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Der Fokus des Arbeitsfelds ist die messtechnisch fundierte Anwendung der 3D-Verfahrenskombination zur Lösung vielfältiger Messaufgaben mit optimaler Datenqualität für interne und externe Kunden.
Das setzt insbesondere eine jeweils problembezogene Messmethodik voraus. Dazu setzen wir kameragestützte 3D-Koordinatenmessverfahren ein, die auf dem fotogrammetrischen Prinzip der Bildtriangulation beruhen. Darunter fallen folgende miteinander flexibel kombinierbare Verfahrensmodifikationen: Mehrbildfotogrammetrie, Messadapter für Geometriemerkmale, Streifenprojektionsverfahren, statische bis hochdynamische Stereofotogrammetrie auf Punktebasis oder aufgabenangepasster Oberflächenmuster und mechanisch-optische Taster.
Innovation is the catalyst for the technology of the future. It is important to develop new and better technologies that can continuously monitor the environmental impact, e.g., for air Quality control or emission detection. In the recently at BAM developed Universal Pump Sensor Control (UPSC3) module, different components and sensors are fused. The combination of the individual components makes the UPSC3 module an excellent monitoring and reference system for the development and characterization of gas specific sensors. Measurements over long periods are possible, for mixed gas loads or for certain gas measurements. The System is part of a mobile sensor network of several sensor units, which can also be used as standalone systems.
Innovation is the catalyst for the technology of the future. It is important to develop new and better technologies that can continuously monitor the environmental impact, e.g., for air quality control or emission detection. In the recently at BAM developed Universal Pump Sensor Control (UPSC3) module, different components and sensors are fused. The combination of the individual components makes the UPSC3 module an excellent monitoring and reference system for the development and characterization of gas specific sensors. Measurements over long periods are possible, for mixed gas loads or for certain gas measurements. The system is part of a mobile sensor network of several sensor units, which can also be used as standalone systems.
The motivation and objective of this research is to develop gas sensors based on fluorescence detection with range of ppm / ppb. For this task a reference system is required, which contains volatile organic compound (VOC) sensors for reference data from different scenarios. The integrated multi-sensor unit can measure different gases through the integrated 3-fold VOC sensor, which can be adapted to the addressed scenario. . The system-integrated flow control, with pump and flow sensor, allows the gas molecules to be transported directly to the VOC sensor. The entire measurement is permanently stored on an integrated memory card. If the previously determined limit range is exceeded, an alarm is generated. The system is an important tool towards further developments in the field of gas sensors and is primarily used for the validation of chemically based gas sensors.
Leaking methane (CH4) from infrastructures, such as pipelines and landfills, is critical for the environment but can also pose a safety risk. To enable a fast detection and localization of these kind of leaks, we developed a novel robotic platform for aerial remote gas sensing. Spectroscopic measurement methods for remote sensing of selected gases lend themselves for use on mini-copters, which offer a number of advantages for inspection and surveillance over traditional methods. No direct contact with the target gas is needed and thus the influence of the aerial platform on the measured gas plume can be kept to a minimum. This allows to overcome one of the major issues with gas-sensitive mini-copters. On the other hand, remote gas sensors, most prominently Tunable Diode Laser Absorption Spectroscopy (TDLAS) sensors have been too bulky given the payload and energy restrictions of mini-copters. Here, we present the Unmanned Aerial Vehicle for Remote Gas Sensing (UAV-REGAS), which combines a novel lightweight TDLAS sensor with a 3-axis aerial stabilization gimbal for aiming on a versatile hexacopter. The proposed system can be deployed in scenarios that cannot be addressed by currently available robots and thus constitutes a significant step forward for the field of Mobile Robot Olfaction (MRO). It enables tomographic reconstruction of gas plumes and a localization of gas sources. We also present first results showing its performance under realistic conditions.
