Acoustic structural integrity monitoring system and method

• US 9,250,117 B2
• Filed: 07/08/2011
• Issued: 02/02/2016
• Est. Priority Date: 07/19/2010
• Status: Active Grant

• Current Assignee: Ultra PCS Limited
• Original Assignee: Ultra Electronics Limited (Ultra Electronics Holdings PLC)
• Inventors: Stothers, Ian McGregor, Hinchliffe, Richard Andrew
• Primary Examiner(s): SAINT SURIN, JACQUES M
• Application Number:
  US13/810,979
• Publication Number:
  US 20130118261A1
• Time in Patent Office: 1,670 Days
• Field of Search: 736/45
• US Class Current: 1/1
• CPC Class Codes: G01H 5/00 Measuring propagation velocity of ultrasonic, sonic or infrasonic waves , e.g. of pressure waves
• CPC Class Codes: G01M 5/0033 by determining damage, crack or wear
• CPC Class Codes: G01M 5/0066 by exciting or detecting vibration or acceleration vibration testing of structures G01M7/00
• CPC Class Codes: G01N 2291/0231 Composite or layered materials
• CPC Class Codes: G01N 2291/0258 Structural degradation, e.g. fatigue of composites, ageing of oils
• CPC Class Codes: G01N 2291/0289 Internal structure, e.g. defects, grain size, texture
• 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 29/14 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 29/36 Detecting the response signal , e.g. electronic circuits specially adapted therefor
• CPC Class Codes: G01N 29/44 Processing the detected response signal , e.g. electronic circuits specially adapted therefor digital signal processing per se G06F17/00

Abstract

Each of a plurality of acoustic sensors (acoustically coupled to a structure for monitoring) is connected to a network bus system via a preamplifier for capturing, processing and reporting acoustic events in a structure, for example aircraft structures. Each of the preamplifiers processes the acoustic event signals received from the sensors when an acoustic emission resulting from an acoustic event (defect in a structure, impact on the structure etc), and passes digital processed signal data relating to the detected acoustic event to a Remote Data Concentrator over the network for collation. The collated data is then stored and/or further processed (at a later time or in near real-time) to determine the source and/or location of detected acoustic emissions in the structure.

Claims

1. A system for detecting structural defects in a structure or impacts on a structure, the system comprising:

a plurality of sensors for detecting acoustic emissions in a structure, each of said sensors outputting a sensor signal dependent upon acoustic emissions resulting from structural defects in a structure or impacts on a structure;

a plurality of preamplifiers, each of said preamplifiers being electrically coupled to and located local to a respective one of said sensors, wherein each of said preamplifiers is configured to receive said sensor signal, and wherein each of said preamplifiers is configured to process said sensor signal and output sensor data derived from said sensor signal in response to a detected acoustic emission resulting from a structural defect in a structure or impacts on a structure; and

a remote data concentrator (RDC) electrically coupled to and located remote from said plurality of preamplifiers, said RDC being configured to receive and collate said sensor data output from said plurality of preamplifiers,

wherein said RDC is configured to output a synchronization sequence and each of said plurality of preamplifiers is configured to receive said synchronization sequence and configured to adjust a local time of said preamplifier in response to said synchronization sequence, said synchronization sequence comprising;

a first data packet for alerting each of said preamplifiers to a start of said synchronization sequence;

a synchronization timing signal; and

a second data packet comprising a master time value, said master time value defining a time at which said RDC sent said synchronization timing signal.

2. A system according to claim 1, wherein each of said preamplifiers comprises:

an analog to digital converter (ADC) for converting said sensor signal into a digital sensor signal;

a buffer coupled to said ADC and configured to receive said digital sensor signal from said ADC and output a block of buffered digital sensor signal; and

a processor coupled to said buffer and configured to receive said block of buffered digital sensor signal from said buffer, and configured to process said block of buffered digital sensor signal to generate and output said sensor data.

3. A system according to claim 2, wherein each of the preamplifiers further comprises:

a trigger coupled to said ADC and configured to receive said digital sensor signal from said ADC and configured to output a trigger signal in response to an acoustic emission above a threshold being detected in said digital sensor signal, and wherein said buffer is configured to output said block of buffered digital sensor signal and said processor is configured to process said block of buffered digital sensor signal in response to said trigger signal.

