Novel Fatigue-Damage Sensor for Prediction of Remaining Fatigue Lifetime of Mechanical Components and Structures

In this paper, a novel Internet of Things (IoT) fatigue damage sensor is presented to predict the fatigue damage accumulation level and residual fatigue life of critical mechanical and structural components. The intelligent radio-frequency identification (RFID)-integrated fatigue sensor system has special designed breakable mini beams with multiple parallel oriented geometry and symmetric U-type stress concentrated notches. The fatigue sensing beams with different stress and fatigue lifetime levels are designed to estimate the fatigue damage accumulation and remaining fatigue life of unidirectional and multidirectional structural or mechanical elements, including composite structures. The fatigue damage sensor attached on a real structure goes through the same fatigue life experience of critical structural elements or mechanical components from the beginning of service life or any point in the service life to the end of service life. A fatigue sensor with five parallel symmetric U notched mini beams with different fatigue lifetimes (10% N, 25% N, 50% N, 70% N, 85%–90% N) normalized to the total life (N) of a structure are considered to predict the remaining fatigue lifetime of a real structure using the cumulative damage Miner's rule. The mini fatigue sensor beams attached to the surface of a structure are designed to fail, depending on their fatigue life, earlier than the total fatigue lifetime of the structure, like a fatigue fuse system. The fatigue damage sensing beams fail gradually while passing through the same fatigue cycles as a structural member. When the service lifetime of a real monitored structure is very close to the total fatigue life, the critical maximum lifetime (80%–90% N) notched mini sensor beam breaks and issues an alarm that the service life of the real structural part is approaching its fatigue strength limit and the end of its service life. The smart fatigue damage sensor is wireless-enabled, which makes it possible to check the health status of the sensor over a sensor network as often as one likes. Since the wireless distributed fatigue sensor network system monitors the fatigue health conditions of structures periodically or on demand, the data collected on the sensor network system can be used not only for condition-based fatigue life prediction but also for sensor-based predictive fatigue maintenance and the development of new fatigue design tools for fatigue-sensitive complex and large engineering structures or mechanical systems.