https://ntrs.nasa.gov/search.jsp?R=20140010525 2018-08-14T23:57:11+00:00Z NASA Applications of Structural Health National Aeronautics and Space Administration Monitoring Technology W. Lance Richards 1 , Eric Madaras 2 , William H. Prosser 3 , and George Studor 3 NASA Dryden Flight Research Center, Edwards, California NASA Langley Research Center, Hampton, Virginia NASA Engineering and Safety Center, Hampton, Virginia NASA Johnson Space Center, Houston, Texas September 2013
NASA Focused Structural Health Monitoring National Aeronautics and Space Administration Key Drivers Enabling Vehicle-focused Technologies Structures Real-time, Advanced Sensing decision-making - Multi-parameter Online processing - Sensor arrays Onboard systems Advanced Systems Lightweight, and Processing SHM Small size, - Solid state Low power, - Rugged System solutions - High Speed Materials NDE Ultra-Efficient Algorithms
SHM Aerospace Vehicle Applications National Aeronautics and Space Administration Space Shuttle pace Shutt hutt h hutt tl tl le le Orbiter er er International ternation ion a al Space Spac ce ce ce e Launch Launch h h Station n Vehicles es es NASA Structural Vehicle Vehicle Vehicle e e Compos Compos Composite os sit te te e Pressure Pressur re re re Health Crew Crew Crew Crew Crew w w w Systems Sy ms ms Modul Module Modul le le Monitoring Technology Uninhabited Uninhabited d Reentry Reentry ry y Aerial Vehicles es es Ve Ve Vehicles hicle es es Space Vehicles es 3
Topics National Aeronautics and Space Administration • Structural Health Monitoring – Definition – SHM vs NDE • Agency Overview of SHM Activities – Accel & Acoustic-based SHM on STS (Prosser, NESC) – Wireless-based SHM on ISS / STS (Studor, JSC) – Piezo-based SHM on ISS (Madaras, LaRC) – Fiber-optic-based SHM on Aerospace Vehicles (Richards, DFRC) • Uninhabited Aerial Vehicles • Composite Crew Module • Reentry Vehicles • Space Vehicles • Vehicle Pressure Systems • Expendable Launch Vehicles 4
Space Shuttle Orbiter Wing Leading Edge Impact Detection System (WLEIDS) National Aeronautics and Space Administration
Wing Leading Edge Impact Detection System (WLEIDS) Development • Columbia accident investigation testing - Recovery of DFI sensor data on MADS focused impact testing on RCC • Additional impact testing - Ascent impacts - MMOD impacts Vehicle testing • System development and implementation • Flight results •
Columbia Accident Investigation Catastrophic Impact Damage Test on RCC Panel 8 July 7, 2003 AE Accelerometers Sensors 1 2 3 4 5 6 7 J1 J2 J3 8 Panel 6 Panel 5 Panel 7 Panel 8 Panel 10 Triax Panel 9 400.00 Impact on Panel #8: Acoustic Emission Sensor Data Broken Panel 1 2 350.00 331.71 310.81 3 4 300.00 254.73 5 6 236.03 250.00 Peak g’s 200.00 7 8 150.00 136.60 100.00 67.55 61.33 42.68 57.01 32.35 52.54 18.40 32.57 31.47 22.89 38.43 35.89 50.00 29.19 24.18 23.88 33.00 25.76 47.53 18.17 26.60 22.15 30.75 14.39 37.2 37.2 7.9 7.9 24.3 7.3 24.3 7.3 24.2 Air Blast Test 6.7 20.9 20.9 0.00 Accelerations
WLEIDS Operations National Aeronautics and Space Administration • Installed on all Shuttles • Successfully flown on all flights since Columbia Sensors and Data • Detected small impacts Recorder in Wing during ascent – Small amplitude, nondamaging WLEIDS probable – Likely popcorn foam impact • Detected several small signal MMOD impacts
Topics National Aeronautics and Space Administration • Structural Health Monitoring – Definition – SHM vs NDE • Agency Overview of SHM Activities – Accel & Acoustic-based SHM on STS (Prosser, NESC) – Wireless-based SHM on ISS / STS (Studor, JSC) – Piezo-based SHM on ISS (Madaras, LaRC) – Fiber-optic-based SHM on Aerospace Vehicles (Richards, DFRC) • Sensor Development • Strain-based Parameter Development – Shape, Loads, Liquid Level, Magnetic Field • Sensor Attachment / Characterization • System Development • Ground / Flight Applications 9
Space Shuttle / ISS Evolution of Micro-WIS Systems Columbia Shuttle fleet DIDS ISS assembly System MicroWIS Extended Life MicroSGU / Wideband Enhanced WB Ultra-sonic WIS (SBIR) MicroWIS MicroTAU MicroTAU MicroTAU (new Ph2 SBIR) Date Certified 1997 2001 2005 2007 2000/2001 2002 Purpose IVHM Thermal Models Cargo Loads MPS Feedline Wing Leading ISS Impact/Leak Cert Life Dynamics Edge Impacts Monitoring Extension 1.7” dia. x 0.5” 2.7”x2.2”x1.2” 2.7”x 2.2” x 1.2” 3.0”x 2.5” x 1.5” 3.25”x2.75”x1.5 3.4” x2.5”x 1.1” Dimensions Sample Rate Up to 1Hz Up to 1Hz Up to 500Hz Up to 20KHz Up to 20KHz Up to 100KHz (3 channels) (3 channels) (3 channels) (10 channels) Data Storage None 2Mbytes 1Mbyte 256Mbytes 256Mbytes 1Gbyte Battery Life 9 months 10+ years 2-3 missions 1 mission 1 mission 3 years Sensor Types Temperature Temperature Acceleration & Accelerometer & Accelerometer & Ultrasonic (Flight Cert) and (Flight Cert) and Strain (Flight Temperature Temperature Microphone and Resistive Resistive Cert) or Resistive (Flight Cert) or (Flight Cert) or Acoustic sensors: Strain, sensors: Strain, sensors. Includes Piezoelectric and Piezoelectric and Emission Accelerometer, Accelerometer, Pressure as Resistive Sensors Resistive Sensors Pressure Pressure Trigger Channel.
