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2008 (AD5933) Structural Health Monitoring Using Electro-Mechanical Impedance
2008 (AD5933) Structural Health Monitoring Using Electro-Mechanical Impedance
2008 (AD5933) Structural Health Monitoring Using Electro-Mechanical Impedance
Fatigue
& Fracture
& Fracture
of of
Engineering
Engineering
Materials
Materials
& Structures
& Structures
doi: 10.1111/j.1460-2695.2008.01248.x
A B S T R A C T This paper reports recent achievements of novel structural health monitoring (SHM)
techniques for damage diagnosis for critical members of civil, mechanical and aerospace
structures using electro-mechanical impedance sensors. The basic concept of this tech-
nique is to use simultaneously both high-frequency structural excitations and responses
employing piezoelectric sensors to monitor the local area of a structure for changes in
structural impedance that would indicate imminent damage. In this paper, several princi-
pal software and hardware issues on these topics are described. A new impedance model
is proposed that incorporates the effects of sensor and bonding defects for sensor self-
diagnosis. Temperature effects-free impedance-based damage detection algorithm using
effective frequency shifts based on cross-correlation coefficients is presented. In a sense
of tailoring wireless sensing technology to the impedance methods, an active sensor node
incorporating a miniaturized impedance sensing device, an on-board microcontroller,
and a radio frequency (RF) telemetry is introduced. A data compression algorithm is
embedded into the on-board chip of the active sensor node to enhance its local data
processing-capability. Finally, this paper concludes with a discussion of further studies
and future applications.
714
c 2008 Blackwell Publishing Ltd. Fatigue Fract Engng Mater Struct 31, 714–724
STRUCTURAL HEALTH MONITORING 715
c 2008 Blackwell Publishing Ltd. Fatigue Fract Engng Mater Struct 31, 714–724
716 S . P A R K et al .
Fig. 2 Crack detection on a steel truss member using a PZT sensor array (Park et al., 2006).
signatures gives good information for damage localization The main limitation of the use of the aforementioned
and severity by implying the sensing area of the impedance damage metric in impedance methods is how to set appro-
method is much localized (around 50 mm for this priate decision limits or thresholds values. The decision
example). is typically made based on arbitrary values, that is, ‘small
c 2008 Blackwell Publishing Ltd. Fatigue Fract Engng Mater Struct 31, 714–724
STRUCTURAL HEALTH MONITORING 717
variations’ for undamaged cases and ‘large variations’ for sors/actuators are confirmed to be operational, is there-
damage cases. In order to diagnose damage with levels of fore critically important issue to successfully implement
statistical confidence, the impedance-based monitoring is the SHM process. Because PZT materials are brittle,
cast in the context of an outlier detection framework.11,12 sensor fracture and subsequent degradation of mechan-
They showed that the optimal decision limits with levels ical/electrical properties are the common types of sen-
of statistical confidence for more systematic damage di- sor/actuator failures. In addition, the integrity of bonding
agnosis can be established. However, it is noted that the layer between a PZT sensor and a host structure should
decision limits shall be continuously updated according be maintained and monitored throughout their service
to undesirable ambient changes including sensor/bonding lives. Saint-Pierre et al.20 and Giurgiutiu et al. 21 pro-
layer’s deteriorations and temperature changes. posed a de-bonding identification algorithm by monitor-
ing the resonance of a PZT sensor measured by elec-
trical impedances. As the de-bonding area between the
PZT sensor and the host increases, the shape of the
A NEW ELECTRO-MECHANICAL IMPEDANCE
PZT sensor’s resonance becomes sharper and more dis-
MODEL FOR SENSOR SELF-DIAGNOSTICS
tinctive, and the magnitudes of the host resonances are
Various models to carry out the dynamic analysis for reduced. Blackshire et al.22 studied the performance of
the electro-mechanical impedance method have been surface-bonded PZT sensors on operational aircraft envi-
developed so far. Typical examples include a static ronment. Park et al.23,24 introduced a piezoelectric sensor-
model,13 a dynamic finite element model,14 a single de- diagnostic procedure based on tracking the imaginary
gree of freedom (SDOF)’s impedance-based model using parts of the measured electrical admittance. Also, it was
spring-mass-damper (SMD) system15 and a two DOFs’ confirmed that the bonding layer between a PZT sen-
impedance-based model including a bonding layer be- sor and a host structure significantly influences the mea-
tween a PZT sensor and a host structure.16 However, sured electrical admittance. However, it has not provided
Liang et al.15 did not take into account the effect of a fully integrated electro-mechanical impedance model
bonding layers between a PZT sensor and a host struc- that can present explicitly the influences due to sensor
ture on the dynamic interaction in the coupled electro- quality and/or bonding effects. In this context, a new
mechanical system. Xu and Liu16 did not consider degra- electro-mechanical impedance model that can be utilized
dation of sensor quality due to ageing effects and/or that of for both functions of SHM and sensor diagnostics was
coupling effects due to bonding defect. Bhalla and Soh17 proposed by Park et al.25 The authors established a rig-
investigated the effects of the shear-lag on the electro- orous impedance model incorporating the sensor quality
mechanical admittance measurements. They found that index of a PZT and coupling degradation effects between
the bonding layer can significantly modify the measured a PZT and bonding layer/host structure for better estima-
admittance signatures, and suggested the use of an ad- tion of the electro-mechanical impedance signatures and
hesive with high shear modulus, the smallest practicable sensor self-diagnostics considering sensor and/or bonding
bond-thickness and small-sized PZT sensor in order to defects on the subsequent admittance measurements.
