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Global Crisis/Sustainability Technologies

In Actuator/Piezoelectric Devices

By Kenji Uchino

Int’l Center for Actuators & Transducers, The Penn State University, University Park, PA 16802, USA.

<[email protected]>

Abstract: There are four factors that have influences on engineering: Social/culture/religion, Technology/science, Economics, and Politics/law. The strength of the impact of these factors becomes different according to history. Alchemy of the 16th century is an example of “Socio-Engineering”. From the Christian doctrine, “Heliocentric model” was denied, but “alchemy” was approved. Religion was controlling science. In the 17th~18th centuries, people were solved from the spell of religion and engineering based on science and technology, so-called “Techno-Engineering” is respected instead. In the 18th~19th centuries, technologies for mass production at low manufacturing cost were required and “Econo-Engineering” became mainstream to enhance national strength. The intention of increasing national wealth and military strength increased friction and that led to the First and Second World War in the 20th century. Engineering of this period is mainly government-led production of war weapons, and it was a beginning of “Politico-Engineering”. After the wars, mass production technologies for the reconstruction/recovery revived, but when the 21st century began, as a consequent result, environmental degradation, resource depletion, and food famine have become major problems. Global regulations are strongly called, and the government-initiated technology (“politico-engineering”) has become important again in order to overcome the regulations. Politico-Engineering covers (1) legally-regulated normal technologies such as sustainability, and (2) crisis technologies. This paper introduces leading actuator/sensor and piezoelectric technologies, relating with the above “sustainability” and “crisis” technologies, aiming at further research expansion in this area. The sustainable society requires (a) usage of non-toxic materials (Pb-free piezoelectrics), (b) disposal technology for existing hazardous materials (high power ultrasonic transducers), (c) reduction of contamination gas (diesel injection valves), (d) new energy source creation (piezoelectric renewable energy harvesting systems), and (e) energy-efficient device development. Crisis technologies are categorized into five types: (a) natural disasters (earthquakes, tsunamis, tornadoes, hurricanes, lightning, etc.), (b) epidemic/infectious diseases (smallpox, polio, measles, and HIV), (c) enormous accident (Three-Mile-Island core meltdown accident, BP oil spill etc.), (d) intentional accidents (acts of terrorism, criminal activity, etc.), (e) civil-war, war, territorial aggression. Keywords: Crisis technology; Sustainability technology; Politico-engineering; Piezoelectric actuator; Pb-free piezoelectrics; Piezoelectric energy harvesting; Ultrasonic cavitation; Ultrasonic motor.

ISIEM 2013 1/1

Bio-History of Kenji Uchino• University professor = 40 years

• Tokyo Tech – 10 yrs, Sophia Univ – 8 yrs, Penn State – 24 yrs

• Company executive = 21 years• Government Officer = 4 years• Japanese 20 years vs. US Citizen 22 years• “One step ahead”

• Age 40s = Academic initiative• Age 50s = Entrepreneur• Age 60s = Program officer

• “Discover/Inventor”• Piezoelectric ML actuators, PMN electrostrictors, Relaxor single

crystals, Micro motors, Piezoelectric transformers, HiPoCS

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- in Piezoelectric Devices -Kenji Uchino

Int’l Center for Actuators & TransducersThe Pennsylvania State University

1. Background

3. Paradigm Shift in Engineering

• Politico-Engineering• Cooperation, Protection, Reduction

Continuation2. Politico-Engineering

• Sustainability Technology• Crisis Technology

WWII Results in JapanPolitico-Engineering

Hiroshima 1945

Politico-Engineering

Three-Mile-Island（USA）

Fukushima Daiichi（Japan）

Date １９７９．３．２８２０１１．３．１１

Reason Human error of the equipment usage

Earthquake/Tsunami & Electr. shutdown

Level Melt-down Melt-down & ExplosionCommand President/State Army TEPCO/Prime Minister

Initial Actions

Water spray/ Evacuation in 80km

area in 24 hrs

Delay of water spray/ Evacuation in 20 km

area after 3 days

Comparison: Nuclear Power Plant Accidents

Problem: Delayed decision by the political leader induced the most serious explosion !

