Method for satisfying certification requirements and verifying the integrity of structural health management systems

• US 7,366,627 B2
• Filed: 05/31/2005
• Issued: 04/29/2008
• Est. Priority Date: 05/31/2005
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Nutaro, Joseph J., Gordon, Grant A., Wilt, Nicholas J.
• Primary Examiner(s): Barlow; John
• Assistant Examiner(s): Washburn; Douglas N
• Application Number:
  US11/142,038
• Publication Number:
  US 20060282297A1
• Time in Patent Office: 1,064 Days
• Field of Search: 737/69, 702/85, 702/105
• US Class Current: 702/105
• CPC Class Codes: G01M 5/00 Investigating the elasticity of structures, e.g. deflection of bridges or air-craft wings G01M9/00 takes precedence
• CPC Class Codes: G01N 35/00693 Calibration
• CPC Class Codes: G01N 35/00712 Automatic status testing, e.g. at start-up or periodic

Abstract

A method is disclosed wherein a plurality of sensors mounted on a structure, a baseline data set for each of the plurality of sensors and a calibration procedure verify the integrity of a structural health management system. Initially a baseline data set is established. Before performing the structural health assessment a calibration-in data set for each of the plurality of sensors is collected. The calibration-in data set is compared to the baseline data set for each sensor of the plurality of sensors. If the calibration-in data set and the baseline data set match then a structure characterization is performed. If the calibration-in data set and the baseline data set do not match, a calibration-out procedure is performed to generate a calibration-out data set. If the calibration-out data set and the calibration-in data sets match, then a determination is made that the structural health management system was working.

Claims

1. A method for verifying the integrity of a structural health management system comprising a plurality of sensors mounted on a structure, the method comprising:

establishing a baseline data set for each of the plurality of sensors;

performing a calibration-in procedure to collect a calibration-in data set for each of the plurality of sensors;

comparing the calibration-in data set for each sensor of the plurality of sensors to the baseline data set for each sensor of the plurality of sensors; and

if the calibration-in data set and the baseline data set match;

performing a structural characterization;

performing a calibration-out procedure to generate a calibration-out data set;

verifying that the structural health management system is working by comparing the calibration-out data set and the calibration-in data set for each sensor of the plurality of sensors; and

generating a signal indicating the structural health management system is working, if the calibration-out data set and the calibration-in data set match.

2. The method of claim 1 further comprising performing the calibration-in procedure and the calibration-out procedure within a predetermined time limit.

3. The method of claim 2 wherein the step of performing a calibration-in procedure further comprises performing a calibration-in procedure on a subset of the plurality of sensors, the subset chosen based on fulfilling the predetermined time limit.

4. The method of claim 1 wherein the step of establishing a baseline data set for each of the plurality of sensors further comprises generating an electrically stimulated elastic wave at each of the plurality of sensors and storing information from a return pulse.

5. The method of claim 1 further comprising, if the calibration-in data set does not match the baseline data set, the steps of:

identifying non-matching sensors of the plurality of sensors whose calibration-in data does not match its baseline data set;

evaluating each of the non-matching sensors against neighboring sensors to determine a set of ambiguous sensors;

identifying one or more areas surrounded by the set of ambiguous sensors; and

characterizing the one or more areas surrounded by the set of ambiguous sensors.

6. The method of claim 5 further comprising

if the characterization fails to detect any damage:

identifying the ambiguous sensors as failed sensors;

establishing a new baseline data set for areas containing damaged sensors after repair; and

if the characterization detects any damage;

considering the previously ambiguous sensors as working;

characterizing any remaining uncharacterized area; and

performing a calibration-out procedure.

7. The method of claim 5 wherein the step of evaluating each of the non-matching sensors further comprises:

determining a time-of-flight between each of the non-matching sensors and the neighboring sensors associated with each of the sensors; and

comparing the time-of-flight with a baseline time-of-flight.

8. The method of claim 7 wherein the step of establishing a baseline time-of-flight further comprises electrically stimulating each sensor of the plurality of sensors and ordering the neighboring sensors pairs from the plurality of sensors using the time-of-flight measurements associated with the received electrically stimulated mechanical pulses.

