The present document covers the studies over Structural Health Monitoring systems via vibration based methods. The topic is organized in two parallel studies. The first one analyzes the integrity of metal-composite single lap bonded joints. The second one approaches similar analyses for sandwich structures. The monitoring was made by investigating the dynamic response both computationally and experimentally to verify the reliability of applying vibration based SHM procedures, specifically with the objective of identifying the presence of debonding damage. The dynamic responses were obtained via accelerometers and piezoelectric sensors placed on top of the investigated structures (on the outward surface). The purpose for the accelerometers is to provide reference data for the analyses involving the piezoelectric sensors. Different metrics of damage identification were investigated, all working over a determined frequency range. They quantify the damage by analyzing either the magnitudes or phase angles of the dynamic responses among the undamaged and damage structures. This present work proposed modifications to some methodologies of damage quantification found in the literature and compared the results. The new metrics offered more reliable values for the damage quantification on several of the analyses. It was verified that the metrics are valid for the scenarios observed in the present study. The experimental analyses showed also the influence on the dynamic response due to the position of small elastomeric elements. In regards to the finite element analyses, the computational models showed similar results to the experimental data, the more accurate ones being the models for the bonded joints. For the computational models, improvements can be applied into the piezoelectric sensor (e.g. by using new finite element formulations), as well as the region of debonding (e.g. by using contact algorithms). It is important to highlight that the elastic properties of the skins for the sandwich structure were obtained by the literature, so the model can be improved in the future by applying properties obtained experimentally. / Esta dissertação aborda os estudos realizados no campo de Sistemas de Monitoramento da Integridade Estrutural por meio de métodos baseados em vibrações. O tópico abordado é organizado em dois estudos paralelos. O primeiro é relativo ao monitoramento da integridade de juntas coladas metal-compósito. O segundo versa sobre análises semelhantes em estruturas sanduíche. O monitoramento foi executado através das análises das assinaturas dinâmicas das estruturas, tanto computacionalmente quanto experimentalmente, visando avaliar a capacidade de metodologias vibracionais de SHM em detectar dano de descolamento. As respostas dinâmicas foram obtidas por meio de acelerômetros e sensores piezelétricos dispostos sobre a superfície das estruturas avaliadas. Os acelerômetros fornecem dados de referência para as análises realizadas com base nas respostas do sensor piezelétrico. Diferentes métricas de identificação de dano são abordadas, sendo que todas estão baseadas em análise no domínio da frequência, utilizando parâmetros de magnitude ou ângulo de fase das estruturas danificadas e intactas. O presente trabalho propôs alterações em algumas das metodologias encontradas na literatura e comparou os resultados das métricas originais com as modificadas. As métricas modificadas apresentaram resultados mais consistentes em vários cenários de análise. Constatou-se também que as métricas abordadas mostram-se válidas para os casos observados no presente estudo. As análises experimentais também evidenciaram a influência na assinatura dinâmica da estrutura sanduíche causada pelo posicionamento de pequenos elementos elastoméricos. Com relação às análises via elementos finitos, os modelos computacionais apresentaram resultados similares aos obtidos experimentalmente, sendo os da junta colada os mais precisos. Tais modelos computacionais podem ser melhorados no futuro por meio de uma modelagem mais detalhada dos elementos piezelétricos (por exemplo: por meio de novas formulações), como também da região de descolamento (por exemplo: por meio da implementação de algoritmos de contato). Deve-se ressaltar também que as propriedades elásticas das lâminas externas da estrutura sanduíche foram obtidas da literatura, assim sendo, o modelo poderá ser melhorado em estudos futuros por meio do emprego de propriedades obtidas experimentalmente.