Necessity of Politico-Engineering

External Forces on “Engineering”

Economics

Society /Culture /Religion

Politics/Law

Technology/Science

“STEP”

ENGINEERING

Socio-Engineering

Techno-Engineering

Econo-Engineering


~ 16th

Century17th -18th

Century

18th ~ 19th Century (Industrial Revolution)

20th ~ 21st Century (World War)


Discovery of Piezoelectrics• Piezoelectricity

– Electrical charge when mechanical stress is applied

– Discovered by Jacque and Pierre Curie in 1880

Pierre Curie

Gabriel Lippmann

Converse Piezoelectricity Strain induced in a material by application

of electric field Discovered in 1881 by Gabriel Lippmann

Piezoelectricity.” TheFreeDictionary.com

Technology/Science

Technology/Science

What’s “Piezoelectric Effect”?CONVERSE PIEZOELECTRIC EFFECT

IgniterMicrophonePressure Sensor

DIRECT PIEZOELECTRIC EFFECT

ClockSpeakerActuator

High d and k in Pb(Zn1/3Nb2/3)O3-PbTiO3

- Crystal Orientation Dependence

[J.Kuwata, K.Uchino and S.Nomura: Ferroelectrics, 37, 579 (1981)]

Morphotropic Phase Boundary

E // [001]E //

Ps

Technology/Science

Field Induced Strains in Single Crystals Pb(Zn1/3Nb2/3)O3-PbTiO3 etc.

[S.E. Park and T.R. Shrout: Mat. Res. Innovat. 1, 20 (1997)]

Rhombohedral to tetragonal field induced transition

Technology/Science

Fabrication process for a multilayer (ML) ceramic actuator.

(Cutting/slicing, Polishing)

Sintered bulk ceramic

Ceramic plate/disk

(Electroding, Drying)

Laminated structure

(Resin coating)(Lamination, Curing)

(External electrode printing)

Multilayer device

(Binder mixing, Vacuumization)

Calcined powder

Slurry

(Slip casting)

Green sheet

(Punching)(Electrode printing)

(Lamination, Press, Cutting)

Green chip

(Binder evaporation, Sintering)(External electrode printing)

Multilayer device

Cut & Bond Method vs. Tape Cast Method

Polarization directionInternal electrode

External electrode

Economics

Piezoelectric Device Market Trends

Information Resources: iRAP (Innovative Research & Products); Market Publishers; IDTechEx

Economics

Applications of Piezoelectric Single CrystalsSONAR & Underwater Transducer

Piezoelectric Energy Harvesting Actuator (USM) / Sensor / Composite

Medical Ultrasound Probe Medical Imaging + HIFU

Economics

Piezo actuatormodule

Piezo Injector

Injectorhead

Injectorbody

NozzlePeugeot Diesel Vehicle

Piezo Unit

Internal ElectrodeAdhesive

Resin Mold

Side Electrod

e

Product Planning Creativity- Specifications -

Diesel Injection Valve (Siemens)

Economics

Piezo Unit


Resin Mold

Side Electrode

Drive Voltage Determination

１０Ｖ１００Ｖ１０００Ｖ

Discrete &

EDU

Cost

Thin Layer ML

Thick Layer

Piez

o St

ack

Pric

e

High Energy (High Current Capacitance)

Low Energy (Low Current Capacitance)

Shall we reduce the Drive Voltage as low as 12 V?

Too much costly for thin layer MLs

Minimum system cost suggests the drive voltage around 160 V, leading to the layer thickness 80 m.

Product Planning Creativity- Specifications -

Total Cost

Min

imum

Cos

t

Economics

Shipwreck of Titanic

April, 1912

Politics/Law

Langevin TransducersPolitics/Law

λ = 5 cmF = 30 k Hz

Langevin & Einstein

World War I – 1914-18U-Boat

Politics/Law

Permittivity contour map on the MgO-TiO2-BaO system, and the patent coverage composition range

(dashed line).[Ogawa and Waku, 1944]

USJapanRussia

World War II – 1939-45Politics/Law

3

Politico-Engineering - Overview− Politically-Initiated Science and Technology −

USA

Year

Coun

try

Pow

er (G

DP)