4. A system according to claim 3, wherein said trigger is disabled for a hold-off period following a detected acoustic emission to prevent further triggering of said trigger until said hold-off period has expired.

5. A system according to claim 4, wherein said hold-off period is between 2 ms and 10 ms.

6. A system according to claim 1, wherein said sensor data comprises one or more of a time of arrival at a sensor of an acoustic emission in a structure, a rise time of an acoustic emission signal, a peak value of an acoustic emission signal, and an energy value within an acoustic emission signal.

7. A system according to claim 1, wherein each of said plurality of preamplifiers comprises a capture and compare unit configured to receive said synchronization sequence from said RDC and configured to switch said preamplifier into a synchronization mode in response to detection of said first data packet, said preamplifier being prevented from processing said sensor signal and/or outputting said sensor data whilst in said synchronization mode.

8. A system according to claim 7, wherein said capture and compare unit further comprises a synchronization trigger configured to output a synchronization trigger signal in response to detection of said synchronization timing signal, and wherein said preamplifier is configured to store a local time value in response to activation of said synchronization trigger signal, said local time value defining a local time of said preamplifier when said synchronization signal is received, and wherein said preamplifier is configured to calculate a synchronization offset value defining a difference between said master time value and said local time value, and wherein said preamplifier is configured to adjust a local time of said preamplifier using said synchronization offset value such that said master time value and said local time values are substantially synchronized.

9. A system according to claim 8, wherein said capture and compare unit further comprises a counter configured to count clock cycles in response to activation of said synchronization trigger signal, and

wherein said stored local time value is calculated by subtracting a value on said counter at a second time from a local time value stored at said second time.

10. A system according to claim 8, wherein said preamplifier is configured to calculate a rate of drift of said master time value and/or said local time value, and configured to adjust said local time in response to said rate of drift such that said master time and said local time are substantially synchronized.

11. A system according to claim 1, wherein said RDC comprises a capture and compare unit configured to receive said synchronization timing signal from said coupling with said plurality of preamplifiers, and

wherein said RDC is configured to determine said master time value from a time at which said capture and compare unit of said RDC receives said synchronization timing signal.

12. A system according to claim 1, wherein said synchronization timing signal forms part of a data packet.

13. A system according to claim 1, further comprising a synchronization electrical coupling between said RDC and said plurality of preamplifiers, and wherein said synchronization timing signal is sent from said RDC over said synchronisation electrical coupling to said preamplifiers.

14. A system according to claim 1, wherein said RDC is configured to perform said synchronization sequence at substantially regular intervals.

15. A system according to claim 1, further comprising a data storage device electrically coupled to said RDC, said data storage device being configured to receive and store said collated sensor data from said RDC.

16. A system according to claim 15, further comprising a processor coupled to said data storage device and configured to read and process said collated sensor data and configured to determine a source and/or location of said detected acoustic emissions from said sensor data.

17. A system according to claim 1 wherein said electrical coupling between said RDC and said plurality of preamplifiers is via a network bus.

18. A system according to claim 17, where said RDC and preamplifiers are coupled over a CAN-bus network.

19. A system according to claim 1, further comprising a second RDC electrically coupled to and located remote from a second plurality of preamplifiers, and wherein each of said second plurality preamplifiers is electrically coupled to and located local to a respective one of a second plurality of sensors.

20. An aircraft comprising the system according to claim 1, wherein said plurality of sensors are acoustically coupled to a structure of said aircraft for monitoring structural defects in said structure or impacts on said structure.

21. A method for detecting structural defects in a structure or impacts on a structure, the method comprising the steps of:

detecting acoustic emissions resulting from structural defects in a structure or impacts on a structure with a plurality of sensors, and outputting a sensor signal indicative of said detected acoustic emission, wherein each of said sensors is electrically coupled to and located local to a respective one of a plurality of preamplifiers;

receiving said sensor signal at said preamplifier;

processing said sensor signal at said preamplifier, and outputting sensor data from said preamplifier, said sensor data being derived from said sensor signal;

receiving and collating said sensor data at a remote data concentrator (RDC), said RDC being located remote from and being electrically coupled to said plurality of preamplifier; and

synchronizing a local time of said plurality of preamplifiers with a master time of said RDC, said method of synchronizing comprising the steps of;

outputting a synchronization sequence from said RDC;

receiving said synchronization sequence at each of said plurality of preamplifiers; and

adjusting a local time of said preamplifier in response to said synchronization sequence in order to synchronize said master time and said local time of said preamplifiers,

wherein said processing and outputting occurs in response to a detected acoustic emission resulting from a structural defect in a structure or impacts on a structure.

