The SMART Layer (reg. TM) manufactured by Acellent is a thin flexible layer with a network of miniature piezoelectric actuators
and sensors that can be embedded inside or mounted onto metal and composite structures to acquire information on
structural integrity. Currently, SMART Layers (reg. TM) are used to assess the condition of structures and to monitor impact
events. The layers can be used to perform built-in structural inspection by exciting the devices with a periodic or
transient burst controlled input and analyzing the corresponding structural response. The technology can also be applied
to areas concerned with Homeland Security. For example, the technology can be used for motion monitoring and
monitoring of structures used in defense applications. By having a network of sensors that monitor loads on a structure, it
is possible to monitor the movement of people by measuring the loads exerted by them. The SMART Layer (reg. TM) technology
can be used to enhance the readiness of structures used for homeland defense such as manned and unmanned aircraft,
missiles and radar systems. It can also be used to monitor a pipeline network for any terrorist related activity that can
potentially damage the pipe system. A brief overview of such potential applications is presented here.
Monitoring the integrity of filament wound composite structures such as solid rocket motors and liquid fuel bottles is important in order to prevent catastrophic failures and to prolong the service life of these structures. To ensure the safety and reliability of rocket components, they require frequent inspection for structural damages that might have occurred during manufacturing, transportation, and storage. The timely and accurate detection, characterization and monitoring of structural cracking, delamination, debonding and other types of damage is a major concern in the operational environment. Utilization of a sensor network system integrated with the structure itself can greatly reduce this inspection burden through fast in-situ data collection and processing. Acellent Technologies, Inc. is currently developing integrated structural monitoring tools for continuous monitoring of composite and metal structures on aircraft and spacecraft. Acellent's integrated structural monitoring system consists of a flexible sensor/actuator network layer called the SMART Layer, supporting diagnostic hardware, and data processing/analysis software. Recently, Acellent has been working with NASA Marshall Space Flight Center to develop ways of embedding the SMART Layer inside filament wound composite bottles. SMART Layers were designed and manufactured for the filament wound bottles and embedded in them during the filament winding process. Acellent has been working on developing a complete structural health monitoring system for the filament wound bottles including data processing tools to interpret the changes in sensor signal caused by changes in the structural condition or material property. A prototype of a filament wound composite bottle with an embedded sensor network has been fabricated and preliminary data analysis tools have been developed.
Structural health monitoring is a new technology that has been increasingly evaluated by the industry as a potential approach to improve the cost and ease of structural inspection. By improving structural inspection, structures can be made safer and more reliable, thus reducing the cost of structure ownership. Acellent Technologies is developing tools for structural health monitoring. The tools Acellent is offering are the SMART Layer and the SMART Suitcase. The SMART Layer is a flexible layer with a distributed array of piezoelectric transducers made using the printed circuit process that allows easy installation onto structures for in-situ sensing. The SMART Suitcase is an instrument that can interact with the SMART Layer and process the information collected from the structures. Acellent has been providing the system to researchers and companies to try out this new technique. Currently, this system is being evaluated by aircraft manufacturers for monitoring fatigue cracks from rivet holes, by an automotive company for inspecting flaws in composite/foam components, and by aerospace companies for detecting damages in composite/honeycomb sandwich structures. Other recent developments include the addition of fiber-optic sensors onto the SMART Layer and proving the SMART Layer for composite RTM process.
Knowledge of integrity of in-service structures can greatly enhance their safety and reliability and lower structural maintenance cost. Current practices limit the extent of real-time knowledge that can be obtained from structures during inspection, are labor-intensive and thereby increase life-cycle costs. Utilization of distributed sensors integrated with the structure is a viable and cost-effective means of monitoring the structure and reducing inspection costs. Acellent Technologies is developing a novel system for actively and passively interrogating the health of a structure through an integrated network of sensors and actuators. Acellent's system comprises of SMART Layers, SMART Suitcase and diagnostic software. The patented SMART Layer is a thin dielectric film with an embedded network of distributed piezoelectric actuators/sensors that can be surface-mounted on metallic structures or embedded inside composite structures. The SMART Suitcase is a portable diagnostic unit designed with multiple sensor/actuator channels to interface with the SMART Layer, generate diagnostic signals from actuators and record measurements from the embedded sensors. With appropriate diagnostic software, Acellent's system can be used for monitoring structural condition and for detecting damage while the structures are in service. This paper enumerates on the SMART Layer and SMART Suitcase and their applicability to composite and metal structures.
Conference Committee Involvement (4)
Industrial and Commercial Applications of Smart Structures Technologies
27 February 2006 | San Diego, California, United States
Industrial and Commercial Applications of Smart Structures Technologies
7 March 2005 | San Diego, California, United States
Industrial and Commercial Applications of Smart Structures Technologies
16 March 2004 | San Diego, CA, United States
Industrial and Commercial Applications of Smart Structures Technologies
4 March 2003 | San Diego, California, United States
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