minimize the influence of the bonding layer. Recently, In Eq. (1) of the previous section, because tan κl ≈ κl in
Annamdas and Soh18 proposed a three-dimensional (3D) the frequency range of interest in most applications of the
impedance model for damage analysis and PZT character- impedance-based SHM, Eq. (1) can be simplified as
ization and Madhav and Soh19 reported that the bonding
layer can be treated as a part of the host structure by ana- Zs
Y = j ωC 1 − κ31 2
, (3)
lyzing 3D influence of the bonding layer between the PZT Zs + Za
sensor and the host structure. However, the metrics that wl T
where C(= ε̄ )
h 33
is the capacitance of the PZT sensor,
can be used for the bonding quality assessment was not 2
d 31 Ȳ E
clearly identified, and the ability to discriminate bond- and κ31
2
(= ε̄33
T ) is the electro-mechanical coupling factor
ing failures from structural damage was not thoroughly of the PZT sensor.10
investigated. However, Eq. (3) does not consider influences caused by
One critical aspect of the electro-mechanical impedance- changes in sensor qualities and bonding layer’s shear lag
based SHM technologies is that usually large numbers of effects or coupling degradation effects. To overcome this
distributed sensors are needed to perform the required limitation, Park et al.25 proposed a rigorously integrated
monitoring process. In addition, the structures in ques- impedance model including the control parameters for
tion are usually subjected to various external loading and sensor quality assessment and the coupling degradation
environmental condition changes that may adversely af- effects between a PZT and bonding layer/host structure
fect the functionality of SHM sensors. The PZT sensor for better estimation of the electro-mechanical impedance
self-diagnostic and validation procedure, where the sen- signatures and sensor diagnostics on the subsequent
c 2008 Blackwell Publishing Ltd. Fatigue Fract Engng Mater Struct 31, 714–724
718 S . P A R K et al .
c 2008 Blackwell Publishing Ltd. Fatigue Fract Engng Mater Struct 31, 714–724
STRUCTURAL HEALTH MONITORING 719
where x̄(ωi ) and ȳ(ωi ) are the mean values of the under the temperature varying environment. As shown in
impedance signatures of the intact cases at ωi ; and σX Fig. 4a, a mass flow controller (MFC) sensor was used
and σY are the standard deviations for each. to detect the presence of an artificial cut inflicted on the
The proposed strategy was applied to health monitor- specimen. An MFC sensor of 28 × 14 × 0.02 mm3 was
ing of a lab-sized steel truss bridge member of Fig. 2a placed with a distance of 40 mm away from the middle
