Frequency-adaptable structural health and usage monitoring system (HUMS) and method with smart sensors

• US 10,607,424 B2
• Filed: 10/24/2017
• Issued: 03/31/2020
• Est. Priority Date: 02/10/2012
• Status: Active Grant

• Current Assignee: Appareo Systems LLC (AGCO Corporation)
• Original Assignee: Appareo Systems LLC (AGCO Corporation)
• Inventors: Batcheller, Barry D., Wiig, Johan A.
• Primary Examiner(s): Nolan, Peter D
• Application Number:
  US15/792,524
• Publication Number:
  US 20180047225A1
• Time in Patent Office: 889 Days
• CPC Class Codes: B64D 2045/0085 Devices for aircraft health monitoring, e.g. monitoring flutter or vibration
• CPC Class Codes: B64D 45/00 Aircraft indicators or protectors not otherwise provided for camouflage F41H3/00
• CPC Class Codes: G01M 5/0066 by exciting or detecting vibration or acceleration vibration testing of structures G01M7/00
• CPC Class Codes: G07C 5/008 communicating information to a remotely located station transmission systems for measured values G08C
• CPC Class Codes: G07C 5/0808 Diagnosing performance data testing of vehicles G01M17/00; testing of electrical installation on vehicles G01R31/005
• CPC Class Codes: G07C 5/085 using electronic data carriers

Abstract

A structural health monitoring system comprising intelligent sensors and serial communications devices interconnecting the sensors, data acquisition units and a programmable logic controller (PLC). The intelligent sensors are individually programmable and can be tuned to listen to specific frequencies based on a scaling factor based on the sensor'"'"'s location in the system being monitored, a set of pre-known frequencies based on the sensor'"'"'s location in the system being monitored, and the output of a central frequency-based system sensor. An aircraft flight control application of a method embodying the present invention includes anomaly detection based on comparing one or more preprogrammed flight plan regimen variables with actual aircraft performance parameters, and taking appropriate corrective action.

Claims

1. A health and usage monitoring system (HUMS) for detecting an anomalous condition indicated by the sensed vibrations on an aircraft with a vibration operating parameter, which HUMS includes:

a first intelligent sensor mounted on the aircraft and configured for sensing vibrations and performing signal processing on the sensed vibration data;

said first intelligent sensor mounted near a first component on the aircraft and monitoring the vibration of the first component;

a communication interface connected to said first intelligent sensor and receiving vibration operating parameter output therefrom;

a data acquisition unit connected to said communication interface and receiving said vibration operating parameter data output therefrom;

a programmable logic controller (PLC) connected to said data acquisition unit and receiving data output therefrom, said PLC preprogrammed with flight regimen operating parameters, including vibrations, for said aircraft;

a second intelligent sensor mounted at a remote location on the aircraft from said first intelligent sensor, said second intelligent sensor configured for sensing a rotational speed of a second component on the aircraft;

data received from the second intelligent sensor configured to be used by PLC to configure the operation of the first intelligent sensor, and data received from the second sensor comprising a digital representation of the rotation speed of the second component on the aircraft, said digital representation being configured to derive key system frequencies which the first intelligent sensor is configured to monitor; and

said PLC including a vibration anomaly detection function configured for comparing said preprogrammed flight regimen with an actual flight parameter and providing an anomaly output in response to detecting a vibration operating parameter anomaly.

2. The HUMS according to claim 1, which includes:

an output device connected to said PLC and configured for receiving output therefrom, said output device identifying said vibration anomaly condition to a user or a ground control system for said aircraft.

3. The HUMS according to claim 1, which includes:

said communication interface comprising a serial device configured for serial transmission of operating parameter data from said sensor to said data acquisition unit.

4. The HUMS according to claim 1, which includes:

a serial data connection between said data acquisition unit and said PLC, said serial data connection configured for serial transfer of operating parameter data.

5. The HUMS according to claim 1, which includes:

said intelligent sensor comprising a vibration sensor and said operating parameter comprising vibration frequency and/or amplitude.

6. The HUMS according to claim 1, which includes:

said intelligent sensor comprising an aircraft directional attitude sensor.

7. The HUMS according to claim 6 wherein said directional attitude sensor provides output comprising aircraft orientation relative to X, Y and Z axes.

8. The HUMS according to claim 1 wherein said intelligent sensor comprises an accelerometer providing an output comprising acceleration relative to X, Y and Z axes.

9. The HUMS according to claim 1 wherein said flight regimen operating parameters include aircraft course, altitude and speed.

10. The HUMS according to claim 1 wherein at least one of said intelligent sensors is configured for detecting one or more of aircraft operating parameters comprising:

temperature;

pressure;

rotational speed; and

stress.

11. A health and usage monitoring system (HUMS) for detecting an anomalous condition indicated by the sensed vibrations on an aircraft with a vibration operating parameter, which HUMS includes:

a first intelligent sensor mounted on the aircraft and configured for sensing vibrations and performing signal processing on the sensed vibration data;

said first intelligent sensor mounted near a first component on the aircraft and monitoring the vibration of the first component;

a communication interface connected to said first intelligent sensor and receiving vibration operating parameter output therefrom;

a data acquisition unit connected to said communication interface and receiving said vibration operating parameter data output therefrom;

a programmable logic controller (PLC) connected to said data acquisition unit and receiving data output therefrom, said PLC preprogrammed with flight regimen operating parameters, including vibrations, for said aircraft;

a second intelligent sensor mounted at a remote location on the aircraft from said first intelligent sensor, said second intelligent sensor configured for sensing a rotational speed of a second component on the aircraft;

data received from the second intelligent sensor configured to be used by PLC to configure the operation of the first intelligent sensor, and data received from the second sensor comprising a digital representation of the rotation speed of the second component on the aircraft, said digital representation being configured to derive key system frequencies which the first intelligent sensor is configured to monitor;

said PLC including a vibration anomaly detection function configured for comparing said preprogrammed flight regimen with an actual flight parameter and providing an anomaly output in response to detecting a vibration operating parameter anomaly;

an output device connected to said PLC and configured for receiving output therefrom, said output device identifying said vibration anomaly condition to a user or a ground control system for said aircraft;

said communication interface comprising a serial device configured for serial transmission of operating parameter data from said sensor to said data acquisition unit;

a serial data connection between said data acquisition unit and said PLC, said serial data connection configured for serial transfer of operating parameter data;

said intelligent sensor comprising a vibration sensor and said operating parameter comprising vibration frequency and/or amplitude;

said directional attitude sensor providing output comprising aircraft orientation relative to X, Y and Z axes;

said intelligent sensor comprises an accelerometer providing an output comprising acceleration relative to X, Y and Z axes; and

said flight regimen operating parameters including aircraft course, altitude and speed.