O presente trabalho correlacionou diversas funções de respostas em frequência (FRF) de juntas do tipo simples, coladas e fabricadas em titânio-compósito (resina epóxi reforçada por fibra de carbono). As FRFs produzidas foram investigadas (experimental e numericamente) tanto para juntas intactas como para juntas com falha, estas provenientes, por exemplo, do uso em serviço ou então, com resultado do processamento inadequado de um reparo. Com base nessas análises buscou-se, portanto, subsidiar o desenvolvimento de um sistema de monitoramento estrutural a partir da avaliação de seu comportamento dinâmico, medido pelo uso de pastilhas piezelétricas integradas à estrutura. Para que o respectivo objetivo fosse alcançado. Num primeiro momento, a fim de compreender os fenômenos envolvidos, conduziu-se a atividade de revisão bibliográfica, que baseada na consulta dos trabalhos mais recentes publicados sobre a análise de juntas coladas empregando abordagem numérica, analítica e/ou experimental. Em seguida, foram desenvolvidos modelos computacionais preliminares com solução via Método dos Elementos Finitos (MEF), a fim de se obter as diretrizes mínimas para uma proposta de fabricação das juntas híbridas (metal-compósito). Tal estratégia permitiu reduzir efeitos indesejados, que pudessem comprometer os resultados experimentais. Em posse dos resultados computacionais fabricou-se amostras de juntas metal-compósito com e sem dano. Num primeiro momento, foram realizadas análises numéricas através do desenvolvimento de modelos computacionais (com solução via MEF) das juntas, metal-compósito, monitoradas por transdutores piezelétricos. Em seguida, as juntas híbridas foram submetidas a ensaios experimentais dinâmicos, empregando técnicas de monitoramento com auxílio de transdutores piezelétricos e acelerômetros. Por fim, avaliaram-se potencialidades e limitações dos modelos computacionais desenvolvidos, através de estudos de caso, comparando os resultados experimentais com os resultados numéricos. / The herein proposed research has correlates Frequency Response Functions (FRF) of several hybrid titanium-composite (epoxy resin reinforced with carbon fiber) single lap bonded joints. The FRFs were investigated (numerically and experimentally) for joints with and without failures which may arise as the result of in service events or bad maintenance practices. The result of the dynamic analyses provided by the FRFs has substantiated the proposal of a damage detection method using piezoelectric elements capable which are capable to detect minor alterations on the dynamic behavior of the joint. In order to reach the proposed objective, the first action towards the given objective was study the problem through a bibliographic revision of the research subject, for this purpose the most recent published works related to numerical, analytical and experimental analyses of bonded joints were thoroughly evaluated and segregated. Afterwards, models of the joints were proposed using Finite Element Models (FEM) to obtain a preliminary result of the joints behavior to eventually substantiate the manufacturing processes, reducing the amount of material, time and cost of the experiments. Based upon the results of the FEM the coupons were manufactured with and without damages, using the methods and techniques available on the maintenance field for restoration of composite elements. Before proceed to the comparison between the modeled and experimental results, additional models were proposed using previous work\'s results to get results from the piezoelectric monitored joints. Afterwards, all experimental tests were conducted using accelerometers and piezoelectric elements to provide the means through it the advantages and drawbacks of the proposed monitoring method could be checked, by comparison between the experimental and modeled results.