c 2008 Blackwell Publishing Ltd. Fatigue Fract Engng Mater Struct 31, 714–724
720 S . P A R K et al .
of the welded zone on the outside surface of a flange. A More detailed descriptions of the temperature compen-
thermo-coupler was also placed near the MFC sensor for sation techniques on the impedance measurements are
temperature measurement. The impedance and tempera- presented from Park et al.28 and Koo et al.30
ture measurements were carried out continuously during a
long period for the healthy (intact) and damage states. An
artificial cut of 4 mm long and 0.5 mm wide was inflicted
at Test 199 on the welded zone of the specimen. As shown HARDWARE DEVELOPMENT ISSUES
in Fig. 4b, it was observed that traditional RMSD met- FOR IMPEDANCE-BASED SHM
rics without any temperature compensation algorithms
Tailoring wireless sensing technology
show erroneous diagnostic results including false alarms
to the impedance-based SHM
and damage missing cases. To compensate the adverse
temperature variation effects, maximum CCs of Eq. (5) By the way, the use of wireless sensors and net-
were calculated. Figure 4c shows a typical example of the works are becoming increasingly popular as a research
temperature compensation. In two impedance signatures topic for SHM system. In particular, development of
for intact cases (Tests 1 and 58) measured at the differ- a self-contained wireless sensor incorporating all the
ent temperature (15.3 ◦ C and 25.3 ◦ C), it is observed that functions including on-board actuating/sensing, power
after the effective frequency shift, the impedance signa- generation, on-board data processing/damage diagnos-
ture of Test 58 is well matched with the reference sig- tic and RF module is strongly required. With the
nature of Test 1. After applying this temperature com- current trend of SHM heading towards unobtru-
pensation algorithm to all measured impedance signals, it sive self-contained sensors, the approaches integrating
was demonstrated that the maximum CC values with the micro-electro-mechanical systems (MEMS) and RF
effective frequency shift provided good damage diagnos- telemetry-based active sensing systems on the electro-
tic results, introducing an abrupt drop after the 4 mm cut mechanical impedance-based damage detection tech-
damage inflicted at Test 199, as shown in Fig. 4d. How- nique are being investigated untiringly by several re-
ever, the CC values among the signatures for the intact searchers.31,32,33
cases are still suffering from significant fluctuation due to The on-board active sensor system interrogates a struc-
the temperature variations, which may cause significant ture utilizing a PZT sensor and the low-cost impedance
false alarming as well as damage missing cases. In order method, and all the structural interrogation and data anal-
to determine a proper decision limit (or threshold level) ysis is pursued in near real-time at the sensor location.
for damage detection, statistical decision methods such as Moreover, a wireless telemetry that alerts the end-user
the outlier analysis are required. In this study, the opti- to any harmful changes in the structure can be read-
mal threshold value for damage detection considering the ily installed. Conventional impedance analyzers, such as
fluctuation in the CC values was decided as 0.742 (with a HP4294A for the electro-mechanical impedance method
confidence level [CL] of 99.5%) through an outlier analy- are too expensive and too bulky, which is not attractive
sis. As expected, it has been found that after the 4 mm cut for real-world application. So, a new impedance measur-
damage infliction the CC values dropped abruptly under ing chip device of low cost, portable and readily combined
the threshold value with a significant difference, so that with a wireless telemetry was developed by Analog Device,
reliable SHM and damage detection may be carried out AD5933, which costs only 150$. Fig. 5 shows AD5933 and
under temperature variations by the present impedance- its block diagram. Park et al.34 reported a successful cor-
based method. However, it is noted that the decision limit rosion detection result on an aluminium beam structure
(or threshold level) shall be properly selected consider- by utilizing the miniaturized impedance measuring chip,
ing the daily temperature range and the minimum target AD5933. Mascarenas et al.32 devised an active sensor node,
damage level for detection, and continuous updating of as displayed in Fig. 6, which consists of AD5933, a micro-
the decision limit (or threshold level) is needed, as more controller (ATmega128L) and an RF transmitter (XBee).
data would be available, so that more reliable SHM may A PZT sensor interrogates a host structure by using a self-
be achieved on real structures under temperature varying sensing technique of the AD5933. All the process includ-
condition. ing structural interrogation, data acquisition, signal pro-
Thus, it can be concluded that the temperature effects cessing and damage diagnostic is being performed at the
on the impedance data would cause only parallel shifts sensor location by the microcontroller. And only damage
with both vertical and horizontal directions keeping their diagnostic result implying ‘damage’ or ‘no damage’ will
original patterns without any changes on themselves while be transmitted to the end-user through the RF data trans-
structural damage effects would cause considerable sig- mission. Finally, the light-emitting diodes (LED) shows
nal changes such as the resonant peak values’ shifts and ‘green’ or ‘red’ colour according to ‘intact’ or ‘damage’
new peak’s appearances or original peak’s disappearances. state, respectively.
c 2008 Blackwell Publishing Ltd. Fatigue Fract Engng Mater Struct 31, 714–724
STRUCTURAL HEALTH MONITORING 721
Fig. 6 An active sensor node for wireless impedance-based SHM system (Mascarenas et al., 2006).
