System and method for monitoring structural health of bonded components

• US 10,210,740 B2
• Filed: 11/09/2015
• Issued: 02/19/2019
• Est. Priority Date: 11/09/2015
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Ihn, Jeong-Beom, Choi, Keeyoung
• Primary Examiner(s): Tun, Nay
• Assistant Examiner(s): Kingston, Shawna M
• Application Number:
  US14/935,887
• Publication Number:
  US 20170132901A1
• Time in Patent Office: 1,198 Days
• Field of Search: None
• CPC Class Codes: G01M 5/0016 of aircraft wings or blades
• CPC Class Codes: G01M 5/0033 by determining damage, crack or wear
• CPC Class Codes: G01M 5/0083 by measuring variation of impedance, e.g. resistance, capacitance, induction
• CPC Class Codes: G08B 21/18 Status alarms G08B21/02 takes precedence
• CPC Class Codes: G08B 5/00 Visible signalling systems, e.g. personal calling systems, remote indication of seats occupied

Abstract

The present disclosure relates to a system for monitoring structural health of bonded components includes an energy-harvesting device. The system also includes a damage-detection module powered by electrical energy from the energy-harvesting device. Further, the system includes electrically-conductive ink applied onto the bonded components and across an interface between the bonded components. The electrically-conductive ink forms an electrical circuit with the damage-detection module. Additionally, the system includes a visual-indication device electrically coupled with the damage-detection module. The visual-indication device is configured to visually indicate damage to the bonded components in response to receipt of electrical energy. The damage-detection module is configured to detect a break in the electrically-conductive ink and to transmit electrical energy from the energy-harvesting device to the visual-indication device in response to detecting the break in the electrically-conductive ink.

Claims

1. A system for monitoring structural health of bonded components, the system comprising:

a damage-detection module powered by electrical energy from an energy-harvesting device;

bonded components, comprising a first bonded component and a second bonded component, wherein;

the first bonded component and the second bonded component each comprises a contact surface;

the first bonded component and the second bonded component are bonded at the contact surfaces by a bonding material;

the contact surfaces face each other; and

the first bonded component and the second bonded component comprise non-contact surfaces that do not face each other and are not bonded to each other;

electrically-conductive ink applied onto the bonded components at the non-contact surfaces and traversing back and forth between the bonded components on the non-contact surfaces, the electrically-conductive ink forming an electrical circuit with the damage-detection module; and

a visual-indication device electrically coupled to the damage-detection module, the visual-indication device configured to visually indicate damage to the bonded components in response to receipt of electrical energy;

wherein the damage-detection module is configured to detect a break in the electrically-conductive ink and to transmit electrical energy from the energy-harvesting device to the visual-indication device in response to detecting the break in the electrically-conductive ink.

2. The system according to claim 1, wherein the energy-harvesting device, damage-detection module, and visual-indication device are affixed to at least one of the bonded components.

3. The system according to claim 1, wherein the energy-harvesting device, damage-detection module, and visual-indication device are integrated into at least one of the bonded components.

4. The system according to claim 1, wherein the energy-harvesting device, damage-detection module, and visual-indication device are permanently coupled to at least one of the bonded components.

5. The system according to claim 1, wherein the non-electrical energy comprises kinetic energy.

6. The system according to claim 5, wherein the energy-harvesting device comprises a piezoelectric generator.

7. The system according to claim 1, wherein the visual-indication device generates a permanent visual indication of damage to the bonded components.

8. The system according to claim 7, wherein the visual-indication device comprises a thermochromic marker.

9. The system according to claim 1, wherein the damage-detection module comprises a switch component configured to transmit electrical energy from the energy-harvesting device to only the electrically-conductive ink when a break in the electrically-conductive ink is not detected and to transmit electrical energy from the energy-harvesting device to only the visual-indication device when a break in the electrically-conductive ink is detected.

10. The system according to claim 9, wherein the switch component comprises a passive switch component.

11. The system according to claim 9, wherein the switch component comprises a transistor.

12. The system according to claim 1, wherein a visual indication of damage to the bonded components provided by the visual-indication device is visible only in black-light lighting conditions.

13. The system according to claim 1, wherein the interface comprises a bonding material.

14. The system according to claim 1, wherein the electrically-conductive ink follows a pattern comprising multiple passes across the interface about a periphery of the interface.

15. A method of monitoring structural health of bonded components, the method comprising:

applying electrically-conductive ink onto bonded components at non-contact surfaces and traversing back and forth between the bonded components on the non-contact surfaces to form an electrical circuit, wherein;

the bonded components comprise a first bonded component and a second bonded component;

the first bonded component and the second bonded component each comprises a contact surface;

the first bonded component and the second bonded component are bonded at the contact surfaces by a bonding material;

the contact surfaces face each other;

the first bonded component and the second bonded component comprise non-contact surfaces; and

the non-contact surfaces do not face each other and are not bonded to each other;

converting non-electrical energy into electrical energy;

transmitting the electrical energy through the electrical circuit;

detecting a break in the electrically-conductive ink; and

visually indicating a break in the electrically-conductive ink on a visual-indication device, powered by the electrical energy, in response to a break in the electrically-conductive ink being detected.

16. The method according to claim 15, wherein applying the electrically-conductive ink onto the bonded components and across the interface between the bonded components to form the electrical circuit comprises applying multiple passes of electrically-conductive ink across the interface about a periphery of the interface.

17. The method according to claim 16, wherein applying multiple passes of electrically-conductive ink comprises applying multiple passes each having at least one of a square, triangular, or sinusoidal shape.

18. The method according to claim 15, wherein converting non-electrical energy into electrical energy comprises converting kinetic energy into electrical energy using at least one piezoelectric generator.

19. A structure, comprising:

a substrate comprising a damaged portion;

a patch applied to the damaged portion of the substrate, wherein an interface is defined between the substrate and the patch, wherein the patch and substrate are bonded at contact surfaces that face each other, wherein the patch and substrate comprise non-contact surfaces that do not face each other and are not bonded to each other;

an energy-harvesting device affixed to the substrate and configured to convert non-electrical energy into electrical energy;

a damage-detection module affixed to the substrate and powered by electrical energy from the energy-harvesting device;

electrically-conductive ink applied onto the substrate and onto the patch at the non-contact surfaces and traversing back and forth between the patch and the substrate, the electrically-conductive ink forming an electrical circuit with the damage-detection module; and

a visual-indication device electrically coupled with the damage-detection module and spaced away from the electrically-conductive ink, the visual-indication device configured to visually indicate damage to the interface in response to receipt of electrical energy;

wherein the damage-detection module is configured to detect a break in the electrically-conductive ink and to transmit electrical energy from the energy-harvesting device to the visual-indication device in response to detecting the break in the electrically-conductive ink.