Method for verifying sensors installation and determining the location of the sensors after installation in a structural health management system

• US 7,660,690 B2
• Filed: 07/11/2007
• Issued: 02/09/2010
• Est. Priority Date: 10/29/2004
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Thompson, Steven R., Gordon, Grant A., Nutaro, Joseph
• Primary Examiner(s): Raymond; Edward
• Assistant Examiner(s): Desta; Elias
• Application Number:
  US11/776,288
• Publication Number:
  US 20070255522A1
• Time in Patent Office: 944 Days
• Field of Search: 702/33, 702/104, 702/116, 702/150, 702158-159, 73/10.1, 324/207.11, 324/207.12, 324/207.14
• US Class Current: 702/116
• CPC Class Codes: G01N 2291/0231 Composite or layered materials
• CPC Class Codes: G01N 2291/0427 Flexural waves, plate waves, e.g. Lamb waves, tuning fork, cantilever
• CPC Class Codes: G01N 2291/0428 Mode conversion
• CPC Class Codes: G01N 2291/106 one or more transducer arrays
• CPC Class Codes: G01N 2291/2694 Wings or other aircraft parts
• CPC Class Codes: G01N 29/07 by measuring propagation velocity or propagation time of acoustic waves
• CPC Class Codes: G01N 29/11 by measuring attenuation of acoustic waves
• CPC Class Codes: G01N 29/223 Supports, positioning or alignment in fixed situation mounting transducers per se G10K11/004

Abstract

In the present invention, a method is provided for installing and locating a plurality of sensors distributed on a structure as part of a structural health monitoring system. The method includes verifying the proper installation of the plurality of sensors and determining the location of the plurality of sensors. In one aspect of the present invention, the step of verifying the proper installation further comprises verifying that each of the plurality of sensors are properly coupled to a sensor data collector and verifying that each of the plurality of sensors are installed in a proper location. In another aspect of the present invention, the step of determining the location of the plurality of sensors further comprises determining the positioning of each sensor in reference to fixed structures in the structure.

Claims

1. A method for installing and locating a plurality of sensors distributed on a structure as part of a structural health monitoring system comprising:

verifying that each of the plurality of sensors are properly coupled to a sensor data collector;

verifying that each of the plurality of sensors are installed in a proper location;

retrieving a list of sensor pairs formed from the plurality of sensors, each sensor pair comprising a selected sensor and a neighbor sensor;

for each sensor pair, sending a pulse from the selected sensor and detecting it at the neighbor sensor to determine a sensor time of flight between the selected sensor and the neighbor sensor;

for each sensor pair, calculating a separation distance between the selected sensor and the neighbor sensor using the sensor time of flight;

for each sensor pair, determining a difference between the calculated separation distance and an expected separation distance;

confirming the installation is correct if the difference is within a predetermined threshold; and

determining the location of the plurality of sensors.

2. The method of claim 1 further comprising:

generating a listing of all sensor pairs for which the calculated separation distance exceeds the expected separation distance by the threshold;

removing sensor pairs that have been recently rewired;

for all sensor pairs remaining, identifying a located selected sensor as the selected sensor that appears most often in the listing; and

providing an indication to switch a connection between the located selected sensor and the data collector with the sensor occupying the located selected sensor position.

3. The method of claim 2 further comprising:

generating a listing of all sensor pairs that are correctly wired and for which the calculated separation distance exceeds the expected separation distance;

removing the sensor pairs that represent recently repositioned sensors;

for all remaining sensors pairs, identifying a located selected sensor as the selected sensor that appears most often on the list; and

forming an indication that the located selected sensor needs to be repositioned.