Embedding PCA-data compression algorithm into dimensions 61.5 × 5 × 0.4 cm3 jointed together with
the active sensor node four pairs of bolts and nuts of diameter 8 mm. The MFC
sensor was placed at 16 cm apart from the middle of the
On the use of the aforementioned active sensor node,
joint section of the specimen. Note that the boundary
wirelessly transmitting the health-diagnostic information
condition of the specimen was kept with a simply sup-
to end-user is very crucial. Because the size of the raw
ported condition during all the experiment. The electro-
impedance data is prohibitive for a direct use and the raw
mechanical impedance for an intact case (baseline) was
impedance data are usually very sensitive to some am-
measured at a frequency range of 60–70 kHz from the
bient noise effects, the PCA-data compression technique
MFC sensor. Then, the several damage cases with one,
could be applied as a pre-processing module to reduce the
two and three loose bolts on the specimen were inflicted
data dimensionality and eliminate the unwanted noises. In
in sequence, and the electro-mechanical impedances were
this technique, the most significant principal components
recorded for each damage case. From the comparison be-
(PCs) obtained from the raw impedances contain those
tween the traditional RMSD method without any data
features that are dominant in most of the frequency re-
pre-processing (Fig. 7b) and the new RMSD method with
sponses.
PCA-data compression (Fig. 7c), it was observed that the
The effectiveness of the proposed PCA-data compres-
results using the impedances reconstructed with only two
sion approach for the impedance-based wireless SHM
PCs showed more significant damage detection capabil-
was verified through an experimental study inspecting
ity than the result using the original raw impedance data.
loose bolts in a bolt-jointed aluminium structure by Park
Therefore, it can be addressed that the PCA-data com-
et al.35 As shown in Fig. 7a, a MFC sensor of 4 × 2.54 ×
pression provides some noise elimination effects so as to
0.0267 cm3 associated with AD5933 was surface-mounted
enhance the damage detection capability of the traditional
to the specimen that consists of two aluminium beam of
impedance-based SHM technique. This result presents
c 2008 Blackwell Publishing Ltd. Fatigue Fract Engng Mater Struct 31, 714–724
722 S . P A R K et al .
Fig. 7 Impedance-based damage detection using PCA-data compression (Park et al., 2008).
that the RMSD method using only a few PCs, which CONCLUSIONS
might be the most sensitive due to damage, extracted from
This paper presents recent achievements in terms of sev-
the original impedance data will be able to reduce a false-
eral principal software and hardware issues on damage di-
positive damage call in real-world SHM applications. In
agnosis using electro-mechanical impedance sensors for
addition, this study contributes to both improvement of
online health monitoring of critical members in civil, me-
local data analysis capability and saving of power con-
chanical and aerospace structures. First, a new impedance
sumption of the on-board chip of the aforementioned
model for both functions of structural damage detection
active sensor node.
c 2008 Blackwell Publishing Ltd. Fatigue Fract Engng Mater Struct 31, 714–724
STRUCTURAL HEALTH MONITORING 723
and sensor self-diagnostics was formulated that incorpo- 2 Giurgiutiu, V. and Rogers, C. A. (1997) Electro-mechanical
rates the effects of sensor and bonding defects. Then, the (E/M) impedance method for structural health monitoring and
temperature effects-compensation technique referred to nondestructive evaluation. In: Proceedings of International
Workshop on Structural Health Monitoring, September 18–20,
as ‘effective frequency shifts’ was introduced. In a latter
Stanford, CA, pp. 433–444.
part of this paper, an active sensor node incorporating 3 Park, G., Cudney, H. and Inman, D. J. (2000)
a miniaturized impedance sensing device, an on-board Impedance-based health monitoring of civil structural
microcontroller, and a RF/wireless telemetry was inves- components. ASCE J. Infrastructure Syst. 6, 153–160.
tigated, and a PCA-data compression algorithm was em- 4 Tseng, K. K., Soh, C. K., Gupta, A. and Bhalla, S. (2000)
bedded to the microprocessor for better local data anal- Health monitoring of civil infrastructures using smart
ysis capability of the active sensor node. This result con- piezoceramic transducers. In: 2nd International Conference on
Computational Methodology for Smart Structures and Materials,
tributes to both eliminating of ambient noise effects and
19–20 June, Madrid, pp. 153–162.
