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Procedia Materials Science 6 (2014) 1207 – 1216

3rd International Conference on Materials Processing and Characterization (ICMPC 2014)

Optimization of Piezo-Fibre Composite with IDE Embedded in a

Multilayer Glass Fibre Composite
Vinod Kumar.Ba, Anoop Raveendranb, Victor Davisa,b,*
a
Department of Aeronautical Engineering, K.C.G College of Technology,
Karapakkam, Chennai-600097, India.
b
Department of Aeronautical Engineering, K.C.G College of Technology,
Karapakkam, Chennai-600097, India.

Abstract: This paper deals with studying the effect of positioning and number of PFC with IDE (PFC-W14) embedded in a
multilayer glass fibre composite for energy harvesting. Vacuum Bagging process is used to fabricate eight Multi- layered
composite with PFC-W14 embedded inside the specimen at different locations and numbers. The PFC-W14 is positioned at
different layers of the composite and number of PFC-W14 is varied in order to study various cases of strain acting on composite.
Vibration test for different frequencies were conducted on these eight specimen using electro-dynamic shaker. The generated
energy is directly proportional to the strain or voltage generated along the perpendicular axis of the direction of the strain applied,
which is collected by the Integrated Digitated Electrodes. The max frequency of vibration at which max voltage is generated by
each specimen is observed for different locations and numbers. The results of this study are presented with an eye toward
obtaining guidelines for design of useful energy harvesting structures.
© 2014 Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
© 2014 The Authors. Published by Elsevier Ltd.
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of the Gokaraju Rangaraju Institute of Engineering and Technology (GRIET).
Selection and peer review under responsibility of the Gokaraju Rangaraju Institute of Engineering and Technology (GRIET)
Key Words: Piezo-Fibre composite, Energy harvesting, smart structure, optimization.

1. Introduction

Energy is always essential in building up modern society. It is required everywhere from the household light bulb to
a mission to Space. Some energy can be seen; light for example, but most do not have a visible form.

Nomenclature
V Voltage
Hz Hertz
PFC Piezo fibre composite
IDE Integrated Digitated Electrodes
BNC British Naval Connector

* Corresponding author. Tel.: +919840606927; fax: +91-24502898.

E-mail address:[email protected]

2211-8128 © 2014 Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer review under responsibility of the Gokaraju Rangaraju Institute of Engineering and Technology (GRIET)
doi:10.1016/j.mspro.2014.07.194
1208 B. Vinod Kumar et al. / Procedia Materials Science 6 (2014) 1207 – 1216

Energy is defined in several ways, such as mechanical, electrical, and chemical. All of these definitions are based on
where the energy is stored. Energy is stored everywhere. Heat, electricity, mechanical, chemical, photo, and biomass
forms of energy are all stored differently, but can be converted from one to another. Among many types of energy,
electricity is the most commonly used form for modern devices because it is easy to convert to other types. The term
‘power generation’ commonly refers to energy conversion from other energy forms to electrical energy.

There are many ways to complete electrical conversions. Photocells convert light to electricity,
thermocouples convert heat to electricity, and magneto electric generators convert mechanical energy to electricity.
These are all called power generators and are frequently used in electricity generation. Similar to magneto electric
generators, piezoelectric generators (PEGs) can also convert mechanical energy to electrical energy. PEGs Vibration
based energy harvesting is the most suited for UAV, smaller aircrafts, RC’s etc as whenever aircrafts are flying at an
altitude at a particular speed it induces vibration at various parts of the aircrafts. If we are able to generate power out
of these vibrations it will lead to two types of advantages.
(a) Vibration damping
(b) Power generation using the vibration
If this can be achieved the requirement of an external power source as well as maintenance costs for periodic battery
can be reduced.

There are three ways of harvesting vibration energy, Electromagnetic, electrostatic and piezoelectric. Piezoelectric
system has received more attention than electromagnetic energy harvesting as they give very low output and often
multistage post processing is required to reach a voltage level that can charge a storage component which makes it
bulky. Another advantage of Piezo based energy harvesting system is piezoelectric devices can be fabricated both in
macro-scale and micro-scale due to well established thick film and thin film fabrication techniques.

A great amount of research has been done in the analysis of piezoelectric materials and structures, as reviewed by
Wen H.Ko (1969) presented one of the first suggested applications involving vibration energy harvesting using
piezoelectric materials .US patent titled “Piezoelectric Energy Converter for Electronics Implants” in this, he
proposed harvesting energy from heartbeats for use in powering implanted medical pacemakers by the use of
cantilever piezoelectric beam with a tip mass.

