SMART BEAM

CHAPTER1
INTRODUCTION

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1.1. INTRODUCTION
Nowadays lightweight materials are widely used in many machines in order to reduce the
costs of production and power consumption. But this leads to a new problem: Under the same
excitation, the structure made of the lightweight materials undergoes stronger vibrations than a
structure made of conventional materials. A smart structure can solve this problem . Through the
integration of sensor(s) and actuator(s) with a properly designed control strategy, a smart
structure can reduce the vibration of the lightweight structure. As a smart structure has more
components, it contains more uncertainties in comparison to the ensure its reliability and
robustness. Sensitivity analysis is a method to quantitatively describe the relationship between
the inputs and outputs of a structure. One of the sensitivity analysis methods is the stochastic
analysis of a numerical model, which predicts the structure’s behavior by analysis of the
simulation’s results under thousands of random structural input parameters.

This paper uses a beam structure as a reference system to clarify how to design the
control concepts for it with regard to the system’s sensitivity analysis. The smart beam structure
with its designed geometric and material’s parameters is used as the reference in this project.
During the sensitivity analysis the geometric and material’s parameters are slightly varied
according to their predefined variation. This means the control concept should be robust not only
for the referenced beam structure but also for the beam structure with small variations. numerical
model of a smart beam structure has at least two parts, one is the finite element (FE) model of the
structure, and the other is its control strategy. Karagülle et al. explained a way to build the
numerical model of a smart beam structure including the control system by only use of the
software ANSYS. The displacement of the beam’s end in the time domain can indicate the
performance of the control system under the instantaneous excitation .But this way is
inconvenient for a frequency response analysis, which can directly give an impression of the
vibration behavior of the beam in a wide frequency range. On the other hand, MATLAB is
widely used for the design of a control strategy . But the sizes of the FE model matrices are too
big, which makes the design of a control strategy almost impossible . Rudnyi and Korvink point
out that a model order reduction can solve these problems.

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1.2. PURPOSE
The purpose of this study is to focus on the application of piezoelectric material to control
the vibration of the structures. The study presents an active vibration control technique applied to
a smart beam. Objectives of the research are as follows: Introduction of analytical software
package (Ansys) is also discussed for the modeling of smart beam structure.

 Analysis of smart beam bonded with piezoelectric materials using ANSYS software.
 Comparative study of Ansys results and experimental results.

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CHAPTER 2
NUMERICAL MODELING OF SMART BEAM

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2.1. INTRODUCTION
The FEA is used as the numerical modeling tool to simulate the dynamic characteristics
of structures. In our system, a smart beam of size 450 mm35 mm1.7 mm with a commercially
existing piezoelectric patch actuator

Fig 2.1 Model of Smart Beam

(PI Dura-act 876.A12) of size 50 mm_35 mm_0.7 mm is modeled using the ANSYS/Workbench
software. The designed model is shown in Figure 1.

Numerical modal analysis method is implemented in the ANSYS/Workbench software

platform according to the material properties listed in Table 1. The piezoelectric material
properties are defined using the utilities of the ANSYS/Workbench software package. The
reduced piezoelectric strain matrix (e) and the elastic stiffness matrix (Ce) under constant
electrical field are also defined. To provide a successful modeling and to simulate a realistic
system behavior modal analysis is applied numerically and experimentally.The results of modal
analysis are presented in figure above.

The mode shapes direction of the first three modes of structure is vertical to the XY
plane. The fourth mode shape of smart beam is lateral movement. Presented smart structure
design, the first three natural frequencies of the structure can be controlled due to the mode
shapes directions. Upon examining Table 2, it can be said that the numerical and experimental
results agree well. Additionally, to provide control loop, the system has two inputs (piezoelectric
patch (V) and excitation (g)) and two outputs (the linear strain (mm/mm) and the tip

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displacement (mm)). Realistic numerical model of the system is obtained by considering these
input/output parameters. “Spmwrite” command is used for defining the state-space matrices in
ANSYS/Workbench. The state-space matrices of the smart beam system are extracted from the
results of the modal analysis following the method given in Lu¨ leci.22 It is observed from the
results that there is no need to deploy a complete modal analysis for the smart beam. Instead,
first four modes of the smart beam are investigated within the specified boundary conditions.

