Methods and systems for using active surface coverings for structural assessment and monitoring

• US 7,434,480 B2
• Filed: 12/14/2005
• Issued: 10/14/2008
• Est. Priority Date: 12/14/2005
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Georgeson, Gary E., Westerman, Everett A.
• Primary Examiner(s): Lefkowitz; Edward
• Assistant Examiner(s): ROY, PUNAM P
• Application Number:
  US11/302,617
• Publication Number:
  US 20080223152A1
• Time in Patent Office: 1,035 Days
• Field of Search: 737/67, 737/74, 737/76, 738/01, 738/02, 738/620.41, 738/620.46
• US Class Current: 73/862.041
• CPC Class Codes: G01B 7/20 formed by printed-circuit technique
• CPC Class Codes: G01M 5/0016 of aircraft wings or blades
• CPC Class Codes: G01M 5/0041 by determining deflection or stress
• CPC Class Codes: G01M 5/0083 by measuring variation of impedance, e.g. resistance, capacitance, induction
• CPC Class Codes: G01M 5/0091 by using electromagnetic excitation or detection
• CPC Class Codes: G07C 5/085 using electronic data carriers

Abstract

A system for structural assessment is described that comprises a plurality of sensors and a surface covering for at least a portion of a structure. The sensors are arranged in a pattern and attached to the surface covering. The surface covering is attached to a surface of a structure, and the sensors are configured to provide signals relating to the integrity of the structure to an external device.

Claims

1. A system for structural assessment comprising:

a plurality of sensors; and

a surface covering for at least a portion of a structure, said sensors arranged in a pattern and attached to said surface covering, said surface covering attached to a surface of the structure and configured to provide protection capabilities for portions of the structure to which it is affixed, said sensors networked to locate and size impacts on the surface of the structure, said sensors configured to provide signals relating to the integrity of the structure to an external device, said surface covering comprising a plurality of layers, said surface covering further comprising at least one of a coating and at least one layer of at least one of an impact sensitive material, a strain sensitive material, a heat sensitive material, a low observable material and an electrical shielding material.

2. A system according to claim 1 further comprising a plurality of RFID tags attached to said surface covering, each said RFID tag integrated with one or more of said sensors to provide wireless interrogation and collection of data received from said sensors.

3. A system according to claim 1 wherein said sensors comprise one or more of RFID tags, piezo-electric sensors, strain sensors, eddy current sensors, capacitive sensors, resonance sensors, pulse echo sensors, mechanical impedance sensors, vibration sensors, temperature sensors, moisture sensors and ultrasonic sensors.

4. A system according to claim 1 wherein said sensors are operable for assessing anomalies below the surface of the structure.

5. A system according to claim 4 wherein said inspection system is configured to provide inspection of the structure utilizing triangulation based on data from a plurality of said sensors.

6. A system according to claim 1 further comprising a data acquisition unit capable of recording inputs produced by stress waves passing through each of the plurality of said sensors.

7. A system according to claim 1 wherein said surface covering comprises an appliqué

.

8. A system according to claim 1 wherein said sensors are located between two of said layers.

9. A surface covering for a structure comprising:

a layer of surface covering material;

an adhesive backing attached to said layer of surface covering material;

a plurality of nondestructive evaluation sensors arranged in a pattern and attached to said layer of surface covering material, said sensors networked to locate and size impacts on a surface of the structure; and

an indicator material configured to indicate one or more phenomena occurring with respect to the structure to which said surface covering is attached.

10. A surface covering according to claim 9 further comprising at least one RFID tag integrated with one or more of said sensors to provide wireless interrogation and collection of data from said nondestructive evaluation sensors.

11. A surface covering according to claim 9 wherein said sensors comprise one or more of RFID tags, piezo-electric sensors, strain sensors, eddy current sensors, capacitive sensors, resonance sensors, pulse echo sensors, mechanical impedance sensors, vibration sensors, temperature sensors, moisture sensors and ultrasonic sensors.

12. A surface covering according to claim 9 wherein said sensors are further operable for assessing anomalies below the surface of the structure.

13. A surface covering according to claim 12 said sensors configured to produce signals based on stress waves passing through each of the plurality of said sensors.

14. A surface covering according to claim 9 wherein said indicator material comprises a coating or layer of at least one of an impact sensitive material, a strain sensitive material, a heat sensitive material, a low observable material and an electrical shielding material.

15. A surface covering according to claim 9 wherein said layer of surface covering material comprises a plurality of bonded layers.

16. A method for structural assessment and monitoring of a structure comprising:

providing at least one layer of material that includes a plurality of sensors attached thereto;

utilizing the at least one layer of material and plurality of sensors as a surface coating for the structure, the at least one layer of material configured to provide protection capabilities for portions of the structure to which it is affixed;

networking the sensors to locate and determine a size of impacts on the surface of the structure;

configuring the plurality of sensors to output signals indicative of an integrity of the structure; and

providing at least one of an additional layer and a coating capable of indicating one or more phenomena occurring with respect to the structure to which the at least one of an additional layer and a coating is attached.

17. A method according to claim 16 wherein providing at least one of an additional layer and a coating comprises providing a coating or layer of at least one of an impact sensitive material, a strain sensitive material, a heat sensitive material, a low observable material and an electrical shielding material.

18. A method according to claim 16 further comprising integrating at least one RFID tag with one or more of the sensors to provide wireless interrogation and collection of data from the sensors.

19. A method according to claim 16 wherein providing at least one layer of material that includes a plurality of sensors comprises attaching one or more of RFID tags, piezo-electric sensors, strain sensors, eddy current sensors, capacitive sensors, resonance sensors, pulse echo sensors, mechanical impedance sensors, vibration sensors, temperature sensors, moisture sensors and ultrasonic sensors to the layer of material.