Co-Located Triangulation for Damage Position
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1 Co-Located Triangulation for Damage Position Identification from a Single SHM Node Seth S. Kessler, Ph.D. President, Metis Design Corporation Ajay Raghavan, Ph.D. Lead Algorithm Engineer, Metis Design Corporation 10 Canal Park Cambridge, MA
2 Structural Health Monitoring (SHM) SHM systems detect & interpret adverse changes in a structure to reduce life-cycle costs & improve reliability Integration of NDE into a vehicle to collect prognostic data design into new vehicles or retrofit ageing g vehicles to evaluate health interrogation of system can occur continuously or be ground-based Applicable to any field highest payoff in aerospace vehicles increase asset availability by reducing inspection time & extending life improve safety by providing more frequent & accurate prognostic data reduce costs by 33% through condition-based maintenance (CBM) 2008 Metis Design Corporation PHM Conference
3 Lamb Wave Methods Form of elastic perturbation that propagates in a solid medium best damage size & detection range to sensor area ratio sensitivity and range scales with input power level (with limitations) advantages for detecting/characterizing local damage over large areas Research utilizes concentric piezoelectric actuator/sensor pairs excitation shape and frequency can be optimized for particular geometry pitch-catch: group velocity (E/ρ)1/2, damage slows down waves pulse-echo: reflected wave used to determine damage locations 2008 Metis Design Corporation PHM Conference
4 Signal Processing Methodology Signal Conditioning denoise raw signal remove unwanted artifacts Feature Extraction discriminative features for analysis time, frequency & energy domains Feature Selection repeatable features unique to class can reduce dimensionality (PCA) Algorithms Pattern Recognition (PR) to identify damage presence, type and severity localization performed with time-of-flight flight from single or multiple sensors confusion matrix can be used to calculate confidence levels 2008 Metis Design Corporation PHM Conference
5 Extracting Discriminative Features Several multi-physics approaches are possible time domain compare time-of-flight, between peaks energy domain compare intensity of wave-packets, ratios frequency domain compare overall spectrum, peaks, ratios Technique relies on a baseline or undamaged characterization signals (V) p No Damage Test Article signals (V) p No Damage Test Article Damage detected!! 2008 Metis Design Corporation PHM Conference
6 Sample Results for Aluminum 18 square 1/8 Aluminum quadrants formed by c-channel ribs, Lamb wave tests performed in pulse-echo mode, 80kHz Normalized difference time-of-flight (TOF) algorithm used 2000 tests on undamaged specimen without any false positives 5000 tests t on simulated damage, 100% capture of damage location prediction with better than 0.5 accuracy from Metis Design Corporation PHM Conference
7 Optimization of Sensor Geometry Frequency Selection Diameter Selection Thickness Selection Model-based tools developed to optimize sensor geometry Fundamentals described by dispersion curve input: material properties (E, v, rho, etc.) output: velocity as a function of frequency*thickness 2008 Metis Design Corporation PHM Conference
8 Problem Statement Traditional methods need high sensor density for good location pitch-catch measures delays and/or scatter along direct sensor line paths pulse-echo determines reflected radius of damage from TOF both cases require at least 3 sensors in close proximity to triangulate prediction resolution scales with sensor array size and proximity Complications arise in non-isotropic/homogeneous applications composite & anisotropic i materials present velocity ellipses & stars tapered or ply-drop-off regions yield continuously changing velocity stiffened regions with ribs or doublers exhibit local acceleration of wave New method is desired to resolve these issues high detection resolution with reduced sensor density velocity independence to locate damage in complex structures 2008 Metis Design Corporation PHM Conference
9 Vector-Based Locator Device Co-located triangulation achieves these stated goals damage localization from 1-2 SHM node location(s) accuracy <±5% for angle and ± 5mm location (specimen dependant) enables velocity-free detection in anisotropic materials/structures Employs a novel (patent-pending) localization method sensor consists of multiple concentric elements on a single PZT wafer innovative pulse-echo algorithm to resolve incident id wave angle precisely 1 node can be used to calculate angle/range in isotropic materials 2 nodes can be used to find vector intersection for anisotropic materials Implemented using analog or digital infrastructure passive mode (sit & listen) to determine location of impact event active mode (pulse & listen) to actively seek damage location 2008 Metis Design Corporation PHM Conference
10 Prototype SHM Node Configuration Damage Location 2 r 3 φ Actuator 1 a cm 2008 Metis Design Corporation PHM Conference
11 Theory & Algorithm Structure is excited omni-directionally by PZT actuator 4 co-located concentric sensor elements measure reflection results are plotted in cylindrical coodinates as a function of time Incident angle is determined by slight differences in phase method relies on fast acquisition to resolve differences multiple levels of peak-detection required (interpolation, oversampling) φ = = atan2 atan2 ( t4 t2, t3 t1 ) if t4 t2 t3 ( t t, t t ) π 2 otherwise Distance to damage determined by TOF or vector intersection t1 + t 2 + t 3 + t 4 r = 0.5 c isotropic 4 g t a Metis Design Corporation PHM Conference t 1
12 Single-Node Validation Tests Co-located triangulation setup PZT device laser fabricated & selectively electroded geometry optimized for A 0 Lamb wave (fundamental antisymmetric) 90 khz 3.5-cycle toneburst signal modulated by a Hanning window 5 synchronously sampling 10 MHz data acquisition channels Test setup 0.9 m square 3.2 mm thick 6061 aluminum plate small magnets used to simulate "inverse" damage (increased stiffness) 3 damage sizes: 3.2 mm, 6.4 mm and 12.7 mm diameter 36 data collection points (10 increments) located around a 0.5 m circle 2008 Metis Design Corporation PHM Conference
13 Experimental Vector Results (3.18 mm) 2008 Metis Design Corporation PHM Conference
14 Experimental Vector Results (6.35 mm) 2008 Metis Design Corporation PHM Conference
15 Experimental Vector Results (12.7 mm) 2008 Metis Design Corporation PHM Conference
16 Experimental Distance Results 2008 Metis Design Corporation PHM Conference
17 Angular Position Error Overall average absolute angular error was 2.4% (8.6 ) highest error occurred at odd multiples of 45 lowest error occurred at multiples of 90 Slight dependency on size, error increases with larger damage Damage Maximum Maximum Average Average (mm) (degrees) (%) (degrees) (%) % % % % % 6.8% % 2.5% 2008 Metis Design Corporation PHM Conference
18 Radial Position Error Overall average radial error was 0.9% (2.4 mm) no apparent angular dependency no apparent damage size dependency in the absolute sense algorithm tended to under-predict distance as damage size increased Results obtained using isotropic aluminum wavespeed Damage Maximum Max. Error Avg. Error Avg. Error (mm) (mm) (%) (mm) (%) % % % % % 2.6% % 1.1% 2008 Metis Design Corporation PHM Conference
19 Summary Did not achieve theoretical accuracy, good proof-of-concept Reconciling average methodology error 2 cm diameter SHM node on a 0.5 m diameter circular area ( cm 2 ) locate damage as small as 8 mm 2 with an area of uncertainty of <1.0 cm 2 Provides a path to reliable & efficient damage location detection greatly reduced density & increased accuracy over pitch-catch methods removes velocity dependency of pulse-echo methods eliminates blind-spots & dead-zones produced by phased arrays Provides sufficient information for an operator to make informed guided maintenance decisions with minimal system complexity 2008 Metis Design Corporation PHM Conference
20 Continuing Research Improve accuracy through enhanced peak detection Integrate algorithms within real-time software Implement high-speed micro-instrumentation hardware 28cm Metis Design Corporation PHM Conference
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