Triboluminescent Sensor for Distributed Damage Monitoring

in Composites: Wind Turbine Blade Application

David O. Olawale, Emily Hammel, Tarik J. Dickens, Okenwa I. Okoli
High Performance Materials Institute, FAMU-FSU College of Engineering/Nanotechnology Patronas Group Inc.; okoli@eng.fsu.edu
Comparison of two sensor configurations

Global growth in wind power capacity is fueled by the need for green energy and
energy independence.

Benefits: Early damage detection, timely repairs, reduced accidents & casualty,
reduced downtime & maintenance cost

Uniqueness: No need for external light source or complex & expensive

interrogation systems, easier damage identification & no data overload

Application: Bridges, wind turbine blades, aircrafts

a)

50

Towards Composite Structures with In-situ Damage Sensing Capability

a)

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TL signal (AU)

Bio-inspired solution: ITOF Sensor

TL signal (AU)

Problem

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Impact load (N)

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Impact load (N)

Figure 9. a) Sensor with 30 wt% ZnS:Mn and b) 50 wt% ZnS:Mn exhibit linearity between sensor response and
impact load; 50 wt% sensor exhibits higher sensitivity (0.0033) than 30 wt% sensor (0.0018)

b)

Composite with damage-sensing ability

a)

e)

c)

b)

b)

Figure 1. Global cumulative installed wind capacity

More installed capacity, more accidents

e)

#1 cause of accident: wind blade failure

Causes of wind blade failure: poor maintenance & fire from lightning

Insurance claim: $240,000/wind blade failure

Wind energy responsible for large portion of $200 Million claims paid by GCube
in (2008-2012)

(Source: http://www.humanbody.dke-explore.com/clipart/human/image/exp_human042.jpg)

d)

b) Schematic of ITOF sensor integration into CFRP to provide in-situ damage sensing in wind turbine blades

Objectives

c)

b)

a)

a)

b)

c)

a)

b)

c)

Durability test: direct impact loading on ITOF sensor

a)

Figure 3. Difficulty of access for maintenance crews

(Source: Caithness Windfarm Information Forum)

(Source: www.offshorewind.biz;
http://www.texasenterprise.utexas.edu/article/alternative-energy-grid-faces-logisticalchallenges)

b)

Figure 6. Scanning electron

micrographs of ITOF sensor with
30% wt ZnS:Mn triboluminescent
composite film a) cross-section, b)
random dispersion of ZnS:Mn in
polymer matrix, c) closer view of
ZnS:Mn crystals with fracture lines
on surfaces

TiO2 coated CNT

yarn

a)

c)

The Need
Cost-effective in-situ damage monitoring sensor system for large composite
a)
structures like wind turbine blades and airplanes

b)
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b1)

Polymer optical fiber

(POF)
Figure 4. Schematic of the ITOF sensors components

Impact load (N)

Impact load (N)

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POF with jacket

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Figure 7. Experimental setup for

automated impact test
a) Automated impact hammer,
b) ITOF sensor made into a loop
for double-end coupling into PMT,
c) Photomultiplier tube enclosure

TL signal (AU)

CNT yarn
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a1)

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Figure 12. Successful sensing of multiple impact events at multiple

locations in ITOF-CFRP a) First impact location, b) Second impact location,
c) Third impact location; d) Position of integrated ITOF sensor in composite
panel; a) TL signal detected during first impact event; b) TL signal detected
during second impact event; c) TL signal detected during third impact event;
a) Impact load detected during first impact event; b) Impact load detected
during second impact event; c) Impact load detected during third impact
event.

0.80

Impact load (N)

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Triboluminescence Sensory
Receptor (TSR)

b)

a)

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c2)

Figure 13. Self-sensing of barely visible impact damage in ITOFCFRP a) Impacted surface of CFRP composite with integrated ITOF
sensor with 30% (wt) ZnS:Mn content showing barely visible impact
effect/damage, a) Corresponding TL signal detected by ITOF
sensor at the instant of impact of drop weight with composite plate,
a) Commencement of damage in composite caused by the impact
as detected by FLIR infra red camera, b) Impacted surface of CFRP
composite with integrated ITOF sensor with 50% by weight ZnS:Mn
content showing barely visible impact effect/damage, b)
Corresponding TL signal detected by ITOF sensor at the instant of
impact of drop weight with composite plate, b) Commencement of
damage in composite caused by the impact as detected by FLIR
infra red camera

Conclusion and Future Work

0.90

0.50

TL signal (AU)

Develop smart composites with in-situ and distributed damage monitoring

capability from cradle to grave by utilizing the bio-inspired and proprietary Insitu Triboluminescent Optical Fiber (ITOF) sensor

TL signal (AU)

0.35

Purpose

a)

pende

Investigate durability of ITOF sensor under repeated loading

Fabricate carbon fiber reinforced polymer (CFRP) with integrated ITOF sensor
(ITOF-CFRP)
Demonstrate in-situ and distributed damage monitoring capability in ITOFCFRP

Results

Figure 2. Wind turbine accidents per year

Figure 11. Experimental setup for low velocity impact test on

ITOF-CFRP composite panel
a) Black box housing photomultiplier tube (PMT), b) Power
supply, c) ITOF sensor from composite panel connected to
PMT, d) Impactor with load cell, e) ITOF-CFRP composite
panel, f) Infrared camera (FLIR) system

Figure 5. a) Representation of human body nervous system to be mimicked by ITOF sensor

Existing sensors & condition monitoring focus only on gears & electrical systems
Damage detection in blade primarily by inspection: high cost, high risk, low
frequency, poor maintenance

d)

Figure 10. ITOF-CFRP test panel fabrication a) Fiber lay up,

b) Integration of ITOF sensor using a weave method,
c) Completion of fiber layup, d) Vacuum bagging, e) Composite part fabrication
with vacuum assisted infusion

f)

d)

a)

c)

(Source: Global World Energy Council)

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Number of impacts

Figure 8. No degradation in TL signals from ITOF sensor after 100 impact loading
cycles at same point on the sensor and after over 800 impact loads along a sensor

ITOF sensor produced repeatable and sustained response after 100 impact
cycles at a location and over 800 impact cycles on a single sensor strip
Successfully integrated the ITOF sensor in CFRP to create composite with selfsensing capability and demonstrated capability to detect barely visible impact
damage
Future work to focus on sensor size reduction to ~20 m so it can be easily
woven into carbon or glass fibers during manufacture
Also create an integrated ITOF sensor with lightning strike protection and
electromagnetic interference (EMI) shielding capabilities

Acknowledgments
We thank HPMI for laboratory usage. Funding for this project was provided by the NSF-CMMI-0969413.

Increasing safety & cost-effectiveness of wind energy

by creating composite structures with in-situ damage monitoring capabilities from cradle to grave