This conference presentation was prepared for the Active and Passive Smart Structures and Integrated Systems XVII conference at SPIE Smart Structures + Nondestructive Evaluation, 2023
KEYWORDS: Shape memory alloys, Actuators, Switches, Switching, Prototyping, Control systems, Power supplies, Data acquisition, Computer programming, Standards development
While the use of SMA-actuated devices continues to grow in many industries, current device limitations pose a challenge to successful adoption for certain classes of applications. SMA-actuated devices typically demonstrate motion with non-constant velocity due to the non-linear thermo-mechanically coupled behavior of SMA material transformation, and motion sensitivity to external factors such as voltage and load. This variation in motion can lead to the perception of poor device quality, limiting SMA-actuated devices to applications hidden from the sight of the product user, or requiring them to be augmented with higher cost controls to improve the motion quality. Therefore, a need exists for simple, passive, low-cost device technologies that enable the designer to prescribe desired motion characteristics with relative insensitivity to fluctuation in operating conditions. This paper presents a Damper Controlled Switch (DCS) mechanism that delivers constant velocity and relative insensitivity to operating conditions when combined with a standard SMA wire actuator. The DCS includes a damper that acts against a spring to open a switch when the velocity exceeds a tunable threshold. To validate the ability of the DCS to provide the desired motion quality, experiments were conducted comparing the normal motion of the SMA actuator to the motion produced when the same actuator was fitted with a DCS prototype. The addition of the DCS produced nearly constant actuator velocity, performing significantly better than the SMA actuator alone. The tunability of the DCS was demonstrated producing a wide range of attainable constant velocities. Finally, a set of experiments explored the DCS’s sensitivity to voltage and load, indicating a low sensitivity to a wide range of operating parameters for which the operating limits were identified. The DCS represents a simple, compact technology based on passive, low-cost components, providing a very practical solution that will enable integration of SMA-actuated devices into a broader class of applications.
Over 60% of energy that is generated is lost as waste heat with close to 90% of this waste heat being classified as
low grade being at temperatures less than 200°C. Many technologies such as thermoelectrics have been proposed as
means for harvesting this lost thermal energy. Among them, that of SMA (shape memory alloy) heat engines appears
to be a strong candidate for converting this low grade thermal output to useful mechanical work. Unfortunately,
though proposed initially in the late 60's and the subject of significant development work in the 70's, significant
technical roadblocks have existed preventing this technology from moving from a scientific curiosity to a practical
reality. This paper/presentation provides an overview of the work performed on SMA heat engines under the US DOE
(Department of Energy) ARPA-E (Advanced Research Projects Agency - Energy) initiative. It begins with a review
of the previous art, covers the identified technical roadblocks to past advancement, presents the solution path taken to
remove these roadblocks, and describes significant breakthroughs during the project. The presentation concludes with
details of the functioning prototypes developed, which, being able to operate in air as well as fluids, dramatically
expand the operational envelop and make significant strides towards the ultimate goal of commercial viability.
Shape memory alloy (SMA) wire actuators are quickly becoming technologically ready for a wider range of
commercial applications due both to their exceptional actuation performance and to recent advances in the
manufacture of drawn SMA wire. Shape memory alloys are complex materials requiring a breadth and depth
of knowledge to successfully implement in more demanding industrial applications, knowledge to which most
engineers may not have been exposed. This paper proposes a modular design framework to aid engineers at
any level of expertise to synthesize and analyze SMA wire actuators. The modularity of the framework allows
for changes in design, architecture, and system topology and allows for easy adaptation to the rapid research
advances in the knowledge and understanding of the response and robust use of SMA. The layered structure of
the framework is detailed; differentiating the design tasks by function: modeling, evaluation, optimization, and
design guidance. Each layer is modular within itself, and in particular, the modeling layer allows for a variety of
views to suit the expertise of individual designers. A sample design tool built within the framework is presented
for the synthesis of actuators composed of multiple straight SMA wires acting against linear loads, accompanied
by a physical system demonstration. This example, while basic, demonstrates the general applicability and
flexibility of the framework for aiding many types of users in a large variety of SMA wire actuation design
problems.
Shape memory alloy (SMA) wires are used increasingly in place of traditional actuators because of their compactness, high work density, low cost, ruggedness, high force generation, and relatively large strains. One well known issue with SMA wires is degradation in performance as actuation cycles accumulate, with significant reductions observed as soon as only tens or hundreds of cycles; thus, manufacturers typically recommend very conservative limits on the operation regime. This paper introduces an alternative approach of cycling or "shaking down" SMA wires under controlled conditions prior to installation. This enables the designer to design to the stable post-shakedown specification of the wire to produce actuators with repeatable larger forcing capabilities. This paper presents a preliminary experimental study which explores the functional dependence of shakedown performance on loading and strain history. A methodology is developed by which an SMA wire can be thermally cycled under electrical heating and the performance characterized with a double-exponential empirical model fit which captures the steady state performance of the wire and the rate at which shakedown occurs. Several sets of experiments are conducted to explore the functional dependence of the shakedown performance varying the load applied (29 to 78N), the allowed strain (4 to 7%), and the form of the loading function (linear spring vs. constant). These experimental studies expose important shakedown parameters affecting SMA actuator performance and provide a first step towards creating detailed SMA wire shakedown protocols tailored to the application that will enable the design of higher performance, stable SMA actuators.
