Active damage interrogation method for structural health monitoring

• US 6,006,163 A
• Filed: 09/15/1997
• Issued: 12/21/1999
• Est. Priority Date: 09/15/1997
• Status: Expired due to Term

• Current Assignee: Mcdonnell Douglas Corporation (The Boeing Co.)
• Original Assignee: Mcdonnell Douglas Corporation (The Boeing Co.)
• Inventors: Dunne, James P., Becker, Ronald S., Baumann, Erwin W., Lichtenwalner, Peter F.
• Primary Examiner(s): WACHSMAN, HAL D
• Application Number:
  US08/929,468
• Time in Patent Office: 827 Days
• Field of Search: 702/33-36, 702/39, 702/42, 702/43, 702/56, 702/75-77, 702/103, 702/109-116, 702/170, 702/171, 702/179, 702/180, 702/183-185, 702/191, 702/FOR 166 , 702/FOR 134, 702/FOR 139, 702/FOR 148, 702/FOR 107, 702/FOR 108, 364/528.1, 364/528.15, 395/500.27-500.29, 248/638, 248/562, 248/542, 248/550, 367/13, 367/901, 381/71.2, 381/71.9, 381/71.7, 381/71.11, 381/71.12, 244/75 R, 244/76 R, 244/1 N, 244/117 R, 310/328, 310/326, 310/332, 310/311, 310/313 R, 310/327, 310/320-322, 310/358, 310/369, 73/1.82, 73/865.6, 73/866, 73/1.48, 73/577-579, 73/582, 73/583, 73/588, 73/598, 73/600, 73/659, 73/660, 73/662-664, 73/602, 73/760 , 73/767-769, 73/778, 73/786, 73/788, 73/789, 73/799, 73/801, 73/802, 73/804
• US Class Current: 702/36
• CPC Class Codes: G01H 11/08 using piezoelectric devices
• 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 2291/0258 Structural degradation, e.g. fatigue of composites, ageing of oils
• CPC Class Codes: G01N 2291/02827 Elastic parameters, strength or force
• CPC Class Codes: G01N 2291/0427 Flexural waves, plate waves, e.g. Lamb waves, tuning fork, cantilever
• 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 29/069 Defect imaging, localisation and sizing using, e.g. time of flight diffraction [TOFD], synthetic aperture focusing technique [SAFT], Amplituden-Laufzeit-Ortskurven [ALOK] technique
• CPC Class Codes: G01N 29/2475 Embedded probes, i.e. probes incorporated in objects to be inspected
• CPC Class Codes: G01N 29/262 by electronic orientation or focusing, e.g. with phased arrays phased arrays per se G10K11/34
• CPC Class Codes: G01N 29/4418 with a model, e.g. best-fit, regression analysis
• CPC Class Codes: G01N 29/46 by spectral analysis, e.g. Fourier analysis or wavelet analysis spectral signal processing per se G06F17/14
• CPC Class Codes: G10K 11/004 Mounting transducers, e.g. provided with mechanical moving or orienting device mountings specially adapted to a particular sound-producing device, see the preceding groups G10K1/00 - G10K9/00, e.g. G10K1/26, G10K1/28, G10K9/22; arrangements of sonic watch equipment on submarines B63G8/39; buoys B63B22/00

Abstract

An active damage interrogation (ADI) system (and method) which utilizes an array of piezoelectric transducers attached to or embedded within the structure for both actuation and sensing. The ADI system actively interrogates the structure through broadband excitation of the transducers. The transducer (sensor) signals are digitized and the transfer function of each actuator/sensor pair is computed. The ADI system compares the computed transfer function magnitude and phase spectrum for each actuator/sensor pair to a baseline transfer function for that actuator/sensor pair which is computed by averaging several sets of data obtained with the structure in an undamaged state. The difference between the current transfer function and the baseline transfer function for each actuator/sensor pair is normalized by the standard deviation associated with that baseline transfer function. The transfer function deviation for each actuator/sensor pair is then represented in terms of the number of standard deviations, or sigmas, from the baseline. This statistic, termed the TF Delta, is then processed by a windowed local averaging function in order to reduce minor variations due to random noise, etc. The Windowed TF Delta for each actuator/sensor pair is then integrated over the entire excitation frequency spectrum, to thereby produce the Cumulative Average Delta, which provides a single metric for assessing the magnitude of change (deviation from baseline) of that particular actuator/sensor transfer function. The Cumulative Average Delta (CAD) for each actuator/sensor transfer function provides key, first-level information which is required for detecting, localizing, and quantitatively assessing damage to the structure.