Leaking methane (CH4) from infrastructures, such as pipelines and landfills, is critical for the environment but can also pose a safety risk. To enable a fast detection and localization of these kind of leaks, we developed a novel robotic platform for aerial remote gas sensing. Spectroscopic measurement methods for remote sensing of selected gases lend themselves for use on mini-copters, which offer a number of advantages for inspection and surveillance over traditional methods. No direct contact with the target gas is needed and thus the influence of the aerial platform on the measured gas plume can be kept to a minimum. This allows to overcome one of the major issues with gas-sensitive mini-copters. On the other hand, remote gas sensors, most prominently Tunable Diode Laser Absorption Spectroscopy (TDLAS) sensors have been too bulky given the payload and energy restrictions of mini-copters. Here, we present the Unmanned Aerial Vehicle for Remote Gas Sensing (UAV-REGAS), which combines a novel lightweight TDLAS sensor with a 3-axis aerial stabilization gimbal for aiming on a versatile hexacopter. The proposed system can be deployed in scenarios that cannot be addressed by currently available robots and thus constitutes a significant step forward for the field of Mobile Robot Olfaction (MRO). It enables tomographic reconstruction of gas plumes and a localization of gas sources. We also present first results showing its performance under realistic conditions.
Piezoresistive accelerometers use a strainsensing element, generally made of semiconductor material, e.g., silicon to convert the mechanical motion into an electrical signal. This element is usually designed in form of a cantilever beam loaded with a mass. Acceleration causes bending
of the beam, which produces a change of electrical resistance proportional to the applied acceleration.
Main advantages of piezoresistive accelerometers in comparison to other types, e.g., piezoelectric and capacitive, is their robust and highly dynamic behavior, which qualifies them for application in high impact shock applications. Mechanical damping is typically implemented with silicon oil in a way that the output signal is undistorted over a wide frequency range. These characteristics principally qualify them for the application in drop tests carried out at BAM, for which they are calibrated over the frequency range from 1 to 4 kHz. However, using silicon oil for damping, has the drawback of temperature dependent change of its viscosity, leading to temperature dependent deviation of the accelerometer’s sensitivity. This study presents experimental results of the temperature behavior of a piezoresistive accelerometer with a dynamic range up to ±5000 g.
This type of accelerometer is applied for drop tests which are partially performed at temperatures of -40 or +100 °C.
Piezoresistive accelerometers use a strain-sensing element, generally made of semiconductor material, e.g., silicon to convert the mechanical motion into an electrical signal. This element is usually designed in form of a cantilever beam loaded with a mass. Acceleration causes bending of the beam, which produces a change of electrical resistance proportional to the applied acceleration.
Main advantages of piezoresistive accelerometers in comparison to other types, e.g., piezoelectric and capacitive, is their robust and highly dynamic behavior, which qualifies them for application in high impact shock applications. Mechanical damping is typically implemented with silicon oil in a way that the output signal is undistorted over a wide frequency range. These characteristics principally qualify them for the application in drop tests carried out at BAM, for which they are calibrated over the frequency range from 1 to 4 kHz. However, using silicon oil for damping, has the drawback of temperature dependent change of its viscosity, leading to temperature dependent deviation of the accelerometer’s sensitivity.
This study presents experimental results of the temperature behavior of a piezoresistive accelerometer with a dynamic range up to ±5000 g.
This type of accelerometer is applied for drop tests which are partially performed at temperatures of -40 or +100 °C.
Due to the high damping mechanical properties of fiberboard materials, corrugated fiberboard boxes are widely used as transport packagings of dangerous goods. Since there is risk of vertical impact within the distribution system, drop tests are performed as design type tests to assess a package’s ability to withstand damage. In this context, however, little is known regarding the transient mechanical response of a filled fiberboard box. The reason is that the nature of the packaging material presents challenges in identifying the deformation mechanisms experimentally. The aim of this work is to provide a framework for predicting the damage resistance of complete, filled corrugated fiberboard boxes which are ready for transportation. Therein, drop test finite-element simulations are used and validated by experimental results. These numerical calculation models are a valuable tool for virtual product development and contribute to the optimization of the design cycle.
Design and Implementation of Smart Multisensor Monitoring System for Safe Workplaces with LoRaWAN
(2020)
This project addresses the application of safe workplaces in offices and chemical laboratories where indoor air quality plays an important role. The LoRaWAN (Long Range Wide Area Network) is used as a communication interface to make important sensor data globally accessible. The goal of the development is to create a sensor node and an online and offline solution that collects the data from the sensor nodes and stores it on a local server or in a cloud. In cooperation with the companies WISTA GmbH and IONOS, a test sensor network is going to be established in the Berlin-Adlershof area.