The numerical model of a smart beam structure has at least two parts, one is the finite
element (FE) model of the structure, and the other is its control strategy. Karagülle et
al.explained a way to build the numerical model of a smart beam structure including the
controlsystem by only use of the software ANSYS. The displacement of the beam’s end in the
time domain can indicate the performance of the control system under the instantaneous
excitation. But this way is inconvenient for a frequency response analysis, which can directly
give an impression of the vibration behavior of the beam in a wide frequency range. On the other
hand, MATLAB is widely used for the design of a control strategy. But the sizes of the FE model
matrices are too big, which makes the design of a control strategy almost impossible. Rudnyi and
Korvink point out that a model order reduction can solve these problems. It reduces the size of
the structural matrices, which can be extracted from an FE model without carrying out a
harmonic simulation. The reduced matrices can be used in the control system. Having this
knowledge, the path used in this paper to build the numerical model of the smart beam structure
is shown in Figure 2.2.

Fig2.2 .Numerical model Building

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There are many different kinds of control concepts that can be used to reduce the beam
structure’s vibration. Lead control (LC) is one of the popular active damping controllers, which
can be used to compensate the beam structure’s vibration. The Linear Quadratic Regulator
(LQR) and its extension, the Linear Quadratic Gaussian regulator (LQG), are very often
discussed as a controller for a smart beam structure. Therefore, LC and LQR are chosen in this
project for further analysis introduces the smart beam structure and shows the way to build its FE
model in the reduced state-space form. Chapter 3 focuses on the design process of the potential
controlS. Li, S. Ochs, T. Melz concepts for the reference smart beam structure. Their
performances are compared in according to various criteria. The robustness of these control
concepts is checked by varying some structural parameters of the smart beam structure.

2. 2.THE SMART BEAM STRUCTURE

A smart beam structure consists of a beam structure, at least a sensor, an actuator, and an
appropriate control strategy.. The smart beam structure used in this project is an aluminum beam,
whose one side is clamped and whose other side is free. This beam is assumed to be an Euler-
Bernoulli beam therefore its deformation is based on the basic equation of structural dynamics. A
vertical dynamic force at the free end of the beam acts as an excitation for the beam structure.
Piezoelectric ceramic patches are widely used as sensor or actuator in a smart structure. PIC 151,
which is a type of the piezoelectric ceramic with a high permittivity, a high coupling factor, and
a high piezoelectric charge constant, is chosen for this smart structure. These two piezoelectric
patches are collocated at the top and the bottom of the beam and act separately as actuator and
sensor. The sensor detects the vibration of the beam and transfers the signal to the controller.
Then the controller computes the desired control signal and sends it to the actuator. The
controller is designed to compensate the beam’s vibration. The dimensional and material data of
the reference smart beam structure are listed in detail in figure below.

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Fig 2.3.Smart beam Structure

A smart structure is a structure that can reduce the structural vibration by integration of
sensor(s), actuator(s), and controller(s). The sensor detects the vibration of the beam and
transfers the signal to the controller. Then the controller computes the desired control signal and
sends it to the actuator. The controller is designed to compensate the beam’s vibration. A
piezoelectric patch is often used as a sensor or an actuator in a smart structure, as in this research
project. A smart structure with a properly designed controller can reduce the structural vibration
without changing the structure’s physical dimensions. As a smart structure]has more components
in comparison to a passive structure, it can contain more uncertainties.Therefore, it should be
well analyzed to ensure its reliability and robustness. Sensitivity analysis is a method that can
describe the system’s behavior quantitatively. This paper explains how to build a numerical
model of a smart beam structure and how to design the control concepts for it with regard to the
sensitivity analysis of this system.

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CHAPTER 3
FINITE ELEMENT MODEL

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3.1. INTRODUCTION

In this project, the FE model of the smart beam structure is built by use of the software
package ANSYS Workbench.First the mechanic structure of the aluminum beam and the two
piezoelectric patches is built in ANSYS. The type of contacts between the piezoelectric patches
and the beam is defined as ideally bonded . The element type for the beam is SOLID186, which
is a three dimensional structural SOLID element. SOLID226, which is an element type for
coupled field components,is chosen for the piezoelectric patches. Some pretests aimed to find out
a proper size of the elements are done. By comparing the simulation results of the beam
structures, which the size of the elements are set separately to be 0.002 m and 0.004 m, there are
no differences.Therefore, the size of the elements is determined to be 0.004 m. The structural
damping is defined according to the Rayleigh damping, which is a mass- and stiffness-
proportional ,where it is the approximated structural damping, M is the structural mass matrix, K
is the structural stiffness matrix, is the mass-proportional damping coefficient, and is the
stiffness proportional damping coefficient.

