Sensor system

• US 9,127,597 B2
• Filed: 09/23/2011
• Issued: 09/08/2015
• Est. Priority Date: 09/23/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Masiello, Kathryn A., Wright, Robert Steven, Duce, Jeffrey Lynn, Mitchell, Bradley J., Marshall, Joseph A. IV
• Primary Examiner(s): BLOUNT, ERIC
• Application Number:
  US13/242,044
• Publication Number:
  US 20130079955A1
• Time in Patent Office: 1,446 Days
• Field of Search: 340/584, 340/945, 340/577, 701/3, 702/130, 702/182
• US Class Current: 1/1
• CPC Class Codes: F02C 9/28 Regulating systems responsive to plant or ambient parameters, e.g. temperature, pressure, rotor speed F02C9/30 - F02C9/38, F02C9/44 take precedence
• CPC Class Codes: F05D 2260/80 Diagnostics
• CPC Class Codes: G01J 5/0014 for sensing the radiation from gases, flames
• CPC Class Codes: G01J 5/0066 for hot spots detection
• CPC Class Codes: G01J 5/025 Interfacing a pyrometer to an external device or network; User interface
• CPC Class Codes: G01J 5/48 Thermography; Techniques using wholly visual means
• CPC Class Codes: G07C 5/0816 Indicating performance data, e.g. occurrence of a malfunction
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

Concepts and technologies are disclosed herein for a sensor system for detecting, characterizing, monitoring, and analyzing data. According to some embodiments disclosed herein, a monitoring system is configured to obtain data from a sensor system. The sensor system includes two or more sensors and can indicate an operating state detected at a monitored structure by the sensors. The monitoring system also obtains operational data including a threshold value for the sensors and an expected value for the sensors. The monitoring system is configured to adjust the thresholds based, at least partially, upon the operational data to obtain an adjusted threshold value, and to compare the data value to the adjusted threshold. The monitoring system can determine if the monitored structure is operating in an alarm condition.

Claims

1. A system comprising a monitoring system configured to execute computer executable instructions stored in a memory to:

obtain data from a sensor system comprising a plurality of sensors, wherein one or more of the plurality of sensors comprises a temperature sensor deposited onto at least one surface of a monitored structure, the temperature sensor comprising a first trace formed from a first thermocouple material, a second trace formed from a second thermocouple material, and at least one junction whereat the first trace and the second trace intersect, and wherein the data indicating an operating state is detected at the monitored structure by at least one of the plurality of sensors;

obtain operational data comprising a threshold value for each of the plurality of sensors and an expected value for each of the plurality of sensors;

adjust the thresholds based, at least partially, upon the operational data to obtain an adjusted threshold value;

compare the sensed data value to the adjusted threshold; and

determine if the monitored structure is operating in an alarm condition.

2. The system of claim 1, wherein the monitored structure comprises an aircraft propulsion system, and wherein the temperature sensor is integrated into at least one structure of the aircraft propulsion system.

3. The system of claim 1, wherein the temperature sensor is deposited using at least one of a plasma flame spray, anatomized jetted spray, or a screen print.

4. The system of claim 1, wherein the temperature sensor is printed onto a flexible substrate and the flexible substrate is attached to at least one surface of the monitored structure.

5. The system of claim 1, wherein the temperature sensor is printed onto a substrate and the substrate is attached to a surface of the monitored structure at a hot side of the structure.

6. The system of claim 1, wherein the temperature sensor is printed onto a substrate and the substrate is attached to a surface of the monitored structure at a cold side of the structure.

7. The system of claim 6, wherein the sensor further comprises an anemometer printed on the cold side of the structure, and wherein obtaining the data comprises obtaining a temperature reading obtained with the temperature sensor, adjusting the obtained temperature based, at least partially, upon data obtained from the anemometer, and estimating a temperature at a hot side of the structure based upon the data obtained from the temperature sensor and the anemometer.

8. The system of claim 1, wherein the monitoring system is further configured to execute computer executable instructions stored in the memory to:

generate an alarm, in response to determining that the structure is operating in the alarm condition;

provide the alarm to an alarm recipient; and

store the data in a data storage device.

9. The system of claim 8, wherein the alarm recipient comprises an operating crew.

10. The system of claim 1, wherein the alarm condition comprises an overheat condition.

11. The system of claim 1, wherein the alarm condition comprises a fire condition.

12. The system of claim 1, wherein the monitored structure comprises an aircraft engine structure formed from a panel comprising a plurality of hexagonally-profiled cells.

13. The system of claim 12, wherein the at least one of the plurality of sensors comprises a sensor printed on a substrate, and wherein the substrate is disposed within the panel and disposed as a septum within the panel.

14. The system of claim 12, wherein the at least one of the plurality of sensors comprises a sensor printed on a substrate, and wherein the substrate forms one surface of at least one of the hex cells of the panel or is attached to at least one surface of at least one of the hex cells of the panel.