Taylor.G.W and Burns.J.R (1983)presented one of the earliest published works in vibration energy harvesting
with piezoelectric materials. They proposed the use of an array of polyvinylidene fluoride (PVDF) piezoelectric
polymer film to harvest hydrodynamic energy from ocean waves. Although no physical system was proposed or
built, it was theorized that a 100 MW power plant utilizing PVDF could deliver power to onshore grid at a cost of
2.5 cents per kWh.

Umeda et al. (1996) performed works to explore the fundamentals of impact energy conversion using
piezoelectric materials. Umeda first developed an equivalent circuit model to predict the response of a piezoelectric
vibrator plate when impacted with a steel ball. The existence of an optimal load resistance for maximum power
transfer from the piezoelectric layers was shown in stimulation results. Much of the potential energy from the steel
ball is transferred back to the ball when rebounding off of the vibrator plate, thus decreasing the efficiency of energy
conversion. An experimental study to validate their previously developed model and also rectification and storage of
the electrical outputs of the piezoelectric vibrator via a bridge rectifier and storage capacitor was performed by
Umeda in the following year. Results of the experimental testing showed the ability of the piezoelectric vibrator to
charge the storage capacitor using impact energy, and that for a capacitor pre-charged above 5V, an efficiency of
35% was achieved.

A novel concept is presented by Steven.R.Anton (2011) which involves the combination of piezoelectric devices
and new thin film battery to form multifunctional self-charging, load bearing energy harvesting devices for use in
UAV systems. The proposed self charging structures contain both power generation and energy storage capabilities
in a multilayered, composite platform consisting of active piezoceramic layers for scavenging energy, thin film
batteries for storing scavenged energy, and a central metallic substrate layer. The compact nature of the device
allows easier integration into UAV systems and their flexibility provides the ability to carry load as structural
members.

N.W. Hagood et al. (1990) of United States Patent designed a composite for actuating and sensing deformation.
The composite have a series of flexible, elongated piezoelectric fibres arranged in a parallel array with adjacent
 B. Vinod Kumar et al. / Procedia Materials Science 6 (2014) 1207 – 1216 1209

fibres separated by relatively soft polymer. The piezoelectric fibres have a common poling direction transverse to
their axial extension. The composite further includes flexible conductive material along the axial extension of the
fibres for imposing or detecting an electric field.

“Piezoelectric Energy Harvesting with a Clamped Circular Plate: Analysis” by Sunghwan Kim et al. (2005)
mentions about the small generation capability that has not been attractive for mass energy generation. He develops
an increased interest in wearable computer concepts and remote electrical devices that has provided motivation for
more extensive study of piezoelectric energy harvesting. The theory behind cantilever-type piezoelectric elements is
well known, but the transverse moving plate elements, which can be used in energy generation from pressure
sources is not yet fully developed. The power generation in a pressure-loaded plate depends on several factors.
Among them, the thickness of each layer is important, as is the electrode pattern used. In this article, two clamped
circular plate structures, a fully electroded unimorph, and a so-called regrouped electrode unimorph, are modeled.
These models are then used to calculate energy generation with varying thickness ratios. The results of this analysis
are presented with an eye toward obtaining guidelines for design of useful energy harvesting structures.

“Smart structures and piezoelectric materials” by S. Kamle refers to smart materials and structures that can assess
their own health, perform self repair or can make critical adjustments in their behaviour as condition changes. He
mentions about the helpful characteristics provided by a human body for the application of Piezo sensors and
actuators. The results from the experiments indicate that the PVDF sensors and actuators show much promise for
controlling acoustic radiation from the hood.

In this project effect of positioning and numbers of PFC-W14 at various layers of composite on voltage
generation of the composite has been studied which leads to finding an optimal position of placing a Piezo fibre
inside a multilayer composite to generate maximum voltage output.

2. Manufacturing
The manufacturing process was carried out at Advanced Composites Division, CSIR-NAL, Bangalore. The piezo
fibre embedded composites are prepared by vacuum baggage process. Different configurations of the composite
samples are prepared by placing PFC-W14 at different locations of the composite. Samples of different thickness are
prepared. Samples with two of PFC-W14s are also prepared. These are for the comparison study of the samples
based on the thickness, number of PFC-W14 in a single specimen, arrangement of PFC-W14 in a specimen and the
position of PFC-W14 in the specimen.

2.1. Material selection

The following materials have been used for the fabrication of piezoelectric fibre embedded composite.