4. The method of claim 1 wherein the step of determining the location of the plurality of sensors further comprises:

retrieving a list of sensor pairs derived from the plurality of sensors, each sensor pair comprising a selected sensor and a neighbor sensor;

for each selected sensor, determining a sensor time of flight between the selected sensor and each neighbor sensor and using the sensor time of flight to determine the distance between the selected sensor and each neighbor sensor;

for each selected sensor, determining a boundary time of flight between the selected sensor and a plurality of local boundaries surrounding the selected sensor;

for each selected sensor, calculating exclusion regions using the boundary time of flight to determine where the selected sensor can not be located with respect to the selected sensor'"'"'s local boundaries;

for each selected sensor, calculating an updated position using the boundary time of flight between the boundaries and the sensors and the sensor time of flight between each sensor pair;

for each selected sensor, comparing the updated position with a previous position; and

for each selected sensor, if the updated position is within a predetermined threshold of the previous position, estimating the selected sensor'"'"'s location at the updated position.

5. The method of claim 4 further comprising setting the location of the selected sensor at the updated position if the updated position exceeds the previous position by the predetermined threshold and is outside the selected sensor'"'"'s exclusion region.

6. The method of claim 5 further comprising determining a modified updated position for the selected sensor such that the modified updated position is not within the exclusion region and is as close as possible to the updated position, if the updated position is within the exclusion region and the updated position exceeds the previous position by the predetermined threshold.

7. The method of claim 6 wherein all sensors are correctly located when each of the plurality of sensors are within the predetermined threshold of the previous position.

8. A method for verifying the installation of a plurality of sensors in a structural health monitoring system comprising:

verifying that each of the plurality of sensors are properly coupled to a data collector;

retrieving a list of sensor pairs derived from the plurality of sensors, each sensor pair comprising a selected sensor and a neighbor sensor;

for each sensor pair, sending a pulse from the selected sensor and detecting it at the neighbor sensor to determine a sensor time of flight between the selected sensor and the neighbor sensor;

for each sensor pair, determining a calculated separation distance between the selected sensor and the neighbor sensor using the sensor time of flight;

for each sensor pair, determining a difference between the calculated separation distance and an expected separation distance;

confirming the installation is correct if the difference is within a predetermined threshold.

9. The method of claim 8 further comprising:

generating a listing of all sensor pairs for which the calculated separation distance exceeds the expected separation distance by the predetermined threshold;

removing from the listing the sensor pairs that have been recently rewired;

for all sensor pairs remaining, determining a located selected sensor corresponding to the selected sensor that appears most often;

providing an indication that a connection between the located selected sensor and the data collector needs to be switched with the sensor occupying the located selected sensor position;

generating a listing of all sensor pairs that are correctly wired and for which the calculated distance exceeds the expected distance;

removing the sensor pairs that represent recently repositioned sensors;

for all remaining sensors pairs, identifying a located selected sensor as the selected sensor that appears most often on the list; and

indicating that the located selected sensor needs to be repositioned.

10. A structural health monitoring system comprising:

a plurality of sensors installed on a structure; and

a processor coupled to each of the sensors and operable to;

retrieve a list of sensor pairs formed from the plurality of sensors, each sensor pair comprising a selected sensor and a neighbor sensor;

for each sensor pair, initiate a pulse from the selected sensor and detect the pulse at the neighbor sensor to determine a sensor time of flight between the selected sensor and the neighbor sensor;

for each sensor pair, determine a calculated separation distance between the selected sensor and the neighbor sensor using the sensor time of flight;

for each sensor pair, determine a difference between the calculated separation distance and an expected separation distance; and

determine if each sensor is coupled to a data collector and if all sensors are properly installed within a predetermined location if the difference is within a predetermined threshold.

11. The system of claim 10 wherein the processor is further operable to:

generate a listing of all sensor pairs for which the calculated distance exceeds the expected distance by the predetermined threshold;

remove the sensor pairs that have been recently rewired;

for all sensor pairs remaining, identify a located selected sensor as the selected sensor that appears most often in the listing; and

indicate that a connection between the located selected sensor and the data collector needs to be switched with the sensor occupying the located selected sensor position.

12. The system of claim 10 wherein the processor is further operable to:

generate a listing of all sensor pairs that are correctly wired and for which the calculated distance exceeds the expected distance by more than the predetermined threshold;

remove the sensor pairs that represent recently repositioned sensors;

for all remaining sensors pairs, identify a located selected sensor as the selected sensor that appears most often on the list; and

forming an indication that the located selected sensor needs to be repositioned.