Les structures intelligentes sont de plus en plus présentes dans différentes industries et notamment dans les domaines de l'aéronautique et du génie civil. Ces structures sont dotées de fonctions qui leur permettent d'interagir avec leur environnement, d'adapter leurs caractéristiques structurelles (raideur, amortissement, viscosité, etc.) selon les besoins ou de surveiller leur état de santé ou « SHM » (Structural Health Monitoring). Aujourd’hui, les performances des méthodes de contrôle actif peuvent être considérablement dégradées lors de l’apparition d’endommagement. Le contrôle actif tolérant aux dommages ou « DTAC » (Damage Tolerant Active Control) est un champ de recherche récent qui s'intéresse à l'élaboration d'approches intégrées pour réduire les vibrations tout en surveillant l'intégrité de la structure, en identifiant les éventuels dommages, et en reconfigurant la loi de commande.Cette thèse apporte une contribution au DTAC en proposant une approche originale basée sur la norme H∞ modale . Les méthodes proposées se focalisent principalement sur le cas où plusieurs actionneurs et capteurs piézoélectriques non-collocalisés sont utilisés pour atténuer les vibrations des structures endommagées. Le manuscrit comprend quatre parties principales. Le chapitre 2 présente des rappels sur la commande H∞ et sur sa solution sous optimale obtenue par une approche par inégalité matricielle ou « LMI » (Linear Matrix Inequality), sur lesquels s’appuient les développements proposés dans ce travail. Le chapitre 3 décrit la norme H∞ modale introduite pour le contrôle actif des vibrations. Cette commande présente une sélectivité modale élevée, permettant ainsi de se concentrer sur les effets du dommage tout en bénéficiant des propriétés de robustesse qu'offre la commande H∞ vis-à-vis du spillover et des variations de paramètres. Une nouvelle stratégie de rejet des vibrations est proposée au chapitre 4. C'est une approche dite préventive où une prise en compte lors de l'élaboration de la commande H∞ modale, des zones fortement contraintes de la structure, où le risque d’endommagement est élevé est réalisée. Un algorithme SHM est proposé afin d'évaluer la sévérité du dommage pour chaque mode. Le chapitre 5 propose une nouvelle approche modale à double boucle de commande pour faire face à des endommagements imprévisibles. Un premier correcteur est conçu dans ce but pour satisfaire les contraintes de performance et de robustesse sur la structure saine, tandis que le second a pour objectif de conserver un contrôle satisfaisant quand un dommage survient. La loi de commande s'appuie sur un observateur d’état et d'un algorithme SHM pour reconfigurer en ligne le correcteur. Toutes les approches DTAC proposées sont testées en utilisant des simulations (analytiques et éléments finis) et/ou des expérimentations sur des structures intelligentes. / Smart structures have increasingly become present in different industry applications and particularly in the fields of aeronautics and civil engineering. These structures have features that allow interactions with the environment, adapting their characteristics according to the needs (stiffness, damping, viscosity, etc.), monitoring their health or controlling their vibrations. Today smart structure active control methods do not respond appropriately to damage, despite the capacity of external disturbances good rejection. Damage-tolerant active control (DTAC) is a recent research area that aims to develop integrated approaches to reduce the vibrations while monitoring the integrity of the structure, identifying damage occurrence and reconfiguring the control law of the adopted active vibration control method.This thesis contributes to DTAC area, proposing a novel modal control framework and some applying strategies. Developed methods focus in non-collocated flexible structures, where multiples piezoelectric sensors and actuators are used to attenuate damaged structure vibration. The chapters present four main topics and the conclusions. Chapter 2 reviews the regular suboptimal H∞ problem and its respective solution based on the linear matrix inequality (LMI) approach, which is a fundamental tool for the development of subsequent topics. Chapter 3 introduces the modal H∞-norm based method for vibration control, which reveals high modal selectivity, allowing control energy concentration on damage effects and presenting robustness to spillover and parameter variation. A new control strategy is developed in Chapter 4, taking into account existing knowledge about the structure stressed regions with high probability of damage occurrence, leading to specific requirements in the modal H∞ controller design. A structural health monitoring (SHM) technique assesses each damaged mode behavior, which is used to design a preventive controller. Chapter 5 presents a novel modal double-loop control methodology to deal with the unpredictability of damage, nevertheless ensuring a good compromise between robustness and performance to both healthy and damaged structures. For this purpose, the first loop modal controller is designed to comply with regular requirements for the healthy structure behavior, and the second loop controller is reconfigured aiming to ensure satisfactory performance and robustness when and if damage occurs, based on a state-tracking observer and an SHM technique to adapt the controller online. In all these chapters, simulated (analytical and finite elements based) and/or experimental aluminum structures are used to examine the proposed methodology under the respective control strategies. The last chapter subsumes the achieved results for each different approach described in the previous chapters.

The dissertation thesis with the topic „Simulation Modelling of Electrical Drives for Selected Critical Applications“ focuses on the area of given applications in civil aviation. The selected application that the thesis deals with is an electrically driven and electronically controlled fuel pump supplying fuel to an aviation motor of the APU type. The thesis gives a comprehensive description of the design cycle of the unit and demonstrates implementing all the required critical functions. In the course of the design of the unit modern techniques in mathematical modelling, simulation, verification, monitoring and prediction of the operation status of airborne equipment were uses to the utmost extent. The purpose of these was to show the suitability of their application with regard to decreasing design time and cost, increasing lifetime and servicing intervals, as well as increasing user comfort and decreasing price. At the same time the required reliability was to be kept. The thesis also aims to prove and verify the suitability of using electronically commutated dc motors in critical applications in civil aviation. To reach this goal, it is necessary to design a robust drive control which would meet the given reliability requirements.