1960 1980 2000

Japan China

1960s: Initial Growth=Infra-structure1980s: Rapid Growth=Mass-production2000s: Growth Maturing=Sustainability

Domestic Politics

Global RegimeEcono-Politics


PRODUCT PLANNING

- Japanese Technology Trend Change -

• 1960's – Heavier

Thicker

Longer

Larger

• Ship manufacturing

• Steel industry

• Building construction

• Power plant (dam)

重

厚

長

大

Domestic Politics

Domestic Politics


Industrial Pollution• Minamata Disease (Nippon Chisso)

Heavy Metal (Mercury)

• Air Pollution (Steel Industries)• Acoustic Noise (Traffic)

• Nuclear Power plant (Energy Source)Three Mile Island Power Plant Melt-Down


PRODUCT PLANNING

- Japanese Technology Trend Change -

• 1980's – Lighter

Thinner

Shorter

Smaller

• Printer, Camera

• TV, Computer

• Printing time• Communication period• “Walkman”• Air conditioner

軽

薄

短

小

Econo-Politics

Econo-Politics


Medical/Ecological Problems

• Greenhouse EffectCO2 Generation, Global Warming

• Oil CrisisLack of Fossil Energy Source

• Population Growth/Longer LifetimeAverage Lifetime in JapanFemale=86 years old, Male=80 years old


PRODUCT PLANNING - Japanese Technology Trend Change -

• 2000's –Cooperation

Protection

Reduction

Continuation

• Kyoto Protocol• Global standard –Internet, Computer cable• Defense technology• Infectious disease

• Pb, Dioxin, CO2, Energy consumption

• Food supply – Genetic technology• Population –Medical/bio technology

協

守

減

維

Global Regime





1. Background





Categorization of Technology• Normal Technology

– New discovery/invention– Designing/manufacturing/marketing– Sustainability

• Crisis Technology– Natural disaster– Infectious/contagious disease – Enormous accident– Intentional (terrorist/criminal) incident– External & civil war/territorial invasion

Politically-Initiated Engineering


Categorization of Technology• Normal Technology

– New discovery/invention– Designing/manufacturing/marketing– Sustainability

• Power and energy (lack of oil, nuclear power plant, new energy harvesting)

• Rare material (rare-earth metal, Lithium) • Food (rice, corn – bio-fuel)• Toxic material

– Restriction (heavy metal, dioxin, Pb)– Elimination/neutralization (Mercury, Asbestos)– Replacement material

• Environmental pollution• Energy efficiency (piezoelectric device)



“Sustainability” Technologiesin Piezoelectric Devices

• Usage of non-toxic materials– Pb-free piezoelectrics, (K,Na)(Ta,Nb)O3

• Disposal technology of existing hazardous materials– Ultrasonic treatment

• Reducing contamination gas– Diesel injection valve

• New energy source creation– Piezoelectric energy harvesting

• Energy-efficient device development

Sustainability

1940-50 BaTiO3 -- CeramicLow piezoelectric properties

Perspectives of the Piezo-Materials Development

1950-60 Pb(Zr,Ti)O3 -- Ceramic Good performance

1980- Pb(Zr,Ti)O 3-- Thin/thick filmCrystal orientation (Rhomb. [001])

Crystal orientation (Rhomb. [001])Pb(Zn1/3Nb2/3)O3-- Single crystal

2000- BaTiO3 -- Single crystalPb-free materials (Eco-problem)Crystal orientation (Tetra. [111])

KNbO3 --Single crystal

Eco Technology

Sustainability

(a) (b)Number of Japanese patents for composition (a) and companies (b)

16

13

8

7

5

Bi-layered typecompound

(Bi1/2Na1/2)TiO3 typecompound

(Na,K)NbO3 typecompound

Tungsten bronzetype compound

Others

Total: 49 patents2

27

3

1

1

2

9

1

1

5

1

2

4

1

2

4

1

0 5 10 15

KYOCERA

MURATA

TDK

TOKIN

TOYOTA

MATSUSHITA

NISSAN

Others

Number of Disclosed Japanese patent

Bi-layered type(Bi,Na)TiO3 type(Na,K)NbO3 typeTungsten BronzeOthers

Pb-Free Piezoelectrics[No more PZT?]