The mechanical and geometrical properties of impact targets greatly influence the outcome of a drop test. The International Agreement concerning the International Carriage of Dangerous Goods by Road (ADR) as well as ISO 2248 describe the characteristics of impact targets for drop tests of dangerous goods packagings.
According to these regulations, the impact target’s surface needs to be unyielding, under testing conditions non-deformable, flat, and integral with a mass at least 50 times that of the heaviest packaging to be tested. The problem is that many production facilities, especially manufacturers of corrugated fibreboard boxes, do not have their own testing device with the required 50 times mass ratio of the impact target for a regulation compliant drop test during series production. Furthermore, at UN level it is considered necessary to revise these requirements.
In the present paper, the impact target requirements are examined in detail and compared with those in other technical areas (e.g., impact target for container for the transport of radioactive materials). A research method is being developed to investigate the dependency between the mass ratio of the packaging and the target as well as the damage resistance of a drop tested package in relation to specific design characteristics. The results are of high relevance for industry purposes and intended to ensure a uniform level of safety assessment for the mechanical testing of dangerous goods packagings.
QI-Digital is a joined project aiming at digitalising Quality Infrastructure (QI) processes involving standardization, conformity assessment, accreditation, metrology, and market surveillance [1]. Federal institute of material research and testing (BAM) is working on the creation of a digital calibration certifi-cate (DCC) to achieve digital metrological traceability and conformity assessment. The utilisation of machine readable and executable DCCs in the XML format is demonstrated on an example of a tem-perature measurement at a hydrogen refueling station. The certificates will be retrieved and analysed automatically at a Process Control System or at a Digital Twin.
Damages in infrastructure due to moisture amount to billions of Euros every year. For a more predictive structural health monitoring in civil engineering, the detection and monitoring of hazardous moisture in steel reinforced concrete constructions is of high interest. The sensors have to be wireless, elsewise they weaken the concrete cover of the rebars. The lifetime of such constructions is normally decades, thus the sensors have to be battery-free and fully passive. Considering these requirements, passive RFID-based sensors are developed. Communication and energy supply are realized wireless via the electromagnetic field of a RFID transmitter. The passive RFIDbased sensors are embedded into the concrete to enable the monitoring of moisture transport in porous materials. Results of the hydration process are shown.
Embedded wireless sensor systems for long-term SHM and corrosion detection in concrete components
(2017)
State-of-the-art communication standards like RFID and Bluetooth Low Energy enable the development of sensor systems which can be completely embedded into concrete components for long-term SHM and early damage detection. Objective of the project KonSens which is carried out at BAM is the development, implementation, and validation of sensors for measuring of Parameters relevant for corrosion, like moisture, pH value, and electrical conductivity, inside steel reinforced concrete components. The primarily addressed application is detection and evaluation of corrosion processes in concrete bridges.
In contrast to cable connected sensors, embedded wireless sensors avoid any pathways for intrusion of moisture and chemicals, e.g., chlorides which could trigger corrosion activity. To allow for long-term, ideally life-time operation, the once embedded sensor systems must work highly energy efficient. One option are passive RFID sensor systems, which work without battery. The energy is transmitted to the system through the electromagnetic field, even to operate sensors. A crucial parameter is the transmission depth in concrete. First experiments with RFID sensors working at frequencies of 13.56 MHz (HF) and 868 MHz (UHF) embedded in concrete specimen resulted positive for transmission depths of up to 13 cm, which is quite promising, considering that corrosion would appear first at the top level of rebars.
A second generation of passive RFID sensor systems has been implemented with improved antenna design. Current experiments using these systems focus on the Transmission characteristics in terms of transmission depths and the impact of concrete moisture. Low-energy humidity sensors are used and analysed regarding their capability for measuring the material moisture. Additionally, a relation between transmitted power to the embedded sensor and the moisture content of the concrete specimen caused by energy absorption can be presumed and is under systematic investigation.