saving of power consumption in the active sensor node. 5 Zagrai, A. N. and Giurgiutiu, V. (2001) Electro-mechanical
The final goal of this ongoing research is to develop a self- impedance method for crack detection in thin wall structures.
contained on-board sensor system that can be utilized for In: 3rd Int. Workshop of Structural Health Monitoring, Stanford
online continuous health monitoring of real civil, me- University, CA, September 12–14.
chanical and aerospace structures. Another important hot 6 Park, G., Sohn, H., Farrar, C. R. and Inman, D. J. (2003)
issue for this system is energy harvesting or power man- Overview of piezoelectric impedance-based health monitoring
and path forward. Shock Vibration Digest 35, 451–463.
agement problem. The solutions of these challenges are
7 Park, S., Yun, C.-B., Roh, Y. and Lee, J.-J. (2005) Health
being pursued by the authors at the moment monitoring of steel structures using impedance of thickness
The present approaches yield an improved methodol- modes at PZT sensors. Smart Struct. Syst. 1, 339–
ogy for real-time damage diagnosis for critical members 353.
of civil, mechanical and aerospace structures. One can 8 Park, S., Yun, C. B., Roh, Y. and Lee, J. J. (2006) PZT-based
envision the current systems placed on the critical mem- active damage detection techniques for steel bridge
bers of in situ real structures including bridges, buildings, components. Smart Mater. Struct. 15, 957–966.
9 Park, S., Ahmad, S., Yun, C.-B. and Roh, Y. (2006) Multiple
power plants, airplanes and rockets to detect the promis-
crack detection of concrete structures using impedance-based
ing some damage. A significant safety enhancement and structural health monitoring techniques. Exp. Mechanics 46,
broad cost savings are predicted through the wide applica- 609–618.
tion of this novel method for damage detection and failure 10 Liang, L., Sun, F. P. and Rogers, C. A. (1994) Coupled
prevention. electro-mechanical analysis of adaptive material
systems-determination of the actuator power consumption and
Acknowledgements system energy transfer. J. Intelligent Mater. Syst. Struct. 5,
12–20.
This work was jointly supported by the Korea Research 11 Park, G., Rutherford, A. C., Sohn, H. and Farrar, C. R. (2003)
Foundation Grant funded by the Korean Government An outlier analysis framework for impedance-based structural
(MOEHRD) (KRF-2005–213-D00092), the Smart Infra- health monitoring. J. Sound Vib. 35, 451–463.
Structure Technology Center (SISTeC) at KAIST spon- 12 Park, S., Inman, D. J., Yun, C.-B. and Park, G. (2006) An
sored by the Korea Science and Engineering Foundation outlier analysis for damage detection of railroad tracks using
(KOSEF) and the Infra-Structure Assessment Research MFC impedance-based wireless SHM system. In: Proceedings of
the 3rd International Workshop on Advanced Smart Materials and
Center (ISARC) sponsored by Ministry of Construction
Smart Structures Technology, Lake Tahoe, CA, 28–30,
and Transportation (MOCT), Korea. This material is May.
also based upon work supported by the National Sci- 13 Crawley, E. F. and Deluis, J. (1989) Use of piezoelectric
ence Foundation under Grant No. CMS 0120827. Any actuators as elements of intelligent structures. AIAA J. 25,
opinions, findings and conclusions or recommendations 1373–1385.
expressed in this material are those of the authors and do 14 Ha, S. K., Keilers, C. and Chang, F. K. (1992) Finite element
not necessarily reflect the views of the National Science analysis of composite structures containing distributed
piezoelectric sensors and actuators. AIAA J. 30, 772–
Foundation. This financial support is greatly appreciated.
780.
Finally, the authors thank Prof. Yongrae Roh of Kyung- 15 Liang, L., Sun, F. P. and Rogers, C. A. (1996)
pook National University, Korea and Dr. Gyuhae Park Electro-mechanical impedance modeling of active material
of Los Alamos National Laboratory, USA for giving their systems. Smart Mater. Struct. 5, 171–186.
kind guidance during the experiments. 16 Xu, Y. G. and Liu, G. R. (2002) A modified electro-mechanical
impedance model of piezoelectric actuator-sensors for
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724 S . P A R K et al .
c 2008 Blackwell Publishing Ltd. Fatigue Fract Engng Mater Struct 31, 714–724