22. A method according to claim 21, wherein processing said sensor signals at said preamplifier comprises:

converting said sensor signal into a digital sensor signal using an analog to digital converter (ADC);

receiving and buffering said digital sensor signal in a buffer coupled to said ADC;

outputting a block of buffered digital sensor signal from said buffer; and

receiving and processing said block of buffered digital sensor signal in a processor coupled to said buffer to generate and output said sensor data.

23. A method according to claim 22, wherein processing said sensor signals at said preamplifier comprises:

outputting a trigger signal in response to an acoustic emission above a threshold being detected in said digital sensor signal, and

wherein said outputting said block of buffered digital sensor signal and said processing of said block of buffered digital sensor signal occurs in response to said trigger signal.

24. A method according to claim 23, wherein said trigger is disabled for a hold-off period following a detected acoustic emission to prevent further triggering of said trigger until said hold-off period has expired.

25. A method according to claim 24, wherein said hold-off period is between 2 ms and 10 ms.

26. A method according to claim 21, wherein said sensor data comprises one or more of a time of arrival at a sensor of an acoustic emission in a structure, a rise time of an acoustic emission signal, a peak value of an acoustic emission signal, and an energy value within an acoustic emission signal.

27. A method according to claim 21, wherein said synchronization sequence comprises:

a first data packet for alerting each of said preamplifiers to a start of said synchronization sequence;

a synchronization timing signal; and

a second data packet comprising a master time value, said master time value defining a time at which said RDC sent said synchronization timing signal.

28. A method according to claim 27, wherein said synchronization method comprises the steps of:

receiving said synchronization sequence at said preamplifier; and

switching said preamplifier into a synchronization mode in response to detection of said first data packet, said preamplifier being prevented from processing said sensor signal and/or outputting said sensor data whilst in said synchronization mode.

29. A method according to claim 28, wherein said synchronization method comprises:

triggering a synchronization trigger at said preamplifier in response to detection of said synchronization timing signal;

storing a local time value at said preamplifier in response to activation of said synchronization trigger signal, said local time value defining a local time of said preamplifier when said synchronization signal is received;

calculating a synchronization offset value defining a difference between said master time value and said local time value; and

adjusting a local time of said preamplifier using said synchronization offset value such that said master time value and said local time values are substantially synchronized.

30. A method according to claim 29, wherein said storing said local time value comprises the steps of:

starting a counter at said preamplifier in response to activation of said synchronization trigger signal;

storing a second local time value of a second time at said preamplifier, wherein said second time is after receiving said synchronization timing signal;

calculating said local time value by subtracting a value on said counter at said second time from said second local time value.

31. A method according to claim 29, wherein said synchronization method further comprises:

calculating a rate of drift of said master time value and/or said local time value at said preamplifier; and

adjusting said local time in response to said rate of drift such that said master time and said local time are substantially synchronized.

32. A method according to claim 27, wherein said synchronization method further comprises

receiving said synchronization timing signal at said RDC from said coupling with said plurality of preamplifiers;

and

determining said master time value from a time at which said synchronization timing signal was received at said RDC.

33. A method according to claim 27, wherein said synchronization timing signal forms part of a data packet.

34. A method according to claim 27, wherein said synchronization timing signal is sent from said RDC over a synchronization electrical coupling separate to an electrical coupling between said RDC and said preamplifiers over which said sensor data is sent.

35. A method according to claim 21, wherein said synchronization method is repeated at substantially regular intervals.

36. A method according to claim 21, further comprising receiving and storing said collated sensor data from said RDC in a data storage device.

37. A method according to claim 36, further comprising reading and processing said collated sensor data determining a source and/or location of said detected acoustic emissions from said sensor data.