Claims

1. A method for monitoring the structural health of a structure having a plurality of transducers, including a plurality of pairs of actuators and sensors, secured thereto, comprising the steps of:

exciting the actuators with broadband excitation across a prescribed frequency range, wherein each of the sensors produces an analog sensor signal in response to the excitation of the actuators;

digitizing the analog sensor signals to thereby produce digitized sensor signals;

computing a transfer function for each actuator/sensor pair using the digitized sensor signals;

comparing the magnitude of each computed transfer function with a baseline transfer function for the corresponding actuator/sensor pair; and

,

deriving a composite damage indication value for the structural health of the structure at the location of each actuator from the determined differences between the computed and baseline transfer functions for each actuator/sensor pair.

2. The method as set forth in claim 1, wherein:

at least one of the transducers comprises a transducer which is capable of both actuating and sensing; and

,

each of said at least one of the transducers comprises both an actuator and a sensor.

3. The method as set forth in claim 2, wherein the structure further has at least one further transducer which is capable of only sensing.

4. The method as set forth in claim 1, wherein the prescribed frequency range is 0 to 100 kHz.

5. The method as set forth in claim 1, wherein the broadband excitation comprises white noise excitation or chirp excitation.

6. The method as set forth in claim 1, wherein the computing step is performed by Fast Fourier Transform processing the digitized sensor signals.

7. The method as set forth in claim 1, wherein the baseline transfer function for each actuator/sensor pair is derived by obtaining a plurality of transfer function data sets for that actuator/sensor pair with the structure in an undamaged condition, then averaging the thusly obtained plurality of transfer function data sets for that actuator/sensor pair to produce an average transfer function data set for that actuator/sensor pair, and then computing a standard deviation of the baseline transfer function for each actuator/sensor pair based upon a statistical comparison of the plurality of transfer function data sets for that actuator/sensor pair with the average transfer function data set for that actuator/sensor pair.

8. The method as set forth in claim 7, wherein the computing a transfer function step includes the sub-steps of:

normalizing the determined differences between the computed and baseline transfer functions for each actuator/sensor pair by computing the number of standard deviations between the computed and baseline transfer function for each acuator/sensor pair, to thereby produce a transfer function deviation for each actuator/sensor pair expressed in terms of the number of standard deviations between the computed transfer function and the baseline transfer function for that actuator/sensor pair;

repeating the normalizing sub-step for each of a plurality of frequencies within the prescribed frequency range to produce a plurality of transfer function deviations over the prescribed frequency range;

integrating the transfer function deviations for each actuator/sensor pair over the prescribed frequency range, to thereby produce a cumulative delta value for each actuator/sensor pair; and

,

deriving the composite damage indication value for the structural health of the structure at the location of each actuator from the cumulative delta values.

9. The method as set forth in claim 8, wherein the transducers are each capable of both actuating and sensing, whereby those transducers which are actuating at a given time comprise actuators at that given time, and those transducers which are sensing at a particular time comprise sensors at that particular time.

10. The method as set forth in claim 9, wherein the structure further has at least one further transducer which is capable of only sensing.

11. The method as set forth in claim 8, further comprising the step of localizing damage to the structure by identifying the highest composite damage indication value.

12. The method as set forth in claim 8, wherein each composite damage indication value is indicative of a level of damage to a local region of the structure surrounding the corresponding actuator.