Packagings for the transport of dangerous goods need to meet special requirements to get an approval. This includes free fall drop testing onto an essentially unyielding surface as a means to assess a package’s resistance to mechanical damage. A main requirement for drop tests is that the impact target’s mass shall be at least 50 times that of the heaviest package to be tested. Nevertheless, many manufacturers do not possess foundation structures with the required mass ratio. Previous evidence highlights that the mass ratio is not a decisive criterion on its own. Parameters such as the impact target foundation’s connection and the impulse experienced by the impacting object are essential as well. However, these factors are not easily verifiable since experimental measurements are not possible at most facilities. The objective of this work is to provide a detailed analysis on the interaction between impact target foundation and subgrade in dynamic impact testing using validated finite-element (FE) models. This research is highly beneficial for industrial application since it allows manufacturers to make informed predictions about the mechanical response of installed impact target foundations.
This project addresses the application of safe and healthy workplaces in offices, chemical laboratories and other workplaces where indoor air quality plays an important role. The LoRaWAN (Long Range Wide Area Network) is used as a communication interface to make sensor data globally accessible.
The objectives of the project are to create a sensor node and an online and offline system that collects the data from the sensor nodes and stores it on a local server, in a cloud, and also locally on the node to prevent communication failures. An important point in this project is the development of the sensor nodes and the placement of these in the premises, thus no development work is involved in Building the infrastructure.
This project addresses the application of safe and healthy workplaces in offices, chemical laboratories and other workplaces where indoor air quality plays an important role. The LoRaWAN (Long Range Wide Area Network) is used as a communication interface to make sensor data globally accessible.
The objectives of the project are to create a sensor node and an online and offline system that collects the data from the sensor nodes and stores it on a local server, in a cloud, and also locally on the node to prevent communication failures. An important point in this project is the development of the sensor nodes and the placement of these in the premises, thus no development work is involved in Building the infrastructure.
Ammonia and its reaction products can cause considerable damage of human health and ecosystems, increasing the necessity for reliable and reversible sensors to monitor traces of gaseous ammonia in ambient air directly on-site or in the field. Although various types of gas sensors are available, fluorescence sensors have gained importance due to advantages such as high sensitivity and facile miniaturization.
Here, we present the development of a sensor material for the detection of gaseous ammonia in the lower ppm to ppb range by incorporation of a fluorescent dye, which shows reversible fluorescence modulations as a function of analyte concentration, into a polymer matrix to ensure the accumulation of ammonia. A gas standard generator producing standard gas mixtures, which comply with the metrological traceability in the desired environmentally relevant measurement range, was used to calibrate the optical sensor system. To integrate the sensor material into a mobile device, a prototype of a hand-held instrument was developed, enabling straightforward data acquisition over a long period.
Contamination of natural bodies of water or soil with oils and lubricants (or generally, hydrocarbon derivatives such as petrol, fuels, and others) is a commonly found phenomenon around the world due to the extensive production, transfer, and use of fossil fuels. In this work, we develop a simple system for the on-field detection of total petroleum hydrocarbons (TPHs) in water and soil. The test is based on the measurement of the fluorescence signal emitted by the molecular rotor 2-[ethyl[4-[2-(4-nitrophenyl)ethenyl]phenyl]amino]ethanol (4-DNS-OH). This dye is embedded in a hydrophobic polymeric matrix (polyvinylidene fluoride), avoiding interactions with water and providing a robust support for use in a test strip fashion. Together with the strips, an embedded optical system was designed for fluorescence signal read-out, featuring a Bluetooth low-energy connection to a commercial tablet device for data processing and analysis. This system works for the detection and quantification of TPHs in water and soil through a simple extraction protocol using a cycloalkane solvent with a limit of detection of 6 ppm. Assays in surface and sea waters were conclusive, proving the feasibility of the method for in-the-field operation.
This paper deals with the development and investi-gation of a volatile organic compound (VOC) system for differ-ent scenarios. The integrated multi-sensor unit can detect dif-ferent gases through the integrated 3-fold VOC sensor, where-by a continuous measurement takes place. The system-integrated flow control, with pump and flow sensor, allows the gas molecules to be transported directly to the VOC sensor. The entire measurement is permanently stored on an integrat-ed Secure Digital (SD) card. If the previously determined limit range is exceeded, an alarm is generated. Due to the combina-tion of different components, numerous applications are possi-ble. The system is the first step or a tool towards further devel-opments in the field of gas sensors and is primarily used for the validation of chemically based gas sensors, and it is still largely extended by application-specific influences.