The reliability of modern gas turbine engines is largely due to careful damage tolerant design a method of structural design based on the assumption that flaws (cracks) exist in any structure and will continue to grow with usage. With proper monitoring, largely in the form of periodic inspections at conservative intervals reliability and safety is maintained. These methods while reliable can lead to the early retirement of some components and unforeseen failure if design assumptions fail to reflect reality. With improvements to sensor and computing technology there is a growing interest in a system that could continuously monitor the health of structural aircraft as well as forecast future damage accumulation in real-time. Through the use of two-dimensional and three-dimensional numerical modeling the initial goals and findings for this continued work include: (a) establishing measurable parameters directly linked to the health of the blade and (b) the feasibility of detecting accumulated damage to the structural material and thermal barrier coating as well as the onset of damage causing structural failure.

This thesis focuses on the development of a health monitoring system for gearbox transmissions. This was accomplished by developing and understanding a two-stage gearbox computer model that emulates an actual gearbox test rig. The computer model contains actual gearbox geometry, flexible shafts, bearings, gear contact forces, input motor torque, output brake torque, and realistic gearbox imbalance. The gear contact force of each gear stage and the input bearing translational acceleration were the main outputs compared between a healthy gearbox and damaged gearbox computer model. The damage of focus was a fatigue crack on the input pinion gear. A sideband energy ratio comparison yielded the computer simulation accurately modeled the difference between a healthy and damaged gearbox. The next step in this study involved the development of a repeatable procedure to initiate and propagate a fatigue crack at the tooth root in an actual spur gear. A damaged spur gear allows for a future comparison of an actual healthy and damaged gearbox system in the lab. A custom fatigue fixture was designed and manufactured for a Martin S1224BS 1 spur gear. The fatigue crack was initiated by position control fatigue testing which deflects the gear tooth a set amplitude for a number of cycles. Over the length of the test, the load that the tooth can withstand in bending decreases as damage begins to occur. Once the max load on the gear has dropped by a significant percentage (5-15%) a crack has initiated and begun to propagate across the tooth face. The use of a scanning electron microscope confirmed the presence a fatigue crack.

The dissertation thesis with the topic „Simulation Modelling of Electrical Drives for Selected Critical Applications“ focuses on the area of given applications in civil aviation. The selected application that the thesis deals with is an electrically driven and electronically controlled fuel pump supplying fuel to an aviation motor of the APU type. The thesis gives a comprehensive description of the design cycle of the unit and demonstrates implementing all the required critical functions. In the course of the design of the unit modern techniques in mathematical modelling, simulation, verification, monitoring and prediction of the operation status of airborne equipment were uses to the utmost extent. The purpose of these was to show the suitability of their application with regard to decreasing design time and cost, increasing lifetime and servicing intervals, as well as increasing user comfort and decreasing price. At the same time the required reliability was to be kept. The thesis also aims to prove and verify the suitability of using electronically commutated dc motors in critical applications in civil aviation. To reach this goal, it is necessary to design a robust drive control which would meet the given reliability requirements.

Táto diplomová práca sa zaoberá návrhom zariadenia schopného vysoko presného merania vibrácií za použitia piezoelektrického akcelerometra. Zariadenie je určené na vyhodnocovanie zdravotného stavu strojov, najmä elektrických strojov ako elektromotor, veterná turbína a iné. Za účelom dosiahnutia vysoko presného a vysoko lineárneho merania v spektre extrémne nízkych frekvencií siahajúcich až ku jednosmerným napätím, cez sub-hertzové pásma po desiatky hertzov, ale aj vo vyšších frekvenciách, bola vyžadovaná možnosť použitia prístupu s jednosmernou väzbou zvaného "posúvanie napäťovej úrovne" a následné vyhodnotenie a porovnanie prístupu so striedavou väzbou, ktorý sa bežne používa pre pripojenie piezoelektrického akcelerometra.

