Piezoelectric accelerometers using a lead-free (K,Na)NbO₃ (KNN) piezoceramic modified by a mixture of two Bi-based perovskites, Bi(Na,K,Li)ZrO₃ (BNKLZ) and BiScO₃ (BS), were designed, fabricated and characterized. Ring-shaped ceramics were prepared using a conventional solid-state reaction method for integration into a compression-mode accelerometer. A beneficial rhombohedral–tetragonal (R–T) phase boundary structure, especially enriched with T phase, was produced by modifying intrinsic phase transition temperatures, yielding a large piezoelectric charge coefficient d₃₃ (310 pC/N) and a high Curie temperature T_c (331 °C). Using finite element analyses with metamodeling techniques, four optimum accelerometer designs were obtained with high magnitudes of charge sensitivity S_q and resonant frequency f_r, as evidenced by two key performance indicators having a trade-off relation. Finally, accelerometer sensor prototypes based on the proposed designs were fabricated using the KNN-BNKLZ-BS ceramic rings, which exhibited high levels of S_q (55.1 to 223.8 pC/g) and mounted f_r (14.1 to 28.4 kHz). Perfect charge-to-acceleration linearity as well as broad flat frequency ranges were achieved with excellent reliability. These outstanding sensing performances confirm the potential application of the modified-KNN ceramic in piezoelectric sensors.

In this study, an Integrated Electronics Piezoelectric (IEPE)-type accelerometer based on an environmentally friendly lead-free piezoceramic was fabricated, and its field applicability was verified using a cooling pump owned by the Korea Atomic Energy Research Institute (KAERI). As an environmentally friendly piezoelectric material, 0.96(K,Na)NbO₃-0.03(Bi,Na,K,Li)ZrO₃-0.01BiScO₃ (0.96KNN-0.03BNKLZ-0.01BS) piezoceramic with an optimized piezoelectric charge constant (d₃₃) was introduced. It was manufactured in a ring shape using a solid-state reaction method for application to a compression mode accelerometer. The fabricated ceramic ring has a high piezoelectric constant d₃₃ of ~373 pC/N and a Curie temperature T_C of ~330 °C. It was found that the electrical and physical characteristics of the 0.96KNN-0.03BNKLZ-0.01BS piezoceramic were comparable to those of a Pb(Zr,Ti)O₃ (PZT) ring ceramic. As a result of a vibration test of the IEPE accelerometer fabricated using the lead-free piezoelectric ceramic, the resonant frequency f_r = 20.0 kHz and voltage sensitivity S_v = 101.1 mV/g were confirmed. The fabricated IEPE accelerometer sensor showed an excellent performance equivalent to or superior to that of a commercial IEPE accelerometer sensor based on PZT for general industrial use. A field test was carried out to verify the applicability of the fabricated sensor in an actual industrial environment. The test was conducted by simultaneously installing the developed sensor and a commercial PZT-based sensor in the ball bearing housing location of a centrifugal pump. The centrifugal pump was operated at 1180 RPM, and the generated vibration signals were collected and analyzed. The test results confirmed that the developed eco-friendly lead-free sensor has comparable vibration measurement capability to that of commercial PZT-based sensors.