Distributed mode system for real time acoustic emission monitoring

• US 7,080,555 B2
• Filed: 06/04/2004
• Issued: 07/25/2006
• Est. Priority Date: 06/04/2004
• Status: Active Grant

• Current Assignee: Texas Research International Incorporated
• Original Assignee: Texas Research International Incorporated
• Inventors: Coughlin, Chris, Austin, Russell K.
• Primary Examiner(s): Williams, Hezron
• Assistant Examiner(s): MILLER, ROSE MARY
• Application Number:
  US10/862,096
• Publication Number:
  US 20060032313A1
• Time in Patent Office: 781 Days
• Field of Search: 735/83, 735/87, 735/94, 702/35, 702/36
• US Class Current: 73/587
• CPC Class Codes: G01H 1/00 Measuring characteristics of vibrations in solids by using direct conduction to the detector G01H9/00, G01H11/00 take precedence
• CPC Class Codes: G01H 1/16 Amplitude
• CPC Class Codes: G01N 2291/0289 Internal structure, e.g. defects, grain size, texture
• CPC Class Codes: G01N 2291/2694 Wings or other aircraft parts
• CPC Class Codes: G01N 29/14 using acoustic emission techniques echo of particles G01N29/046; measuring mechanical vibrations or acoustic waves in solids in general G01H1/00
• CPC Class Codes: G01N 29/2475 Embedded probes, i.e. probes incorporated in objects to be inspected
• CPC Class Codes: G01N 29/2481 Wireless probes, e.g. with transponders or radio links

Abstract

A distributed real time health monitoring system is described for monitoring of acoustic emission signals from different regions of a structure such as aircraft or spacecraft structures. The health monitoring system has its analysis and prognosis intelligence distributed out to the local regions being monitored and therefore does not require extensive cabling systems to carry the high bandwidth information characteristic of acoustic emission.

Claims

1. A method for the continued real time health monitoring of a structure using acoustic emission analysis comprising the steps of:

a. fixedly mounting at least one acoustic emission transducer in a region of said structure to be monitored;

b. distributing, in that same said region, a distributed health monitoring system containing all necessary hardware and software for complete analysis of the raw acoustic emission signals from said at least one transducer;

c. amplifying the voltage signals received from said at least one acoustic emission transducer to produce an amplified signal;

d. filtering said amplified signal to eliminate unwanted frequencies to produce a filtered signal;

e. acquiring, during a pre-determined time period, said filtered signal to identify and record acoustic emission events;

f. diagnosing, from said recorded acoustic emission events for said pre-determined time period, the overall health assessment of said region of said structure;

wherein said diagnosing step further comprises the steps of;

i. calculating in a first calculation, the number of acoustic emission events above a threshold decibel level;

ii. calculating, in a second calculation, a historical index for said acoustic emission events;

iii. calculating, in a third calculation, a cumulative energy for said acoustic emission events;

iv. calculating, in a fourth calculation, a severity of said acoustic emission events;

v. calculating, in a fifth calculation, a measure of relative damage by comparing said historical index and said severity to pre-determined and pre-recorded experimental acoustic emission research data; and

vi. calculating, as a numerical rating, an overall health assessment of said region of said structure for said pre-determined time period, using the results of said first, second, third, and fifth calculations.

2. The method of claim 1 further comprising storing said numerical rating in memory of said distributed health-monitoring system for future use.

3. The method of claim 1 further comprising the step of:

transmitting said numerical rating from said distributed health monitoring system to a new location.

4. The method of claim 2 wherein said transmitting step utilizes wireless transmission.

5. The method of claim 3 wherein said wireless transmission utilizes a radio frequency transmitter.

6. The method of claim 2 wherein said transmitting step utilizes an electronic bus.

7. The method of claim 5 wherein said electronics bus is an avionics bus.

8. A distributed real time health monitoring system for monitoring of acoustic emission signal from a structure using the method of claim 1 comprising:

a. at least one acoustic emission transducer for detecting said acoustic emission signals and outputting transducer signals, said at least one acoustic emission transducer fixedly mounted to a region of said structure to be monitored; and

b. a microcomputer system comprising;

i. computer memory;

ii. data acquisition software to acquire said transducer signals and record acoustic emission events; and

iii. data analysis software to assess and classify the health of said region of said structure.

9. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 8 wherein said at least one acoustic emission transducer for detecting said acoustic emission signals is a piezoelectric ceramic acoustic emission transducer.

10. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 8 wherein said at least one acoustic emission transducer for detecting said acoustic emission signals is a piezoelectric polyvinylidene fluoride acoustic emission transducer.

11. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 8 further comprising, an amplifier system for amplifying said transducer signals to generate amplified signals.

12. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 11 further comprising a band limit filter to filter said amplified signals and generate filtered signals.

13. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 12 wherein said band limit filter limits frequencies to filtered signals between 75 and 500 kHz.

14. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 11 further comprising an analog to digital converter to convert said filtered signals to digital filtered signals.

15. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 8 wherein said microcomputer system further comprises communication circuitry to communicate externally.

16. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 15 wherein said communication circuitry is based on a RS-232 standard.

17. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 15 wherein said communication circuitry is based on a USB standard.

18. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 8 wherein said data analysis software classifies said health of said region of said structure into a numerical rating.

19. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 18 wherein said numerical rating is stored in said memory for future reference.

20. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 18 wherein said numerical rating is transmitted wirelessly to a different location.

21. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 20 wherein said numerical rating is transmitted wirelessly by a radio frequency transmitter.

22. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 18 wherein said numerical rating is transmitted via an electronic bus system.

23. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 22 wherein said electronic bus is an avionics bus on an aircraft.

24. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 23 wherein said avionics bus is based on an ARINC-429 standard.

25. The distributed real time health monitoring system for monitoring of acoustic emission signals of claim 23 wherein said avionics bus is based on a MIL STD 1553.