15. A computer-implemented method for monitoring a structure, the method comprising computer-implemented operations for:

obtaining data from at least one of a plurality of temperature sensors on an operating state of the structure, wherein the plurality of temperature sensors are integrated onto at least one surface of a structure by printing onto the at least one surface of the structure;

obtaining operational data comprising a threshold value for the at least one of the plurality of temperature sensors;

adjusting the threshold based, at least partially, upon the operational data to obtain an adjusted threshold value, wherein adjusting the thresholds comprises;

obtaining an ambient temperature at the monitored structure,

obtaining a thrust adjustment associated with the at least one of the plurality of sensors, and

adjusting the thresholds based, at least partially, upon the ambient temperature and the thrust adjustment to obtain the adjusted threshold value;

comparing the data value to the adjusted threshold; and

determining if the structure is operating in an alarm condition.

16. The method of claim 15, wherein the monitored structure comprises an aircraft propulsion system, and wherein each of the plurality of temperature sensors comprises a thermocouple.

17. The method of claim 15, further comprising storing the data in a data storage device in communication with the monitoring system.

18. A computer-implemented method for monitoring a structure, the method comprising:

obtaining data from at least one of a plurality of independently operating temperature sensors, wherein one or more of the plurality of independently operating temperature sensors are deposited onto the at least one surface of a monitored structure, the data indicating a temperature detected at the monitored structure;

obtaining operational data comprising a threshold value for the at least one of the plurality of temperature sensors;

adjusting the threshold based, at least partially, upon the operational data to obtain an adjusted data value;

comparing the data value to the adjusted threshold;

storing the data in a data storage device in communication with the monitoring system; and

presenting the data in a visual representation comprising a thermal map generated by plotting a matrix of sensor data in positions associated with the sensors.

19. The method of claim 18, wherein each of the temperature sensors is deposited onto a flexible substrate, and wherein each of the temperatures sensors is integrated into at least one component of the aircraft propulsion system by attaching the flexible substrate to at least one surface of an aircraft propulsion system.

20. The method of claim 18, wherein adjusting the thresholds comprises:

obtaining an ambient temperature at the aircraft;

obtaining a standard operating temperature of the aircraft;

obtaining a temperature adjustment by calculating a difference between the standard operating temperature of the aircraft and the ambient temperature;

obtaining a thrust adjustment associated with the at least one of the temperature sensors, the thrust adjustment comprising an expected rise in temperature based upon a percentage of a maximum thrust provided by the aircraft propulsion system when the data is obtained; and

adjusting the thresholds based, at least partially, upon the temperature adjustment and the thrust adjustment to obtain the adjusted threshold values.

21. The method of claim 19, wherein the flexible substrate is attached to a surface of the at least one component of an aircraft engine at a hot side of the at least one component of the aircraft engine.

22. The method of claim 19, wherein the flexible substrate is attached to a surface of the at least one component of an aircraft engine at a cold side of the at least one component of the aircraft engine.

23. The method of claim 22, wherein the temperature sensor further comprises an anemometer deposited on the cold side of the at least one component, and wherein obtaining the data comprises obtaining a temperature reading obtained with the temperature sensor, adjusting the obtained temperature based, at least partially, upon data obtained from the anemometer, and estimating a temperature at a hot side of the at least one component of the aircraft engine based upon the data obtained from the temperature sensor and the anemometer.

24. The method of claim 18, further comprising presenting the data in a visual representation.

25. The method of claim 24, wherein the visual representation comprises a thermal map generated by plotting a matrix of sensor data in positions associated with the sensors.

26. A system comprising a monitoring system configured to execute computer executable instructions stored in a memory to:

obtain data from a sensor system comprising a plurality of sensors, the data indicating an operating state detected at a monitored structure by at least one of the plurality of sensors, wherein one or more of the plurality of sensors comprises a panel, an insert cavity formed in the panel, and a panel insert configured to be selectively inserted into the insert cavity;

obtain operational data comprising a threshold value for each of the plurality of sensors and an expected value for each of the plurality of sensors;

adjust the thresholds based, at least partially, upon the operational data to obtain an adjusted threshold value;

compare the sensed data value to the adjusted threshold; and

determine if the monitored structure is operating in an alarm condition.

27. The system of claim 26, wherein the insert cavity further comprises at least one thermocouple formed therein, and wherein the one or more of the plurality of sensors is configured to measure a temperature at the monitored structure.

28. The system of claim 26, wherein the panel insert is configured to be inserted into the insert cavity from a cold side of the panel, and wherein the panel insert is configured to measure a condition at a hot side of the panel.