• Piezoelectric fibres : PFC –W14

• Glass Fibre : S-Glass Fibres
• Resin : Araldite CY 230-1
• Hardener : Aradur HY 951

2.2 Initial preparation

Once the materials have been selected we move on to the experimental apparatus used for the fabrication.
1210 B. Vinod Kumar et al. / Procedia Materials Science 6 (2014) 1207 – 1216

Apparatus mainly consist of:

• Vacuum pump
• Vacuum port
• Vacuum bag
• Oven

Fig.1. (a) Vacuum Baggage

A set of basic procedures are to be followed before the main fabrication is done. The basic steps carried out as at
start-up for the process are as follows:

x Clean the table using acetone so as to make it dust free.

x Cut the breather, non porous layer, porous layer, peel ply to the required dimension of the composite needed.
x Hylam sheet that is curved at the edges is stuck to the table, as the base plate for the smooth and uniform
surface.
x The vacuum bag is cut to the required dimension, and a double stick tape is used at the boundary to seal the bag
and table.
x Clean the base plate and the surroundings by acetone.
x Wax (wooden polish) is applied to the base plate.
x Around the base plate, tape is stuck on the surface of the table and a non porous layer is stuck on top of it.
x Excess sheet of the layer is trimmed.
x The top end of the vacuum bag is stuck to the table.
x A hole is created on the vacuum bag to place the vacuum port.

2.3 Main Fabrication

Fig.1. (b) Layers Used

According to the required dimensions of the specimens a template is cut, and strips of glass fibre cloth are cut.
Then the weight of the glass fibre and peel ply is checked using electronic weigh balance. The weight of the material
is noted and accordingly the resin-hardener is taken in a container with a ratio 100:10 and stirred well. Once the
epoxy mixture is ready the fabrication process speeds up as the pot life of epoxy is 40 minutes. The glass fibre is
placed on a sheet and epoxy mixture is applied on top of it. Then the sheet is folded, the template is placed on the
top of the sheet and the sheet is cut to the template dimensions. Once the sheet is cut for the required dimension, the
sheet is peeled out and the glass cloth is placed in the peel ply on top of the base plate. Then the epoxy is applied on
the fibre and layers of the fibres are made according to the thickness of the specimen. The piezo fibre is placed on
the top of the glass fibre layers. The electrode end of the piezo fibre is covered using flash breaker before placing it
onto the glass fibres. Then the remaining glass fibres are placed on top of the piezo fibre in layers according to the
thickness. Once the pasting of the layers using epoxy is complete, a peel ply is placed on top, followed by the porous
layer. Then the breather is placed on top of the porous layer and the vacuum port is attached with the breather. The
whole setup is covered with the vacuum bag and sealed using tape. The vacuum pump is connected to the vacuum
port and the pump is switched on. A sample of the fibre is placed in the room temperature to check the curing rate.
The vacuum pressure reading of 680 mmHg is noted and the setup is left to cure for 24-48 hours at room
temperature.
 B. Vinod Kumar et al. / Procedia Materials Science 6 (2014) 1207 – 1216 1211

After 48 hours the sample piece is observed to check the curing. If the sample exhibit brittle fracture then the
composite is cured. Once the composite is cured the pump is switched off, and the vacuum bag is removed. The
composite is taken out of the bag. The specimen is then placed inside the oven for 4 hours at 60oC. Ensure that
the thermocouple locations are below the component and peel ply is removed. Thus the composite is fabricated as
shown in Fig.1. (c).

Fig.1. (c) Glass fibre composite specimens embedded with PFC-W14

3. Experimental Set Up

3.1 Testing apparatus

x Electro-dynamic Shaker
x Function generator
x Voltmeter
x Power Amplifier

Fig.2. Photo Representation of Electro-dynamic Shaker

Electro-dynamic shaker is an instrument used to carry out vibration testing. In this instrument controlled
vibrations can be obtained. Frequency is given as an input. It reproduces ambient conditions for studies of endurance
and reliability in all fields of vibration testing. The electro-dynamic shaker is supported in a rugged revolving frame
for excitation in vertical or horizontal direction. A plunger is inserted at the top of the shaker by means of which the
specimen is made to vibrate at different frequencies.
The electro-dynamic shaker used here is the “TIRA VIB”. Function generator is used to generate the input
frequency and it is connected to the Power amplifier by means of BNC cables. The function generator used is the,
“scientific generator HM5030”.The Power Amplifier Type BAA 120 has been designed to drive any vibration or
modal exciter requiring a 120 VA power amplifier. The rated AC output is 120 VA into a 4 Ohm exciter or resistive
load. The power amplifier has a useable frequency range from 40 Hz to 20 kHz (full capacity) or DC to 100 kHz
(reduced capacity).The instrument can tolerate the temperature and supply line variation while maintaining excellent
stability.
1212 B. Vinod Kumar et al. / Procedia Materials Science 6 (2014) 1207 – 1216

