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SMART BEAM

CHAPTER1 INTRODUCTION

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SMART BEAM

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 EulerBernoulli 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 stiffnessproportional ,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 lowrise 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 precoating 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 Javaenabled 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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