According to the ANSYS Help system, the mass damping represents the friction damping
and can be ignored in most situations. Therefore, in this case the mass damping is defined . In an
experimental simulation it is measured that the whole structural damping ratio is about 5%. Then
the corresponding stiffness value is defined .After building the numerical model, the structural
matrices M (the structural mass matrix),K (the structural stiffness matrix), B (the input
matrix),and C (the output matrix) can be extracted to describe the dynamic behavior of the whole
structure in form of differential equations.

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3.2. MODEL ORDER REDUCTION

This FE model aims at the system’s sensitivity analysis. According to the analysis’
requirement should be able to be built and simulated with more than thousands of small varied
structural parameters’ combination. Therefore, the duration of the model building and simulation
should be short. Moreover, the size of the structural matrices should also be small for the control
design. A good solution to meet both requirements is MOR. For this project, MOR for ANSYS
based on the Krylov subspace method is chosen. The difficulty of MOR lies in the definition of
expansion points to overcome the singularity of the reduced matrices. According to the results of
some pretests two expansion points are defined at (􀀀10;􀀀105).The expanded dimension at each
point can be purposely defined. In this case 6 dimensions are expanded at each point.Then the
reduced structural system can be described by

where Mr, Kr, Br, Cr are the reduced matrices of M,K, B, and C, respectively, q is the
state vector, u is the input vector, and y is the output vector. For this smart beam structure, the
input vector u is composed of the force at the beam’s end u1 and the actuator’s voltage u2.The
output vector y includes the displacement of the beam’s end y1 and the sensor’s voltage y2.The
vibration behavior of the beam structure based on the reduced matrices is checked by comparing
it with that of the non-reduced matrices. The two curves in Figure 3 show that they are in
excellent agreement.

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Fig 3.1 The displacement of the reference smart beam structure.

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CHAPTER 4
CONTROL CONCEPTS

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4.1 The modal experiments and modal analysis of smart beam

This paper aims to research the resonance suppression of smart beam mainly about the resonance
phenomenon, which is common in engineering, generated at the moment of starting the machine
in a resonant frequency and study how to inhibit the transient resonance peak. Firstly, a vibration
test system for smart beam is established getting the resonant frequency of smart beam by
experiments. The modal analysis is done by the Test Lab system belongs to the LMS Company
of Belgium.

4.1.2. The experimental platform

The schematic of the system is shown in Figure. The signal generator generates the sine
wave or standing wave whose frequency is specified. The signal is enlarged by driving power
and a piezoelectricceramic is driven so that the beam begins to vibrate. The vibration of beam is
captured by FBG sensors. The surface strain curves of beam are acquired by fiber modem. The
data is sent to computers directly and the computers calculate the frequency and amplitude of
beam vibration based on the surface strain curves and then gets the output control signals. The
control signal is enlarged by driving power and another piezoelectric ceramic is driven to inhibit
the vibration of beam achieving the active inhibition control.

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FIG 4.1 THE SKETCH MAP OF SYSTEM

There are 4 pieces of piezoelectric ceramics on the cantilever of the experimental

platform. The 2 pieces of up and down consist of one group. All the polarization directions of
piezoelectric ceramics are upward. The two groups of piezoelectric ceramics are driven by
independent powers. The resonance inductors are serialized between power and piezoelectric
ceramics. FBG sensors are pasted in the two ends of piezoelectric ceramics. It will generate
maximum strain by pasting piezoelectric ceramics at the free ends of cantilever from the view of
theories. The reason is that the elastic potential energy of flexible beam is proportional to the
square of the strain. Therefore, it will be the most effective to sense and drive for the
achievement of active control at the maximum elastic potential energy that is the maximum
strain. But, FBG sensors are also considered to use. Because the sensors are pasted at the two
ends of piezoelectric ceramics, the waveforms tested can best describe the vibration of
cantilever. So the piezoelectric ceramics are pasted at the middle of cantilever in this paper.