9. The method of claim 8 further comprising determining that the structural health managements system is damaged if the calibration-out data set fails to match the calibration-in data set.

10. A method for verifying the integrity of a structural health management system mounted on a structure comprising:

(a) performing a calibration-in procedure on the structural health management system using a previous assessment of the structure as a reference and generating a calibration-in data set from the calibration-in procedure;

(b) interrogating the structure to determine if there is damage, the structure treated as an unknown;

(c) performing a calibration-out procedure on the structural health management system using the previous assessment of the structure as a reference and generating a calibration-out data set from the calibration-out procedure;

(d) comparing the calibration-in data set with the calibration-out data set; and

(e) generating a signal indicating the structural health management system is working, if the calibration-in data set matches the calibration-out data set.

11. The method of claim 10 further comprising performing the steps (a) to (c) within a predetermined time limit.

12. The method of claim 10 wherein the step of performing a calibration-in further comprises:

establishing a baseline data set by performing a baseline assessment;

performing a calibration-in procedure to generate the calibration-in data set;

comparing the calibration-in data set to the baseline data set;

if the calibration-in data set and the baseline data set match, executing step (b).

13. The method of claim 12 wherein the step of performing a calibration-in procedure further comprises performing a calibration-in procedure on a portion of the structure, the portion of the structure chosen based on fulfilling the predetermined time limit.

14. The method of claim 12 further comprising, if the calibration-in data set does not match the baseline data set, the steps of:

identifying non-matching sensors of the plurality of sensors whose calibration-in data does not match the baseline data set;

evaluating each of the non-matching sensors against neighboring sensors to determine a set of ambiguous sensors; and

characterizing areas surrounded by the set of ambiguous sensors.

15. The method of claim 12 wherein the step of establishing a baseline data set for each of the plurality of sensors further comprises generating a mechanical elastic wave pulse at each of the plurality of sensors and storing information from a return pulse.

16. The method of claim 14 wherein the step of evaluating each of the non-matching sensors further comprises:

determining a time-of-flight between each of the non-matching sensors and the neighboring sensors associated with each of the sensors; and

comparing the time-of-flight with a baseline time-of-flight.

17. The method of claim 16 wherein the step of establishing a baseline time-of-flight further comprises generating an elastic wave from each of the plurality of sensors and selecting as neighboring sensors those sensor from the plurality of sensors that receive the pulse with the smallest time of flight in a ranked order.

18. The method of claim 14 further comprising

if the step of characterizing detects any damage:

identifying the ambiguous sensors as failed sensors;

rebaseline areas containing damaged sensors; and

if the characterization fails to detect any damage;

characterize any remaining uncharacterized area; and

performing a calibration-out procedure.

19. A structural health management system comprising:

a plurality of sensors mounted on a to-be-tested structure,

one or more processors coupled to each of the sensors and configured to;

establish a baseline data set for each of the plurality of sensors;

perform a calibration-in procedure to collect a calibration-in data set for each of the plurality of sensors;

compare the calibration-in data set for each sensor of the plurality of sensors to the baseline data set for each sensor of the plurality of sensors;

if the calibration-in data set and the baseline data set match;

perform a structural characterization;

perform a calibration-out procedure to generate a calibration-out data set; and

verify that the structural health management system is working by comparing the calibration-out data set and the calibration-in data set and achieving a match for each of the plurality of sensors;

if the calibration-in data set does not match the baseline data set;

identify non-matching sensors of the plurality of sensors whose calibration-in data does not match the baseline data set;

evaluate each of the non-matching sensors against neighboring sensors to determine a set of ambiguous sensors;

identify areas surrounded by the set of ambiguous sensors

characterize the areas surrounded by the set of ambiguous sensors; and

if the characterization fails to detect any damage;

identify the ambiguous sensors as failed sensors;

rebaseline areas containing damaged sensors; and

if the characterization detects any damage;

characterize any remaining uncharacterized area; and

perform a calibration-out procedure.

20. The system of claim 19 further comprising performing the calibration-in procedure and the calibration-out procedure within a predetermined time limit.