed by integration a strain-displacement equation:
[MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] ; (5)
[MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] , (6)
where [MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] is the
normal strain of positive sign in transverse direction of the cantilever
at time step and [MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] is
the normal strain of negative sign in transverse direction of the
cantilever at time step [t.sub.i]. It is seen that this problem can be
reduced to finding the area of the region bounded above by the graph of
a function [partial derivative]u / [partial derivative]x, where
u--displacement in horizontal direction, x--horizontal axis. Bounded
below by the x-axis (cantilevers length), bounded to the left by the
vertical line a = 0.0189, and to the right by the vertical line b =
0.0416. As each different curve represents different point of time area
bounded by each curve has to be calculated A = [A.sup.-] + [A.sup.+]
where [A.sup.+] = [A.sub.t1.sup.+] + [A.sub.t2.sup.+] +...+
[A.sub.tn.sup.+] and [A.sup.-] = [A.sub.t1.sup.-] + [A.sub.t2.sup.-] +
... + [A.sub.tn.sup.-] as shown in Fig. 5, where [A.sub.t1.sup.+] is
normal strain of positive sign at time step 1, and [A.sup.+] is total
sum normal strain for given sign for each of time steps, where n number
of time steps. A represents the total sum of both positive and negative
normal strain. The left side of the region of uncertainty at which the
effective normal strain will be added to [A.sup.+] area from Fig. 5. It
is calculated by subtracting the area bounded by normal strain curves in
the negative part of the graph from area bounded by curves in the
positive part of the graph: [A.sup.+.sub.L]--[A.sup.-.sub.L] from 0.0196
m to 0.024039 m. Where, [A.sup.+.sub.L. is the sum of positive normal
strain at each time step in the left side of the region and
[A.sup.-.sub.L]--negative.
[FIGURE 6 OMITTED]
The right side of the region of uncertainty at which the gain will
be added to [A.sup.-] area from Fig. 5. It is calculated by subtracting
the area bounded by normal strain curves in the opposite part of the
graph from area bounded by curves in the negative part of the graph:
[A.sup.-.sub.R] [A.sup.+.sub.R] from 0.024039 m to 0.0416 m, where,
[A.sup.+.sub.R] is the sum of positive normal strain at each time step
in the right side of the region and [A.sup.-.sub.R]--negative. Optimal
segmentation was found to be at 0.024039 m by the method of
semi-crossing [5].
Total normal strain in transverse direction [SIGMA]A is found as
[SIGMA] A = [A.sup.+] + [A.sup.-] + [A.sub.L] + [A.sub.R]. It represents
the total normal strain per given period of time at one face of the
cantilever. The effective area calculation is done for both optimal and
suboptimal segmentation of the cantilever to make the comparison of the
gain of the segmentation as [A.sub.opt] versus [A.sub.Sub]. For the
investigated cantilever harvesters n = 18 time step per 1/4 period are
used for more precise results. The optimal segmentation and gain was
found for a rectangular cantilever at its second resonant frequency
[[omega].sub.2.sup.rect] = 514 Hz, optimal design cantilevers at its
second and third resonant frequencies [[omega].sup.opt.sub.2] = 534 Hz.
The later sections of the work presents the results of calculation for
different cantilever setups at their resonant frequencies.
3. Results
The graphic representation of calculation position of optimal
segmentation of three cantilevers is shown in Fig. 7. From Fig. 7, a it
can be observed that in the rectangular cantilever the optimal
segmentation line is shifted quite far from the geometric center of the
region of uncertainty, while in Fig. 7, b and c where the optimal shape
cantilever are shown the optimal segmentation line has been shifted by
very small amount. It is also obvious that normal strain curves are
quite symmetric with respect to the center of the region while in the
rectangular cantilever the symmetry is lost. Correlation between
symmetry of the normal strain curves and optimal segmentation can be
outlined. Finding optimal segmentation allowed the calculations of total
normal strain gain with optimal segmentation versus sub-optimal
segmentation. The normal strain curves were integrated to find the total
normal strain at each step of time for optimal and sub-optimal
segmentation. Total normal strain calculation method for constant sign
sections of the cantilevers can be seen in Fig. 7 for each cantilever,
where [MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] is the total
normal strain for given step of time [t.sub.i] of positive or negative
sign. The gain calculation results are given in Table 2. From this table
it can be seen that the biggest gain was found in the rectangular
cantilever, where the segmentation shift was also the greatest and
distribution of normal strain was the least symmetric with respect to
the center of uncertainty.
[FIGURE 7 OMITTED]
On the other hand the gain in optimal shape cantilevers is very
small, only 0.0013% in optimal shape cantilever for the second resonant
frequency and 0.0415% for optimal shape cantilever for third resonant
frequency. From Table 2 it can be seen that region of uncertainty
contained large proportion of total normal strain of bimorph rectangular
cantilever, optimization of this region gained 37.6% more usable strain
in this region and due to its large proportion (14.59% of total normal
strain output) in total normal strain the total gain was also big.
[FIGURE 8 OMITTED]
[FIGURE 9 OMITTED]
From Table 2 it also can be observed that optimal shape cantilevers
had quite small regions of uncertainty and optimization did not make big
effect on total normal strain output. The proportions of the region of
uncertainty versus total normal strain outputs of the cantilevers were
only 1% and 4% for optimal shape cantilevers respectively so naturally
optimization of this region gave small increase in terms of total normal
strain output. Fig. 8 illustrates the spread graphic of the total normal
strain versus length of the cantilever at time step [t.sub.i]. Total
normal strain output versus time step can be seen in Fig. 9. Here Fig.
