Fiber Composite Sensor Integration for Internal Damage Detection
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Solution Overview
Problem
Fiber composite components, such as vehicle body parts, face internal damage from mechanical energy that can alter their vibration behavior, making it difficult to assess their condition without visible signs of damage.
Innovation Solution
Integration of a sensor device with a flexible circuit carrier and micromechanical sensor modules that capture response signals when the component is subjected to test or reference vibrations, allowing comparison with reference signals to determine changes in the component's condition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor modules are integrated into the fiber composite component, then the ability to detect internal damage is improved, but the device complexity increases
Solution Approach 1:
The sensor modules are integrated directly into the fiber composite component structure, with the flexible circuit carrier and sensor modules nested within the component layers. This nesting approach enables damage detection functionality while maintaining a compact, integrated design without adding external complexity.
Solution Approach 2:
The flexible circuit carrier serves multiple functions: it provides mechanical support for the sensor modules, enables electrical connections between modules, and integrates into the fiber composite structure. This merging of functions reduces the number of separate components needed, thereby reducing overall device complexity while maintaining measurement precision.
2Measurement precision
If multiple sensor modules are integrated to capture response signals, then the measurement precision improves, but the ease of manufacture deteriorates
Solution Approach 1:
The flexible circuit carrier is prepared in advance with pre-defined connection paths and contact points for the sensor modules. This preliminary preparation of the carrier structure simplifies the subsequent integration process, as the electrical connections and mechanical mounting positions are already established, reducing manufacturing complexity despite having multiple sensor modules.
Solution Approach 2:
The flexible circuit carrier is designed as a universal platform that can accommodate multiple sensor modules with standardized interfaces. This multi-functional carrier design enables the same manufacturing process to be used for integrating different numbers and types of sensor modules, simplifying production while maintaining high measurement precision through multiple capture points.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables direct feedback on the component's state and condition, facilitating measures such as recommending inspection or repair, and ensuring safety by detecting internal damage like delaminations or fiber breakage.
Implementation Method 1
micromechanical sensor modules that capture response signals when the component is subjected to test or reference vibrations
Data Source
AI summary
Method for testing a fiber composite component, in particular a body component for a vehicle, wherein the fiber composite component comprises a sensor device which is integrated in the fiber composite component, wherein the sensor device comprises a flexible circuit carrier having a sensor module, in particular having a micromechanical sensor module, for ascertaining an acceleration value, said method comprising the steps: setting the fiber composite component into a test vibration, in particular by applying a test pulse to a test site of the fiber composite component; capturing a response signal using the sensor device; and comparing the response signal with a reference signal.