Characterization of Low-Cost Piezoelectric Ceramics for IoT Acoustic Emission Sensors in Industry 4.0

• Grant number: 24/13409-9
• Support Opportunities: Scholarships in Brazil - Scientific Initiation
• Effective date (Start): November 01, 2024
• Effective date (End): October 31, 2025
• Field of knowledge: Engineering - Electrical Engineering
• Principal Investigator: Fábio Romano Lofrano Dotto
• Grantee: Henrique Alves Della Coletta
• Host Institution: Escola de Engenharia de São Carlos (EESC). Universidade de São Paulo (USP). São Carlos , SP, Brazil
• Associated research grant: 24/01374-6 - Development and Implementation of an Internet of Things-Based Acoustic Emission Sensor for Industrial Process Monitoring, AP.R

Abstract

The advancement of Industry 4.0 technologies and the increasing integration of Internet of Things (IoT) based sensors have enhanced industry productivity and sustainability. Traditionally, the identification of the state of tools and machines in factories has been performed by trained workers, who are prone to errors and unable to provide real-time information for all tools, thus slowing the process. Therefore acoustic, vibration, force, and pressure sensors installed directly on machines for continuous monitoring of industrial processes emerge as a solution. However, the adoption rate of these technologies remains low, especially in small and medium-sized enterprises, due to a lack of technical knowledge and high associated costs. Piezoelectric materials are often used in sensor development, particularly acoustic emission sensors. These capture mechanical acoustic waves emitted during the process and convert them into electrical energy for signal analysis. Despite the promising advantages, there remains a gap regarding the viability of using this type of sensor in industrial environments.Consequently, evaluating low-cost piezoelectric ceramics becomes necessary for developing IoT-based acoustic emission sensors, especially for small and medium-sized industries where cost is a limiting factor. This Scientific Initiation project aims to evaluate and characterize these ceramics through time and frequency analyses to meet this demand. Furthermore, it involves encapsulating these ceramics in metallic bodies, analyzing the mechanical interface of the sensors in active processes, and developing electronic signal conditioning circuits to enhance portability and application in embedded sensors. By its conclusion, the project aims to establish the most suitable sensor element and possible signal conditioning circuit for integrating into the IoT acoustic emission sensor currently being developed through the regular assistance project funded by FAPESP, coordinated by the supervising professor.