Wireless Instrumentation Systems Unique Solutions To Real Shuttle Problems National Aeronautics and Space Administration • Temperature Monitoring - Validation of thermal models for design modifications and operations - Micro-WIS (first flown in non-RF configuration) • Structural Loads and Dynamics - SSME support strain data needed for certification life predictions - Cargo to orbiter trunion dynamics and loads - Micro Strain Gauge Unit (Micro-SGU) and Micro Tri-Axial Accelerometer Units (Micro-TAU) • SSME Feed-Line Crack Investigation - Main propulsion system flow-liner dynamics - Wide-Band Micro-TAU • Wing Leading Edge Impact Detection - Sense impact of ascent debris and MMOD on-orbit - Enhanced Wide-Band Micro-TAU (EWBMTAU) • SRMS On-Orbit Loads - Increases needed to support contingency crew EVA repairs at end of boom - Wireless Strain Gauge Instrumentation System (WSGIS) and EWBMTAU - Also used for monitoring Shuttle Forward Nose dynamics during roll-out
ISS Structural Dynamics Accelerometers National Aeronautics and Space Administration Structural Dynamics Measurement System Internal Wireless Instr System External Wireless Instr System Current accelerometer count on ISS is 81 (SDMS: 33 EWIS: 30 IWIS: 18).
Topics National Aeronautics and Space Administration • Structural Health Monitoring – Definition – SHM vs NDE • Agency Overview of SHM Activities – Wireless-based SHM on ISS / STS (Studor, JSC) – Accel & Acoustic-based SHM on STS (Prosser, NESC) – Piezo-based SHM on ISS (Madaras, LaRC) – Fiber-optic-based SHM on Aerospace Vehicles (Richards, DFRC) • Sensor Development • Strain-based Parameter Development – Shape, Loads, Liquid Level, Magnetic Field • Sensor Attachment / Characterization • System Development • Ground / Flight Applications 13
Distributed Impact Detection System Concept National Aeronautics and Space Administration • Original DIDS concept is to detect and locate impacts via a wireless sensors system. Impact Structural Waves Piezoelectric Sensors DIDS System Concept MMOD strike example Module is asleep until event signal threshold is crossed. Sensor module can record four signals at 1MHz rate. Sensors can record and transmit ~6000 events. Batteries can last up to 5 years. Laptop computer can control multiple units. • Current DIDS system concept is to detect leak locations on space vehicles.
DIDS Wireless Sensor Units Crew laptop on ISS Server DIDS Wireless Sensor Units DIDS Wireless Receiver tethered to crew laptop Note: All Sensor hardware is Internal 15 09/12/07
ISS Ultrasonic Background Noise Test (UBNT) System Overview • In order to detect leaks, the amplitude of the ultrasonic Digital Wave - Piezoelectric AE Sensor : • Model B-225.5 background noise levels is required. • Frequency bandwidth: 50kHz - 400kHz SSC • Temperature range: -50 ° C to +100 ° C • Dimensions: 0.625” diameter. x 0.8" H 910Mhz • Connector type: Microdot 910Mhz Certified Ethernet cable Antenna/Data Cable • Length: 2 Meters • SMA connector • Teflon jacket • Kynar heat shrink Sensor Cable DIDS Receiver • Length: 2 Meters connected to SSC via USB DIDS Power Supply WLE L91 Battery Pack JSL File 2 – Energizer L91 AA batteries DIDS 3.0 VDC output (nominal) Server Power supply and DIDS sensor units attached to ISS Module pressure wall using velcro. OCA/Ground AE sensors attached using pre- certified adhesives. Sensor Cable • Length: 2 Meters Principal Investigator NOTE: Diagram illustrates system configuration by System is on orbit in the ISS ISS Module. No more than 7 DIDS sensor units will (LaRC) awaiting astronaut time for used in any ISS Module. installation
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