La détection, la localisation et le suivi de l’évolution de défauts dans les milieux périodiques et les guides d’ondes est un enjeu majeur dans le domaine du Contrôle Non Destructif (CND). La propagation d’ondes dans ce genre de milieux est complexe, par exemple lorsque la vitesse dépend de la fréquence (dispersion) ou de la direction de propagation (anisotropie). La signature du défaut peut également être « noyée » dans le champ acoustique renvoyé par la structure (réverbération ou diffusion multiple). C’est pour répondre à ces enjeux de taille que l’Optimisation Topologique (OT) a été adaptée aux problèmes de diffraction des ondes acoustiques par des défauts infinitésimaux afin d’obtenir des images de réflectivité des milieux inspectés. La méthode peut être appliquée à toutes sortes de milieux, quelle que soit leur complexité, à condition d’être capable de simuler correctement (sur un milieu de référence) la propagation des ondes de l’expérience physique. En s’inspirant de l’OT, les travaux de cette thèse proposent de mettre en oeuvre des méthodes d’imagerie qualitatives adaptées aux spécificités des Cristaux Phononiques (CP) et des guides d’ondes. Dans un premier temps, nous nous attachons à la description du formalisme mathématique de l’Optimisation Topologique et de la Full Waveform Inversion (FWI). Bien que ces méthodes ne cherchent pas à résoudre les mêmes problèmes inverses, nous mettons en évidence leurs points communs. Dans un deuxième temps, nous appliquons l’Imagerie Topologique (IT) à l’inspection en réflexion des milieux faiblement hétérogènes. Dans un troisième temps, nous nous inspirons de l’IT pour définir une nouvelle variante de celle-ci nommée Imagerie Topologique Hybride (ITH). Nous appliquons ces méthodes pour l’inspection en réflexion des CP crées par des tiges d’acier immergées dans l’eau. Nous comparons les performances de ces méthodes en fonction du type de défaut dans le CP. Les simulations numériques correspondantes à certains cas d’étude sont appuyées par des essais expérimentaux concluants. Dans un quatrième temps, nous adaptons l’IT à une configuration d’inspection en transmission afin de mette en oeuvre une méthode de Structural Health Monitoring (SHM) des guides d’ondes. A ce propos, nous avons mis au point une nouvelle méthode d’imagerie mieux adaptée que l’IT aux configurations d’inspection en transmission. / The detection, localization and monitoring of the evolution of defects in periodic media and waveguides is a major issue in the field of Non-Destructive Testing (NDT). Wave propagation in such media is complex, for example when the velocity depends on the frequency (dispersion) or direction of propagation (anisotropy). The signature of the defect can also be "embedded" in the acoustic field reflected by the structure (reverberation or multiple diffusion). It is to answer these stakes of the size that the Topological Optimization (TO) has been adapted to the problems of diffraction of the acoustic waves by infinitesimal defects in order to obtain reflectivity images of the inspected media. The method can be applied to all kinds of media, regardless of their complexity, provided an exact simulation of the wave propagation in a reference medium (without defects) is performed. Inspired by the TO, the work of this thesis proposes to implement qualitative imaging methods adapted to the specificities of Phononic Crystals (PC) and waveguides. First, we focus on the description of the mathematical formalism of Topological Optimization and Full-Waveform Inversion (FWI). Although these methods do not try to solve the same inverse problems, we highlight their similarities. In a second step, we apply Topological Imaging (TI) to the inspection in pulse-echo configuration of weakly heterogeneous media. Thirdly, we draw inspiration from TI to define a new variant of this method called Hybrid Topological Imaging (HTI).We apply these methods for the pulse-echo configuration inspection of PCs created by steel rods immersed in water.We compare the performance of these methods according to the kind of defects in the PC. Numerical simulations for some case studies are supported by conclusive experimental trials. In a fourth step, we adapt the TI to a pitch-catch configuration in order to implement a new method of Structural Health Monitoring (SHM) of waveguides. In this regard, we have developed a new imaging method that is better suited than TI to pitch-catch configurations.

Hydraulic systems are used in many fields of applications for different functions like energy storage in hybrid systems. Generally the mass of hydraulic systems plays a key role especially for mobile hydraulics (construction machines, trucks, cars) and hydraulic aircraft systems. The main product properties like energy efficiency or payload can be improved by reducing the mass. In this connection carbon fiber reinforced plastics (CFRP) with their superior specific strength and stiffness open up new chances to acquire new lightweight potentials compared to metallic components. However, complex quality control and failure identification slow down the substitution of metals by fiber-reinforced plastics (FRP). But the lower manufacturing temperatures of FRP compared to metals allow the integration of sensors within FRP-components. These sensors then can be advantageously used for many functions like quality control during the manufacturing process or structural health monitoring (SHM) for failure detection during their life cycle. Thus, lightweight hydraulic components made of composite materials as well as sensor integration in composite components are a main fields of research and development at the Institute of Lightweight Engineering and Polymer Technology (ILK) of the TU Dresden as well as at the Leichtbau-Zentrum Sachsen GmbH (LZS).