13. The method as set forth in claim 8, further comprising the step of windowed local averaging the transfer function deviation for each actuator/sensor pair prior to performing the integrating step, to thereby produce windowed local averaged transfer function deviations that comprise the transfer function deviations which are integrated in the integrating step.

14. The method as set forth in claim 1, wherein the computing step is performed by computing the magnitude of the analog sensor signals as a function of the frequency of the excitation.

15. The method as set forth in claim 1, wherein the computing step is performed by computing the magnitude and phase of the analog sensor signals as a function of the frequency of the excitation.

16. The method as set forth in claim 1, further comprising the step of comparing the phase of the computed transfer function for each actuator/sensor pair with the phase of the corresponding baseline transfer function for that actuator/sensor pair.

17. The method as set forth in claim 16, further comprising the step of discriminating between damage to the structure and damage to a bond between the transducers and the structure in response to the step of comparing the phase of computed transfer function for each actuator/sensor pair with the phase of the corresponding baseline transfer function for that actuator/sensor pair.

18. The method as set forth in claim 1, wherein the structure is a composite structure.

19. The method as set forth in claim 18, wherein the composite structure is a part of an aerospace vehicle.

20. The method as set forth in claim 1, wherein each of the transducers is a piezoelectric transducer.

21. The method as set forth in claim 1, wherein the structure is a metallic structure.

22. A system for monitoring the structural health of a structure having a plurality of transducers, including a plurality of pairs of actuators and sensors, secured thereto, comprising:

means for exciting the actuators with broadband excitation across a prescribed frequency range, wherein each of the sensors produces an analog sensor signal in response to the excitation of the actuators;

means for digitizing the analog sensor signals to thereby produce digitized sensor signals; and

,

means for computing a transfer function for each actuator/sensor pair using the digitized sensor signals, for comparing the magnitude of each computed transfer function with a baseline transfer function for the corresponding actuator/sensor pair, for determining the difference between the computed and baseline transfer functions for each actuator/sensor pair, and for deriving a composite damage indication value for the structural health of the structure at the location of each actuator from the determined differences between the computed and baseline transfer functions for each actuator/sensor pair.

23. The system as set forth in claim 22, wherein:

at least one of the transducers comprises a transducer which is capable of both actuating and sensing; and

,

each of said at least one of the transducers comprises both an actuator and a sensor.

24. The system as set forth in claim 23, wherein the structure further has at least one further transducer which is capable of only sensing.

25. The system as set forth in claim 22, wherein the prescribed frequency range is 0 to 20 kHz.

26. The system as set forth in claim 22, wherein the broadband excitation comprises white noise excitation.

27. The system as set forth in claim 22, wherein the computing means computes the transfer functions by Fast Fourier Transform processing the digitized sensor signals.

28. The system as set forth in claim 22, wherein the baseline transfer function for each actuator/sensor pair is derived by obtaining a plurality of transfer function data sets for that actuator/sensor pair with the structure in an undamaged condition, then averaging the thusly obtained plurality of transfer function data sets for that actuator/sensor pair to produce an average transfer function data set for that actuator/sensor pair, and then computing a standard deviation of the baseline transfer function for each actuator/sensor pair based upon a statistical comparison of the plurality of transfer function data sets for that actuator/sensor pair with the average transfer function data set for that actuator/sensor pair.

29. The system as set forth in claim 28, wherein the computing means further functions to normalize the determined differences between the computed and baseline transfer functions for each actuator/sensor pair by computing the number of standard deviations between the computed and baseline transfer function for each acuator/sensor pair, to thereby produce a transfer function deviation for each actuator/sensor pair expressed in terms of the number of standard deviations between the computed transfer function and the baseline transfer function for that actuator/sensor pair, to repeat the normalizing function for each of a plurality of frequencies within the prescribed frequency range to produce a plurality of transfer function deviations over the prescribed frequency range, to integrate the transfer function deviations for each actuator/sensor pair over the prescribed frequency range, to thereby produce a cumulative delta value for each actuator/sensor pair, and to derive the composite damage indication value for the structural health of the structure at the location of each actuator from the cumulative delta values.