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4.2. The driving circuit of piezoelectric ceramics

It needs alternating voltage over 300V to drive the piezoelectric ceramics. The
piezoelectric films are driven to vibrate according to alternating voltage over 300V enlarged by
power of 12V directly in this experiment. The principium of the circuit is shown in Fig.2.The
circuit is consisted of integrated timer of photocoupler NE555, driving IC of high voltage and
power FET. NE555 is used to generate standing wave whose frequency is adjustable. Using two
standing waves inverted each other to drive power FETs according to IR2110, the power FETs
motivate transformer coils to generate alternating voltage to drive piezoelectric ceramics

Fig 4.2 The principium of the circuit

The signal generator generates standing waves of 5-30V (directed by the input voltage)
and then through the two primary coils of differential driving transformer. The primary winding
of transformer is 32 laps. The secondary winding is 320 laps. The voltage step-up of transform
drives piezoelectric ceramic due to the matching resonant inductor. The measured capacitance of
piezoelectric ceramics after completed is 3nF .According to the formula of resonant frequency

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Since the inductor has a large capacity, several inductances are serialized to approximate
the resonance of circuit improving the power factors. When the system is built, the separate
powers must be used in digital circuits and power circuits and the two kinds of circuits are
connected by common ground avoiding the FETs and transformers interference the work of
digital circuits.

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CHAPTER 5
COMPARISON FOR REFERENCE OF
SMART BEAM STRUCTURE

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5. COMPARISON FOR THE REFERENCE SMART BEAM STRUCTURE

In this chapter the performances of these two controllers for the reference smart beam
structure are compared in the frequency domain according to the Bode-diagram and also in the
time domain by checking its step response.

5.1 Bode diagram amplitude gain

The Bode diagram’s magnitude plot expresses the amplitude gain, which in this project is
the displacement of the beam’s end in meters. The frequency response of the smart structure with
and without the controller is illustrated in the same Bode diagram (Figure 7). By comparing the
two lines it can be directly determined, if the controller can compensate the vibration at the
beam’s end. From Figure 7 it can be observed that no matter with which controller, the first peak
of the solid line is always sharper than the peak of the dashed line.

Fig 5.1 (a) LQ

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where y1;1;no is the displacement of the beam’s end (y1) at the first resonance
frequency f1 without a controller, and y1,1,c is the displacement of the beam’s end (y1) at the
first resonance frequency f1 with a controller (see also Figure 7(a)). The second criterion is the
offset of the first resonance frequency _f1 (see also Figure 7(b)).

Fig 5.1 (b) LC

The smart beam structure with LQR can reduce 92.3% of the vibration (corresponding
to22.3 dB) at the first resonance frequency f1. This vibration reduction percentage is 96.7%
(corresponding to 29.7 dB) when the structure is connected with the LC. But the vibrations at the
second f2 and the third resonance frequencies f3 are almost the same as those without
controller.LC as an active damping controller that can change the structural vibration’s behavior.

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5.1.2 Step response

The step response of the smart beam structure with various controllers is checked to
ensure if the smart structure is stable under a step force at the beam’s end u1 = 1 N (). The
settling time ts and the response’s final value Ms of these two controllers are compared. The
settling time ts presents the duration until the system is stable. The response’s final value Ms
indicates the accuracy of the controller. The step response of the reference smart beam structure
with both controllers is illustrated in Fig.

Fig 5.2 (a) LQR

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Fig 5.2 (b) LC

5.2 THE CONTROLLERS’ ROBUSTNESS ANALYSIS

As the design of the control concepts is regarding to a stochastic simulation for sensitivity
analysis of the smart beam structure, the robustness of the control concepts must be checked to
ensure that the controller does not only work for the reference structure but also for the struc
tures with small parameter variations. The robustness analysis is done according to a factorial
experiment design.

5.2.1 The factorial experiment

In a stochastic simulation the geometric or material’s parameters of the smart beam

structure are randomly varied in a predetermined range. It is not feasible to check if the
controller is working properly for all these varied structures. Instead of checking for every
simulation combination in a stochastic simulation a statistic simulation is carried out by
combining the minimum , the midpoint (0), and the maximum (+) of each varied parameter. But
if all the geometric or material’s parameters of the smart beam structure are varied, the
simulation combinations are still too many to carry out. Han did a sensitivity analysis of a very
similar smart beam structure based on its analytical model. According to his sensitivity analysis

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result, the beam’s length LB, the beam’s thickness TB, and the actuator’s position SA have more
influence on the beam’s vibration than the other parameters. Hence, these three parameters are
chosen as the designed factors to check the controllers’ robustness and the other parameters are
held constant as for the reference smart beam structure . It shows the design factors’ three varied
levels.