29. A system comprising a monitoring system configured to execute computer executable instructions stored in a memory to:

obtain data from a sensor system comprising a plurality of sensors, the data indicating an operating state detected at a monitored structure by at least one of the plurality of sensors;

obtain operational data comprising a threshold value for each of the plurality of sensors and an expected value for each of the plurality of sensors;

adjust the thresholds based, at least partially, upon the operational data to obtain an adjusted threshold value by

obtaining an ambient temperature at the monitored structure,

obtaining a thrust adjustment associated with the at least one of the plurality of sensors, and

adjusting the thresholds based, at least partially, upon the ambient temperature and the thrust adjustment to obtain the adjusted threshold value;

compare the sensed data value to the adjusted threshold; and

determine if the monitored structure is operating in an alarm condition.

30. A system comprising a monitoring system configured to execute computer executable instructions stored in a memory to:

obtain data from a sensor system comprising a plurality of sensors, including obtaining a temperature with a temperature sensor of a plurality of sensors, the temperature sensor printed onto a substrate attached to a surface of a monitored structure at a cold side of the monitored structure;

adjust the data, including the temperature obtained from the temperature sensor, based at least partially upon data obtained from an anemometer of the plurality of sensors, the anemometer printed on the cold side of the monitored structure;

estimate a temperature at a hot side of the structure based upon the data obtained from the temperature sensor and the anemometer;

obtain operational data comprising a threshold value for each of the plurality of sensors and an expected value for each of the plurality of sensors;

adjust the thresholds based, at least partially, upon the operational data to obtain an adjusted threshold value;

compare the obtained data to the adjusted threshold value; and

in response to the comparison, determine if the monitored structure is operating in an alarm condition.

31. A system comprising a monitoring system configured to execute computer executable instructions stored in a memory to:

obtain data from a sensor system comprising a plurality of sensors, wherein one or more of the plurality of sensors comprises a temperature sensor deposited onto at least one surface of a monitored structure, the data indicating an operating state detected at the monitored structure by at least one of the plurality of sensors, and wherein the monitored structure comprises an aircraft engine structure formed from a panel comprising a plurality of hexagonally-profiled cells;

obtain operational data comprising a threshold value for each of the plurality of sensors and an expected value for each of the plurality of sensors;

adjust the thresholds based, at least partially, upon the operational data to obtain an adjusted threshold value;

compare the sensed data value to the adjusted threshold; and

determine if the monitored structure is operating in an alarm condition.

32. The system of claim 31, wherein the at least one of the plurality of sensors comprises a sensor printed on a substrate, and wherein the substrate is disposed within the panel and disposed as a septum within the panel.

33. The system of claim 31, wherein the at least one of the plurality of sensors comprises a sensor printed on a substrate, and wherein the substrate forms one surface of at least one of the hex cells of the panel or is attached to at least one surface of at least one of the hex cells of the panel.

34. A computer-implemented method for monitoring a structure, the method comprising:

obtaining data from at least one of a plurality of independently operating temperature sensors, wherein one or more of the plurality of independently operating temperature sensors are deposited onto the at least one surface of a monitored structure, the data indicating a temperature detected at the monitored structure;

obtaining operational data comprising a threshold value for the at least one of the plurality of temperature sensors;

adjusting the threshold based, at least partially, upon the operational data to obtain an adjusted data value, wherein adjusting the thresholds comprises;

obtaining an ambient temperature at the aircraft,

obtaining a standard operating temperature of the aircraft,

obtaining a temperature adjustment by calculating a difference between the standard operating temperature of the aircraft and the ambient temperature,

obtaining a thrust adjustment associated with the at least one of the temperature sensors, the thrust adjustment comprising an expected rise in temperature based upon a percentage of a maximum thrust provided by the aircraft propulsion system when the data is obtained, and

adjusting the thresholds based, at least partially, upon the temperature adjustment and the thrust adjustment to obtain the adjusted threshold values;

comparing the data value to the adjusted threshold; and

storing the data in a data storage device in communication with the monitoring system.

35. A computer-implemented method for monitoring a structure, the method comprising:

obtaining data from at least one of a plurality of independently operating temperature sensors, the data indicating a temperature detected at an aircraft engine, wherein each temperature sensor is deposited onto a flexible substrate attached to a surface of the at least one component of the aircraft engine at a cold side of the at least one component of the aircraft engine, wherein each temperature sensor further comprises an anemometer deposited on the cold side of the at least one component, and wherein obtaining the data comprises

obtaining a temperature reading obtained with the temperature sensor,

adjusting the obtained temperature based, at least partially, upon data obtained from the anemometer, and

estimating a temperature at a hot side of the at least one component of the aircraft engine based upon the data obtained from the temperature sensor and the anemometer;

obtaining operational data comprising a threshold value for the at least one of the plurality of temperature sensors;

adjusting the threshold based, at least partially, upon the operational data to obtain an adjusted data value;

comparing the data value to the adjusted threshold; and

storing the data in a data storage device in communication with the monitoring system.