European Community: RoHS (Restrictions on the use of certain Hazardous Substances) limits lead (Pb) in electronic equipments.

Sustainability

(K,Na,Li)(Nb,Ta,Sb)O3[Toyota Central R&D]

Stra

in (1

0-6 ) Oriented LF4

Unoriented LF4

Unoriented LF4

Oriented LF4

Temperature (oC)

Electric Field (V/mm)

[Y. Saito, Jpn. J. Appl. Phys., 35, 5168-73 (1996)]

Oriented ceramic via RTGG (F=91%)

Conventional random ceramic

Inte

nsity

(arb

itrar

y

Sustainability

Cavitaion

Adiabatic Compression（Rapid heating and cooling）

DioxinBurn at low temp. → Another hazardous

materialBurn at high temp. → Innocuous

http://pluto.apl.washington.edu/harlett2/artgwww/acoustic/medical/litho.html

Making hazardous waste innocuousSustainability

Water flow type ultrasonic cleaner

HONDA ELECTRONICS CO.,LTD.

Liquid crystal glass substrate

Large glass

Sustainability

Horn type L-L Coupler

R ad ia tin g face

D riv in g face

H orn type L-L converte r

PZTW

B o lt coup ledLangev in transduse r

S upport

Ultrasonic CleanerUltrasonic Cleaner

Courtesy of Sharp/Honda Electronics

Sustainability

Exhaust Gas Regulation

(From the Nikkei Newspaper, 2006)

Multilayer Actuators for Diesel Injection Valve

Diesel Exhaust Gas Regulation in Japan, Europe and US

Japan, Europe: > 3.5 ton vehicleUS: > 3.85 ton vehicle

NOx (gram/kW hr)

PM (g

ram

/kW

hr)

EU

USUS

JP

(Final JP Target)

Sustainability

(http://www.marklines.com/ja/amreport/rep094_200208.jsp)Energy Consumption by LCA (Well to Wheel)

Oil Natural Gas Oil Natural Gas

(Under a Hybrid Configuration)

Diesel Injection ValveSustainability

Nozzle Needle

High Pressure Fuel

Nozzle Seat

Nozzle Hole

Increase in Injection Amount per Unit Period

Post

Injection Interval

Pilot Pre After

Main

Multiple Injection

Micro Particle

Rectangular Injection Rate

Inje

ction R

ate

Time ←Increase in Fuel Pressure↑

Higher Force of the Actuator

←Increase in Nozzle Speed↑

Quicker Response of the Actuator

Quick responsive and high force actuator

Multilayer Actuators for Diesel Injection ValveSustainability

Piezo actuatormodule

Piezo Injector

Injectorhead

Injectorbody

Nozzle

Peugeot Diesel Vehicle

Piezo Unit


Resin Mold

Side Electrod

e

Diesel Injection Valve (Siemens)

Multilayer Actuators for Diesel Injection ValveSustainability

From Passive Dampers to Adaptive Dampers with Energy Harvesting

Mechanical Noise

Vibration

Piezoelectric Material

Electrical Energy

Passive Damping

Spend 1980s

Energy Harvesting

Accumulate 1990s

Sustainability

K2 & ACX

Sustainability

Lightening Switch - Face

Energy Harvesting with Thunder

Sustainability

WT

Charge output

PZT

EngineComposite Sheet

with Cymbals

Bolt to support the engine

1 mW 1 W

Chasing two rabbits at one time

• Vibration suppression

• Energy harvestingHybrid Car

Energy Harvesting(Penn State Univ & DENSO)

Sustainability

Charging the electronic devices

Flexible piezoelectric textile

Flexible energy harvest circuit

Penn State Univ & Smart Materials

1-5 mW

Sustainability

Metal Tube Ultrasonic Motor (Penn State Univ)

Smart Product Implementation Award, SPIE

Y

X

Elastic hollowcylinder

Plate X

Plate Y

x'y'

Structure of the motor stator

Rotor (spring)

PZT Ceramic

1.5 mm dia x 4 mm long

PSU Patent filed in 2000

Sustainability

MEDICAL CATHETER(Penn State Univ)