30. The system as set forth in claim 29, wherein the transducers are each capable of both actuating and sensing, whereby those transducers which are actuating at a given time comprise actuators at that given time, and those transducers which are sensing at a particular time comprise sensors at that particular time.

31. The system as set forth in claim 30, wherein the structure further has at least one further transducer which is capable of only sensing.

32. The system as set forth in claim 28, wherein each composite damage indication value is indicative of a level of damage to a local region of the structure surrounding the corresponding actuator.

33. The system as set forth in claim 28, wherein the computing means performs windowed local averaging of the transfer function deviation for each actuator/sensor pair prior to integrating the transfer function deviations, to thereby produce windowed local averaged transfer function deviations which are subsequently integrated.

34. The system as set forth in claim 22, wherein the computing means computes the magnitude of the analog sensor signals as a function of the frequency of the excitation.

35. The system as set forth in claim 22, wherein the computing means computes the magnitude and phase of the analog sensor signals as a function of the frequency of the excitation.

36. The system as set forth in claim 22, wherein the computing means further compares the phase of the computed transfer function for each actuator/sensor pair with the phase of the corresponding baseline transfer function for that actuator/sensor pair.

37. The system as set forth in claim 36, wherein the computing means further discriminates between damage to the structure and damage to a bond between the transducers and the structure.

38. The system as set forth in claim 22, wherein the structure is a composite structure.

39. The system as set forth in claim 37, wherein the composite structure is a part of an aerospace vehicle.

40. The system as set forth in claim 22, wherein each of the transducers is a piezoelectric transducer.

41. A system for monitoring the structural health of a structure having a plurality of transducers, including a plurality of pairs of actuators and sensors, secured thereto, comprising:

a first section which excites the actuators with broadband excitation across a prescribed frequency range, wherein each of the sensors produces an analog sensor signal in response to the excitation of the actuators;

a second section which digitizes the analog sensor signals to thereby produce digitized sensor signals; and

,

a third section which computes a transfer function for each actuator/sensor pair using the digitized sensor signals, which compares the magnitude of each computed transfer function with a baseline transfer function for the corresponding actuator/sensor pair, which determines the difference between the computed and baseline transfer functions for each actuator/sensor pair, and which derives a composite damage indication value for the structural health of the structure at the location of each actuator from the determined differences between the computed and baseline transfer functions for each actuator/sensor pair.

42. The system as set forth in claim 41, wherein the baseline transfer function for each actuator/sensor pair is derived by obtaining a plurality of transfer function data sets for that actuator/sensor pair with the structure in an undamaged condition, then averaging the thusly obtained plurality of transfer function data sets for that actuator/sensor pair to produce an average transfer function data set for that actuator/sensor pair, and then computing a standard deviation of the baseline transfer function for each actuator/sensor pair based upon a statistical comparison of the plurality of transfer function data sets for that actuator/sensor pair with the average transfer function data set for that actuator/sensor pair.

43. The system as set forth in claim 42, wherein the third section further functions to normalize the determined differences between the computed and baseline transfer functions for each actuator/sensor pair by computing the number of standard deviations between the computed and baseline transfer function for each actuator/sensor pair, to thereby produce a transfer function deviation for each actuator/sensor pair expressed in terms of the number of standard deviations between the computed transfer function and the baseline transfer function for that actuator/sensor pair, to repeat the normalizing function for each of a plurality of frequencies within the prescribed frequency range to produce a plurality of transfer function deviations over the prescribed frequency range, to integrate the transfer function deviations for each actuator/sensor pair over the prescribed frequency range, to thereby produce a cumulative delta value for each actuator/sensor pair, and to derive the composite damage indication value for the structural health of the structure at the location of each actuator from the cumulative delta values.

44. The system as set forth in claim 43, wherein the transducers are each capable of both actuating and sensing, whereby those transducers which are actuating at a given time comprise actuators at that given time, and those transducers which are sensing at a particular time comprise sensors at that particular time.

45. The system as set forth in claim 44, wherein the structure further has at least one further transducer which is capable of only sensing.