The field of Smart Materials and Structures is evolving from high-end, one-of-a-kind products for medical, military and
aerospace applications to the point of viability for mainstream affordable high volume products for automotive
applications. For the automotive industry, there are significant potential benefits to be realized including reduction in
vehicle mass, added functionality and design flexibility and decrease in component size and cost. To further accelerate
the path from basic research and development to launched competitive products, General Motors (GM) has teamed with
the College of Engineering at the University of Michigan (UM) to establish a $2.9 Million Collaborative Research
Laboratory (CRL) in Smart Materials and Structures. Researchers at both GM and UM are working closely together to
create leap-frog technologies which start at conceptualization and proceed all the way through demonstration and
handoff to product teams, thereby bridging the traditional technology gap between industry and academia. In addition to
Smart Device Technology Innovation, other thrust areas in the CRL include Smart Material Maturity with a basic
research focus on overcoming material issues that form roadblocks to commercialism and Mechamatronic System
Design Methodology with an applied focus on development tools (synthesis and analysis) to aid the engineer in
application of smart materials to system engineering. This CRL is a global effort with partners across the nation and
world from GM's Global Research Network such as HRL Laboratories in California and GM's India Science Lab in
Bangalore, India. This paper provides an overview of this new CRL and gives examples of several of the projects underway.
Piezoceramic functional grading methods, such as the Dual Electro/Piezo Property (DEPP) technique, can successfully produce monolithic actuators which generate higher order deformations when activated (bending, twisting, etc.) while simultaneously increasing reliability by eliminating bonding layers. By synergistically combining ceramic powder with elevated piezoelectric coefficients with a high permittivity dielectric, DEPP actuators are not constrained to the one dimensional property variations as other grading methods. This paper explores the new capability of producing multi-dimensionally graded piezoceramics via the DEPP technique coupled with the Micro-Fabrication by Co-eXtrusion (MFCX) process. It also presents a modeling technique based upon transfer matrix method that builds up the full actuator performance model from elemental beam models derived using an energy approach which captures all the material variations and the resulting complex electric fields. To validate both the fabrication and modeling techniques, a rippling DEPP FGP actuator was fabricated and tested with three oppositely graded regions, demonstrating two dimensional gradients through the length and thickness. This work sets the foundation for monolithic multi-dimensional FGP opening the door to a new class of applications.
Functionally Graded Piezoceramics (FGP) increase actuator lifetime and provide complex deformations; however, to reap these benefits sophisticated grading and fabrication techniques beyond the conventional layered bonding techniques are required. This paper introduces the Dual Electro/Piezo Property (DEPP) gradient technique via MicroFabrication through CoeXtrusion (MFCX). The Dual Electro/Piezo Property (DEPP) grading technique pairs a high displacement lead zirconate titanate (PZT) piezoceramic with a high permittivity barium titanate (BT) dielectric. These compatible materials act synergistically to form dramatic gradients in permittivity across the structure, concentrating the electric field in the more piezoelectrically active region leading to electrically-efficient, large-displacement actuators; with the benefit of increased reliability stemming from the continuous gradients and monolithic nature of the ceramic. The DEPP variation was first evaluated independently of the MFCX process through fabrication and experimental characterization of a powder pressed bimorph. While simple one-dimensionally graded FGPs can be realized by this process, MFCX is needed for any complex, multidimensional gradient. The MFCX process was adapted for DEPP grading and demonstrated by creating a more complex linearly-graded FGP. Both the bimorph and linearly graded specimens had good material quality and generated high displacements correlating well with published FGP theory; with the linear gradient reducing internal stress levels, extending actuator lifetime. This paper presents a general FGP methodology that couples grading and fabrication to generate high yield, low cost monolithic actuators with complicated one-dimensional gradients. Extension of this research will pave the way for more complicated gradients yielding such deformation capabilities as warping, twisting, rippling, and dimpling.
The piezoelectric telescopic actuation architecture capitalizes upon an internally leveraged amplification technique to produce large actuation forces with amplified displacements. This building-block type actuator consists of interconnected concentric, cascaded cylinders with end cap joints that allow for a telescopic type motion. The internal amplification scheme and building-block nature of the telescopic design allow for efficient, densely packed actuators that yield a high work output for a given volume. This paper presents an experimental investigation of the quasi-static force-deflection performance of three unique telescopic prototypes, each manufactured by different means, from various materials, and in distinct geometries. To accurately predict the observed behavior of this architecture, a full three-dimensional numerical model was constructed for each prototype and was used to revise a previously derived analytical model. These models were refined to include extra compliance factors to account for observed actuation losses, focusing primarily on the bonding layer effects. The revised models captured more accurately the complex actuator behavior observed in the experiments and characterized better the loss mechanisms in the telescopic actuation architecture.
Stacks are a popular form of piezoelectric actuation. Unfortunately with this type of actuation architecture the long lengths normally required to obtain necessary displacements can pose packaging and buckling problems. To overcome these limitations, a new architecture for piezoelectric actuators has been developed called telescopic. The basic design consists of concentric shells interconnected by end-caps which alternate in placement between the two axial ends of the shells. This leads to a linear displacement amplification at the cost of force; yet the force remains at the same magnitude as a stack and significantly higher than bender type architectures. This paper describes the fabrication and experimental characterization of three different telescopic prototypes. The actuator prototypes discussed in this paper mark a definitive step forward in fabrication techniques for complex piezoceramic structures. Materials Systems Inc. has developed an injection molding process that produced a functional, five-tube, monolithic telescopic actuator. A three-tube, monolithic actuator was fabricated using a novel polymerization technique developed at the University of Michigan. As a benchmark, a third actuator was built from off-the-shelf tubes that were joined with aluminum end-caps. Each prototype's free deflection behavior was experimentally characterized and the results of the testing are presented within this paper.
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