In the present state of the art, the function integration into lightweight metal structures is generally based upon adhesive bonding of sensors or actuators to the surface. A new technology enables a direct structural integration of lead-zirconatetitanate (PZT) fibers into local microstructures of metal sheets and subsequent joining by forming. This provides a complete functional integration of the piezoelectric ceramic in the metal for sensors and actuators purposes. In a further process step, the composite is shaped by deep drawing with a cup with double curvature radii of 100 mm into a complex 3D surface. During the shaping process it is expected that the PZT- fibers get damaged with the result of degradation of the piezoelectric function. This paper describes the application of various surface processing methods to improve the shaping behavior of the piezoceramic fibers. <p> </p>The production of interconnected parallel fibers is based on piezoceramic plates. The plates are treated by different surface processing. One experimental series is lapped and another series is extra polished by chemical mechanical polishing (CMP). The resulting plates were examined with regard to the fracture strength and the degradation of the piezoelectric properties during manufacturing and operation. It has been shown that the lapped and polished plates have a clearly better persistence with regard to the shaping processes compared to the unprocessed plates. The best results in this process were achieved by the polished plates, which is also transferable to the fibers. Furthermore, the piezoelectric characteristics were better preserved by the lapped and polished plates and fibers.
The paper reports the holistic development of an active piezo-based component concerning the mechanical design and
the control. The active component is used for the reduction of torsional vibrations in a strut of a tripod parallel kinematic
machine. By means of this new component the main drawback of the x, y, z-tripod structure can be eliminated. A
calculation shows the compliance of the connection between actuators and the adjacent mechanical parts as the most
sensitive point of the design. The characteristic values of the piezo actuator were transformed into the active component
with the help of design factors. For reducing the structural vibrations a control laws is presented that changes the
properties of the electro-mechanical structure, like damping or stiffness. This is possible by a feedback of motion signals,
e.g. velocity. The described electro-mechanical model was used for the control design. Experiment results, which are
finally presented, show a reduction of structural vibrations.