Minimal Invasive Surgery

Ultrasonic Medical Device for Blood Clot removal

Sustainability




1. Background






Categorization of Technology• Crisis Technology

– Natural disaster (earthquake, tsunami, tornado, typhoon, thunder)

– Infectious/contagious disease (smallpox, poliomyelitis, measles, HIV)

– Enormous accident (Three-mile-island nuclear power plant melt-down, BP deep-water oil flow)

– Intentional (terrorist/criminal) incident– External & civil war/territorial invasion

• Fukushima Nuclear Power Plant AccidentAutonomous Robot

• 03/11 Kanto-Tohoku EarthquakeSurveillance *Unmanned Aerial Vehicle

*Unmanned Underwater VehicleMonitoring Technology

“Natural Disaster” Technologies

“Enormous Accident”

Crisis Technology

iRobot (http://www.irobot.com/gi/)Autonomous Robot

Crisis Technology

Large Diameter Unmanned Underwater VehicleCrisis Technology

Crisis Technology

Large Diameter Unmanned Underwater Vehicle

US DOD & Japan MOD Development Agreement - 2013

Monitoring Nuclear Power Plant Accident“Enormous Accident” Technologies

AlN Piezo-Transducer up to 600°C (B. R. Tittmann, PSU)

Crisis Technology

Trapping the bacteria changes the weight

Weight load changes the resonance

frequency

Bacteria Sensors“Contagious Disease” TechnologiesCrisis Technology

Z.-Y. Cheng (Auburn University): Private Communication

Crisis Technology

Ultrasonic Hypochlorous Acid Humidifier for Disinfection Purposes (Penn State Univ)

PolyVinyl Chloride Sheet Good corrosion resistance against HClO, NaOH, NaClO and HCl

Crisis Technology

Electrolysis of Salt Water

Neutralization of Anthrax

Terrorist/Territorial Attack

Japan – “Senkaku” Island 2010

USA – World Trade Center Attack 2001

Crisis Technology

Multilayer Piezoelectric Transformer

Input Driving Circuit (Vin=18-24V)

Output CockcroftMultiplier Circuit

Output Voltage Resistive Divider

Airport Security Check – Homeland Security

Crisis Technology

Neutron Accelerator Gamma-Ray Scan

100kV Piezo Power Supply

Pulsed Neutron SourceCrisis Technology

“Green” Weapon− Environmental-Friendly Weapon − Weapon of mass destruction (WMD) –

nuclear bomb, chemical weapon

Laser Gun Rail GunMinimal destructive – pin-point target

“Jus in Bello”

Crisis Technology

Piezo Generators for Ammunitions

Piezo ML

Programmable Air Burst Munition (PABM)

ATK & Micromechatronics Inc. (State College, PA)

Crisis Technology




1. Background





Paradigm Shift of Product PlanningEcono-Engineering Politico-Engineering•Cost/performance technology

•Sustainability technology•Crisis technology

• Natural disaster (East Japan disaster)• Infectious/contagious disease• Enormous accident (Three-mile-island

nuclear power plant melt-down)• Intentional (terrorist/criminal) incident• External & civil war/territorial invasion

CRISIS: Agile decision by political leaders based on S&T knowledge is

essential [Politico-Engineering] !


PRODUCT PLANNING - Japanese Technology Trend Change -

• 2000's –Cooperation

Protection

Reduction

Continuation

• Global standard –Internet, Computer cable

• Defense technology• Infectious disease

• Pb, Dioxin, CO2, Energy consumption

• Food supply – Genetic technology• Population –Medical/bio technology

協

守

減

維


Fundamental S&T

Final Product

Development

Techno Engineering

Fundamental S&T

Final ProductMass-mnfg, Price

Development

EconoEngineering

Fundamental S&T

Final ProductRegulation

Development

PoliticoEngineering

Product Planning Strategy

Single Crystal Piezoelectrics

Multilayer Actuators

BT & Pb-Free Piezoelectrics


ENDThank you!

WWW.PSU.EDU/dept/ICAT

Contact: Kenji Uchino, Director, Professor E-mail: [email protected], Phone: 814-863-8035

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