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CHAPTER 6
MANUFACTURING PROCESS OF
SMART BEAM

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6.1. INTRODUCTION
Smart Beam is a welded light gauge H section steel manufactured by Nippon Steel &
Sumitomo Metal Corporation (hereinafter referred to as light gauge H section steel). Smart Beam
is the H section steel manufactured by using hot strip steel sheets and built up by welding. As the
manufacturing method in Fig. 1 shows, an H section is manufactured by using two hot-rolled
steel sheet coils, one of the sheet coil is guided to the upper and lower flange position after slitted
half, another is guided to the web position after twisted. So, by flowing a high frequency current
between the flange and the web, and they are melted by the generated arc. Then, by applying
pressure, the flange and the web are continuously welded.Owing to the difference in the
manufacturing process, when compared with the hot-rolled H section steel (hereinafter referred
to as rolled H section steel), Smart beam is characterized by its abilities of “producing H section
steel with thinner thickness,” “providing high dimensional accuracies,” and “providing high
affinity with electro deposition coating and powder coating as hot-rolled strip sheets with flat and
smooth surface are used as the mother material.”

As for the product standard, the light gauge H section steel of 400 N/mm2 class is
provided as SWH400 in JIS G 3353 (Welded light gauge steel H sections for general structure),
and it is possible to apply them to the major structures of buildings as the architectural material
designated by Article 37, Section 1 of the Building Stand-ards Act. Furthermore, in Nippon Steel
& Sumitomo Metal, light gauge H section steel of 490 N/m2 class is manufactured, which is
standardized as NSSWH490 in Nippon Steel & Sumitomo Metal Merchandize Standards.
Moreover, as to NSSWH490, the ministerial authorization provided in Article 37, Section 2 of
the Building Standards Act was obtained and NSSWH 490 is authorized to be used for major
structures of buildings .Nippon Steel & Sumitomo Metal started the commercial production in
October 1973, and the accumulated amount of the production reached 5 million tons in July
2014. At the early stage, light gauge H section steel was used mainly for the main frame of low-
rise buildings like manufacturing plants from the view point of saving steel material weight.
However, as such manufacturing plants grew larger in size along with the elapse of time and the
rolled H section steel has come to be used for main frame of such buildings as materials in main
stream. On the other hand, since around the end of 1970s, in the steel-framed

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Pre-fabricated houses, light gauge H section steel has come to be used from the viewpoint of
sectional performance efficiency, substituting the beam material that was built up of two light
gauge channel sections jointed together back to back

Fig 6.1 Manufacturing process of Smart Beam

As factors lying in the background, following features of light gauge H section steel are
listed: the production of light H with relatively thin thickness is possible, the dimensional
accuracy is very high, and the surface is flat and smooth. Such features mean that light gauge H
section steel is well suited to automatic processing lines such as of hole opening by a punching
machine, of cutting a member material by shearing, and of electro deposition coating. Since
after, as the steel-framed prefabricated houses have evolved to high quality industrialized

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Houses and spread as the result of defection from the extension of temporary houses in the early
period, light gauge H section steel have established the position as a standard beam material.
Furthermore, in the spreading stage of light gauge H section steel in the steel-framed
prefabricated houses, Nippon Steel & Sumitomo Metal played an influential role and has come
to supply more than 80% owing to its quality and production capacity. In addition to the features
mentioned above, Smart beam is characterized by that both as-rolled specification and pre-
coating specification types are producible by selecting the kind of steel strip to be used as the
mother material.

