Development and validation of a digital twin system model for a piezoelectric sensor

Abstract

This study presents a multiphysics modeling framework for a piezoelectric force sensor embedded within an automotive tire system, combining finite element and circuit simulation with empirical validation. The project had three primary objectives: (1) to modify an exist- ing two-dimensional axisymmetric tire model in COMSOL® to accommodate localized point loading, (2) to develop a virtual representation of a multilayer piezoelectric sensor capable of predicting voltage output under mechanical stress, and (3) to validate this model utilizing experimental techniques. To address the tire modeling challenge, the axisymmetric geometry was extruded into a complete three-dimensional model to enable the simulation of discrete contact forces. A simplified pseudo-tire model, constructed with linear elastic materials, was able to converge under internal pressure and contact loading, producing a peak von Mises stress of 2 × 10^{2} N/m^{2} and a maximum displacement of 3 × 10^{-2} m at 5 kPa of interior air pressure. For the sensor, a two-dimensional COMSOL model was coupled with an LTspice® circuit to capture electromechanical coupling and time-dependent electrical behavior. The COMSOL simulation produced a peak voltage of 33.55 V and an integrated charge of 1.25 × 10^{−8} C under a ±500 N force sweep. Experimental validation using three- point bending and a voltage follower circuit yielded a capped sensor output of approximately 5 V at 250 N. Comparison between the COMSOL and experimental force–displacement data showed partial agreement, with a standard deviation of 2.71 N and a 24.23 % error. While the simulation accurately captured the sensor’s early behavior, it lacked the nonlinear plateau observed in the experimental results. This discrepancy suggests that future work should in- corporate parasitic loss mechanisms. This integrated modeling approach lays the foundation for digital twin frameworks in next-generation intelligent tire systems.