Fig.3. Photo Representation of Function generator

3.2 Testing procedure

The specimen is clamped on a suitable frame so that it acts as a cantilever beam. The frame is placed in such a
way that the plunger just touches the tip of the beam. The specimen is clamped to the wooden frame very tightly
using the C-clamp and the frame is held very firm so as to induce effective vibration into the specimen. The
electrodes of the PFC-W14 are connected to the voltmeter by means of connecting wires. Function generator and
Electro-dynamic shaker are connected to the Power amplifier.
It was found that some voltage is generated even before the vibration is commenced. This is due to the strain
acting on the specimen when it is clamped to the frame. Initially, the values 0.1A and 0.3V are set in the Power
amplifier. The sine wave is the input signal and the frequency is varied. The vibration frequency ranging from 0.8 to
30 Hz is applied in this case. For each frequency the voltage generated by the specimen is measured using the
voltmeter. Special care is taken while connecting the wires to the voltmeter in case of specimens 3, 4 and 5 as they
have two PFC-W14 in it. The voltage measured will be very less if the positive and negative wires are cross
connected. The voltage generated is measured for all the 8 specimens. The result obtained are plotted with frequency
along X axis and voltage along Y axis. The resonance frequency for each specimen is found from these values.

4. Results and Discussion

4.1. Effect of thickness of multi-layer composite on voltage generation by PFC-W14

2 Specimen 6
1.8
Specimen 1
1.6
1.4 Specimen 7
1.2
Voltage(V)

1
0.8
0.6
0.4
0.2
0
0 5 10 15 20 25 30 35

Frequency(Hz)

Fig.4. (a) Comparison Based on Thickness

Specimen 6 of thickness 1.1mm, specimen 1 of thickness 1.5mm and specimen7 of thickness 2.1mm with PFC-
W14 embedded at exact mid-plane ( i.e. 4th layer for specimen1, 6th layer for specimen6 and 9th layer for specimen7)
are vibrated for various frequency and data’s is recorded.
Fig.4. (a) shows specimen6 giving a maximum voltage of 1.849V at its resonant frequency of 10 Hz.
specimen1 gives a maximum voltage of 1.835V a decrease of 0.76% from specimen6 at it resonance frequency of 8
Hz. Specimen7 gives a maximum voltage of 1.609V a decrease of 12.31% from specimen1 at its resonance
frequency of 7 Hz. These data show that as the thickness increases there is a marginal decrease in voltage generation
but along with that also there is a decrease in the resonance frequency with the increase in the thickness.
 B. Vinod Kumar et al. / Procedia Materials Science 6 (2014) 1207 – 1216 1213

4.2. Effect of position of PFC-W14 embedded in a multilayer composite on voltage generation

25 specimen 1
specimen 2
20
specimen 8

Voltage(V)
15

10

0
0 5 10 15 20 25 30 35
Frequency(Hz)

Fig.4. (b) Comparison Based on Position

Specimens1, 2& 3 are of thickness 1.5mm with PFC-W14 embedded at different positions. In specimen1&2 PFC-
W14 are embedded at 0.6mm and 0.9mm from bottom respectively and in specimen8 PFC-W14 is pasted over its
outermost surface using epoxy resin. Specimen1 generates a maximum voltage of 1.835V at its resonance frequency
of 8Hz which increases by 245.67% (6.38V) in specimen 2 and a phenomenal increase of 1061.3% (21.31V) in
specimen8 at same resonance frequency.

4.3. Effect of connecting two PFC-W14 parallel and laid adjacent to each other in same layer

specimen 2 specimen 1
3
14 Specimen 4
specimen 5
2.5
12
Voltage(V)

Voltage(V)

10 2

8 1.5
6
1
4
0.5
2

0 0
0 5 10 15 20 25 30 35 0 5 10 15 20 25 30 35

Frequency(Hz) Frequency(Hz)

Fig.4. (c) Fig.4. (d)

Comparison of voltage generation of specimen 2 and 5 Comparison of voltage generation of specimen1 and 4.

