New compliant strain gauges for self-sensing dynamic deformation of flapping wings on miniature air vehicles

Over the past several years there has been an increasing interest in the development of miniature air vehicles (MAVs) with flapping wings. To allow these MAVs to adjust to changes in wind direction and to maximize their efficiency, it is desirable to monitor the deformation of the wing during flight. This paper presents a step in this direction, demonstrating the measurement of strain on the surface of the wing using minimally invasive compliant piezoresistive sensors. The strain gauges consisted of latex mixed with electrically conducting exfoliated graphite, and they were applied by spray coating. To calibrate the gauges, both static and dynamic testing up to 10 Hz were performed using cantilever structures. In tension the static sensitivity was a linear 0.4 Ω μe−1 and the gauge factor was 28; in compression, the gauge factor was −5. Although sensitivities in tension and compression differed by a factor of almost six, this was not reflected in the dynamic data, which followed the strain reversibly with little distortion. There was no attenuation with frequency, indicating a sufficiently small time constant for this application. The gauges were thin, compliant, and light enough to measure, without interference, deformations due to shape changes of the flexible wing associated with generating lift and thrust. During flapping the resistance closely tracked the generated thrust, measured on a test stand, with both signals tracing figure-8 loops as a function of wing position throughout each cycle.