Sensors and Sensor Networks: Design, Fabrication and Application of Distributed Micro Sensors Embedded in Metal Tooling

该奖项的目标是开发一种传感方法，为制造过程提供高度可靠和准确的监测和诊断。本研究拟采用系统方法研究基于快速模具制造工艺的嵌入式金属模具分布式微传感器的设计、制造、优化、评估和应用。多学科研究团队致力于推进传感器技术的基础知识，包括用于高温应变和温度测量的传感器设计和制造，将传感器嵌入金属制造工具，以及在制造过程监测和控制决策中解释和使用传感器数据。计划了三个相互关联的研究任务。任务1将侧重于设计、制造、嵌入和优化分布微热机械传感器在金属工具。任务2侧重于研究一种新的过程监控和诊断方法，该方法可以快速识别传感器和过程故障。任务3将解决与传感系统实施和测试相关的问题。该系统的验证和测试将在工业测试台上进行。无线系统的实现也将被探索。新课程开发、现有课程改进、指导和推广活动将吸引学生和行业参与智能工具技术。嵌入式传感系统将在关键过程位置提供高空间和时间分辨率的测量，从而实现更可靠和准确的监测和诊断系统。所提出的嵌入式传感系统在实践中也将极具吸引力，显著提高美国模具行业以及众多制造过程的竞争力。

The objective of this award is to develop a sensing methodology that enables highly reliable and accurate monitoring and diagnosis for manufacturing processes. This proposed research is to use a system approach to study the design, fabrication, optimization, assessment, and applications of distributed micro sensors embedded in metal tooling that is fabricated by Rapid Tooling manufacturing processes. A multidisciplinary research team seeks to advance fundamental knowledge in sensor technologies, including sensor design and fabrication for high-temperature strain and temperature measurements, the embedding of sensors into metal manufacturing tooling, and the interpretation and use of sensor data in decision-making for manufacturing process monitoring and control. Three interrelated research tasks are planned. Task 1 will focus on the design, fabrication, embedding, and optimization of distributed micro thermo-mechanical sensors in metal tooling. Task 2 focuses on the research on a new process monitoring and diagnostics methodology that can quickly identify both sensor and process faults. Task 3 will address issues related to the sensing system implementation and testing. The validation and testing of the system will be conducted on an industrial testbed. Wireless system implementation will also be explored.New course development, existing course improvement, mentoring and outreach activities will attract and engage students as well as industry to smart tooling technologies. Embedded sensing systems will provide measurement with high spatial and temporal resolution at critical process locations, thus enabling a much more reliable and accurate monitoring and diagnosis system. The proposed embedded sensing system would also be extremely appealing in practice, striking to enhance the competitiveness of US Tooling industry as well as numerous manufacturing processes.