A hot-rolled steel strip sheet is used for the as-rolled-specified products and the products
are used for the case where the all member materials are painted by customers after processing
such as hole opening and welding. For the pre coating- specified products, presently a hot-dip
galvanized steel sheet (GI) is used as the mother material and the standard coating weight of GI
is specified as Z27 (minimum total coating weight of both sides to be 275 g/m2) that satisfies the
Grade 3 provided in “The Law Pertaining to the Promotion of Securing of Quality of Houses
hereinafter referred to as Quality Securing Law),” which is classified as the highest in the
deterioration counter measure classification (assessment criteria: countermeasures to ensure
durability of a structural frame for an approximate period of three generations (75–90 years)).
Pre-coating-specified Smart beam is used mainly for members of wooden prefabricated houses
and small beams of wooden houses. In case Smart beam is used for wooden houses, materials are
precoating specified in almost all cases for the purposes including compliance with the
deterioration countermeasures (corrosion resistance) specified in the Quality Securing Law.

Intending for use in the field where the pre-coating-specified materials are used for
members of wooden houses, Nippon Steel & Sumitomo Metal has developed and
commercialized Smart beam termed as “SD-Smart beam (hereinafter referred to as SD-SMB™)
that employs for the mother material the high corrosion resistance-coated steel sheet “Super
Dyma™” as a means to further improve performance. Super Dyma has high corrosion resistance
performance as compared with GI even if coating weight is reduced. This article introduces the
outline of the commercialized SDSMB at first.

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6.2. TECHNICAL SPECIFICATIONS OF SMART BEAM

• IEEE 802.11n

• IEEE 802.11g

• IEEE 802.11b

• IEEE 802.3

• IEEE 802.3u

• IEEE 802.3ab

Device Interfaces

• 802.11n/g/b wireless LAN

• 4 10/100/1000BASE-T Gigabit LAN

Ports

• 1 10/100/1000BASE-T Gigabit WAN

Port

• USB 2.0 port

Antenna Type

• Internal Smart Antennas with SmartBeam™ Technology Security

• WPA & WPA2 (Wi-Fi Protected Access)

• 64/128-bit WEP

QoS

• Port-based QoS prioritizes media and data Device Management

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• Wireless Setup Wizard

• Web-based management using Internet Explorer 6 or later, Firefox 2.0 or later, or another Java-
enabled browser SharePort™ Function Support

• Allows network sharing of a USB multifunction printer or USB storage drive LEDs

• Internet

• Wireless

• WPS

• Power

Power Input

• 100 to 240 VAC, 50/60Hz

Dimensions

• 120.5 x 198 x 32 mm

Weight

• 341 g

Operating Temperature

• 0º to 40º C

Storage Temperature

• -20º to 65º C

Operating Humidity

• 10% to 90% non-condensing

Operating Humidity

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• 5% to 95% non-condensing

Certifications

• FCC Class B

• CE

• IC

• C-Tick

• IPv6 Ready

• Wi-Fi Certified

• WMM

• Compatible with Windows 7 Maximum

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CHAPTER 7
ADVANTAGES

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7.1. ADVANTAGES

 Fast, Reliable Connected to Devices

 Double the Wireless Coverages
 Stay Safe and Secure Focus
 Stability
 Eye safe
 Easy to handle
 Light weight

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CHAPTER 8

CONCLUSION AND FUTURE SCOPE

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8.1. CONCLUSION

Introduction of analytical software package (Ansys) is also discussed here for the
modeling of smart beam structure. This survey will give an introduction to a new researcher in
this field to different published papers at a single glance. Piezoelectric materials have major role
in active vibration control and ANSYS software provides a means for FE modelling of smart
structures, coupled field analysis and closed loop control actions can be simulated by integrating
control laws into the ANSYS. The vibration control of beam is considered as an important
engineering problem because it will enhance the stability of the system.

8.2. FUTURE SCOPE

As a result of this evaluation, the TBPID controller provides more energy

savings than the PPF controller for all presented controllers. As a future work, TBPID controller
design can be used and implemented for vibration control of a helicopter fuselage system in the
flight tests in order to decrease the interior noise level of the vehicle.

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BIBLIOGRAPHY
PAPERS REFFERED
1. Study of Active Vibration Contro1 for Fiber Smart Beam ZHANG Lia, DING Shao-jie, and
Dec 2011.

2. An asymptotically correct classical model for smart beams Sitikantha Roy, Wenbin Yu, Dong
Han, Jan 2007.

WEB REFFERENCES
1. https://journals.sagepub.com/doi/full/10.1177/1461348418782169
2. https://books.google.co.in/books?isbn=1522561374

3. https://kdcusa.com/

1.

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