9, a represents comparison of total normal strain outputs of all three
cantilevers. From here it can be seen that the biggest energy output has
been reached in optimal shape cantilever of the third mode excited by
the second resonant frequency. The smallest total normal strain or
equivalent energy output has been registered in rectangular cantilever
through the difference between optimal and sub-optimal segmentation
outputs was the greatest in this bimorph cantilever setup. From Fig. 9
it can be seen that the widest region of uncertainty with biggest normal
strain is observed in rectangular cantilever. Fig. 9 indicates that for
the optimal shape cantilevers optimal and sub-optimal segmentation total
normal strain output curves overlap (only 4 curves can be seen instead
of 6). From Fig. 8, a it can be seen that only the rectangular bimorph
cantilever shows large difference between optimal and sub-optimal
segmentation. Optimal shape bimorph cantilever curves overlap in optimal
and sub-optimal segmentation revealing very little difference between
optimal and sub-optimal cantilever performance under the same
conditions. Fig. 9, b demonstrates that the difference between optimal
and sub-optimal segmentation for rectangular cantilever is even bigger,
as well as for optimal shape cantilever for the third resonant frequency
excited by the second resonant frequency, though in this case the ratio
of total normal strain output in region of uncertainty versus total
normal strain output for the whole cantilever is very small. The results
show that due to optimal shape of the cantilevers the normal strain
distribution is localized in certain nodes of the cantilever and thus
the ineffective loss of usable normal strain along cantilever is
eliminated or minimized. This is seen from Fig. 8, b where rectangular
cantilever demonstrates large difference between optimal and sub-optimal
segmentation in region of uncertainty, while the optimal shape
cantilevers show very small difference between optimal and sub-optimal
segmentation. Fig. 10 Represents the results of the optimal segmentation
of the cantilevers. Here Fig. 10 schematic representation can be seen of
three cantilevers with optimal segmentation of piezoelectric layers and
directions of polarization for these layers when they are excited by the
second mode of transverse vibrations.
[FIGURE 10 OMITTED]
4. Conclusions
Optimal segmentation along the length of the cantilever was
calculated for each cantilever setup. Optimal segmentation position: for
rectangular cantilever is 0.024039 m; for the optimally-shaped
cantilever of the second mode of transverse vibrations--0.023136 m; for
the optimally-shaped cantilever of the third mode of transverse
vibrations--0.020579 m.
Total normal strain amount of sub-optimal configuration of the
bimorph rectangular sub-optimal segmentation cantilever--0.732532, of
optimal segmentation 0.762948. For the optimally-shaped cantilever for
the second eigen-frequency--sub-optimal 0.891466, optimal 0.891478 and,
for optimally-shaped cantilever for the third eigen-frequency
sub-optimal 0.97936, optimal 0.98353.
Total gain of optimal segmentation cantilever versus sub-optimal
was found to be 4.15%, and 0.00013% and 0.0425% for the optimally-shaped
cantilevers for the second and the third eigen-frequencies respectively.
Optimally-shaped cantilevers had narrower region of uncertainty and
smaller ratio of total normal strain amount in region of uncertainty
versus rectangular cantilever. Total normal strain in bimorph
rectangular cantilever was smaller if compared to the optimized
cantilevers due to larger losses of strain due to wide region of
uncertainty.
Acknowledgments
This research was funded by a grant (No. MIP060/2012) received from
the Research Council of Lithuania.
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Received December 03, 2012 Accepted August 21, 2013
D. Zizys, R. Gaidys, R. Dauksevicius, V. Ostasevicius
Kaunas University of Technology, Kestucio 27, 44312 Kaunas,
Lithuania, E-mail:
[email protected]
cross ref http://dx.doi.org/10.5755/j01.mech.19A4477
TABLE 1
Mechanical properties of the material and dynamic
characteristics of cantilever setups
REC
[[omega].sub.1], Hz 86
[[omega].sub.2], Hz 541
Density, kg/[m.sup.3]
Elastic modulus, N/[m.sup.2]
Poisson's ratio
Length, l
Width, a
Thickness, b
OPT II
[[omega].sub.1], Hz 66
[[omega].sub.2], Hz 534
Density, kg/[m.sup.3] 7850
Elastic modulus, N/[m.sup.2] 2 x [10.sup.10]
Poisson's ratio 0.33
Length, l 0.1 m
Width, a 0.01 m
Thickness, b 0.001 m for rectangular
from 0.0005 m up to 0.0015 m
for optimal shape
OPT III
[[omega].sub.1], Hz 66
[[omega].sub.2], Hz 534
Density, kg/[m.sup.3]
Elastic modulus, N/[m.sup.2]
Poisson's ratio
Length, l
Width, a
Thickness, b
TABLE 2
Total normal strain gain calculation results for three types of
cantilever energy harvesters
Cantilever Segmentation Total strain in
type position along x-direction
cantilever, m
Rectangular
Optimal Opt = 0.024039 0.762948
Sub-Optimal C = 0.030014 0.732532
OPTII
Optimal Opt = 0.023136 0.891478
Sub-Optimal C = 0.023072 0.891466
OPTIII
Optimal Opt = 0.020579 0.983534
Sub-Optimal C = 0.020323 0.979361
Cantilever Region of uncertainty gain, %
type Normal strain in Normal strain in
region of uncertainty region of uncertainty
versus total
normal strain, %
Rectangular
Optimal 14.59 0.111301
Sub-Optimal 11.01 0.080885
OPTII
Optimal 1.03 0.00918
Sub-Optimal 1.02 0.00917
OPTIII
Optimal 4.19 0.03751
Sub-Optimal 3.42 0.03333
Cantilever Total
type Gain in region Gain, %
of uncertainty, %
Rectangular
Optimal +37.6% +4.15%
Sub-Optimal
OPTII
Optimal +0.128% +0.0013%
Sub-Optimal
OPTIII
Optimal +12.5% +0.0425%
Sub-Optimal