Fig.4.(d) shows that there is an increase of 46.81% when two PFC-W14 are parallely connected to each other and
are embedded at central layer when compared to specimen1 and Fig.4. (c) shows that there is an increase of 91.37%
in voltage generation when 2 PFC-W14 are parallelly connected to each other at a distance 0.9mm from the bottom
when compared with specimen 2. In specimen5& 4 two PFC-W14 at same layer has been embedded and it was
observed that resonance frequency was lowered from 7 to 6 Hz and 8 to 7 Hz respectively. This clearly shows that
even if multi PFC-W14 is connected parallely to increase voltage generation it has to be at higher level as much near
the surface or at the top of the surface to get maximum voltage increase which also leads to the decrease in the
resonant frequency of the specimen.
1214 B. Vinod Kumar et al. / Procedia Materials Science 6 (2014) 1207 – 1216

4.4. Effect of embedding 2 PFC-W14 at different layers rather than in same layer adjacent to each other and
connected parallel.

14 Specimen 3
12 Specimen 4
10 Specimen 5
Voltage(V)

8
6
4
2
0
0 5 10 15 20 25 30 35

Frequency(Hz)

Fig.4. (e) Comparison Based On 3-4-5

Fig.4. (e) shows that voltage generation of specimen3 of thickness 1.5mm with 2 PFC-W14 embedded at 0.3mm
and 0.9mm from bottom are connected parallel which generates a maximum voltage of 2.827V which is a sharp
drop by 76.84% when compared with specimen5. Comparing specimen3 and specimen 4 there is a very marginal
increase of 4.93% of maximum voltage generation in specimen 3 as compared to specimen 4 .these results shows
that it is better to embed multi PFC at same layer and connect parallel rather at different layers and then connect it
parallel.

5. Conclusions

This experiment shows that with increase in thickness the voltage generation decreased along with that
resonant frequency at which maximum voltage is generated for a particular thickness showed a decrease which is
clear from Fig.4. (a). Fig.4. (b) shows that the voltage generation kept on increasing from centre to the top. At the
top most there was an increase of voltage generation by about 1061% from 1.835V to 21.31V. It should be noted
that big civilian aircraft’s cockpit works on a 28V battery. Specimen8 fabricated for this paper was able to generate
a maximum voltage of 21.31V for a moderate frequency of 8 Hz. If PFC-W14 are pasted on the tip of wings of a
UAV it will help in increasing its range by recharging of UAV’s battery in air itself. Bigger aircrafts also on engine
failures can use the power generated due to wing loads on the leading edge for working of vital instruments in the
cockpit which will help pilots during emergency landings.
Results from Fig.4. (d) and Fig.4. (c) show that voltage generation can be further increased by keeping
multiPFC-W14 in same layer adjacent to each other and connected parallel. Fig.4. (d) shows that there is an increase
of 46.81 percent when two PFC-W14 were used instead of one at centre ie after 6th layer from bottom. Fig.4. (c)
shows that there is an increase of 91% when two PFC-W14 were used instead of one at a distance of 0.9mm from
the bottom an increase by two times from Fig.4. (d). So positioning of multi PFC-W14 nearest to surface is
important for most efficient increase in voltage generation. Fig.4. (e) shows that voltage generation of specimen3 of
thickness 1.5mm with 2 PFC-W14 embedded at 0.3mm and 0.9mm from bottom are connected parallel which
generates a maximum voltage of 2.827V which is a sharp drop by 76.84% when compared with specimen5.
Comparing specimen3 and specimen 4 there is a very marginal increase of 4.93% of maximum voltage generation in
specimen 3 as compared to specimen 4 .these results shows that it is better to embed multi PFC at same layer and
connect parallel rather at different layers and then connect it parallel.

6. Appendix A
 B. Vinod Kumar et al. / Procedia Materials Science 6 (2014) 1207 – 1216 1215

Table 1 - Specimen Specifications

Specimen1 Specimen2 Specimen3 Specimen4 Specimen5 Specimen6 Specimen7 Specim

en8

Length(mm) 142 142 142 142 142 142 142 142

Width 74 74 74 98 98 74 74 74
Top(mm)

Width 34 34 34 58 58 34 34 34
Bottom(mm)

Total 1.5 1.5 1.5 1.5 1.5 1.1 2.1 1.5

Thickness

Thickness of 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1

‘1’ Glass fibre
layer

No: of Glass 12 12 9 12 12 8 18 12
fibre layers

Thickness of 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3

Piezofibre

No: of 1 1 2 2 2 1 1 1
Piezofibres

Position of Center At a At a distance Placed Placed Center Center At

Piezofibre height of of 0.3mm and Adjacent to Adjacent to the
0.9mm 0.9mm from each other each other Surface
from bottom at Center at a height of the
Bottom of 0.9mm compos
from ite
Bottom

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