Diaphragm-type couplings are high misalignment torque and speed transfer components used in aircrafts. Crack
development in such couplings, or in the drive train in general, can lead to component failure that can bring down an
aircraft. Real time detection of crack formation and growth is important to prevent such catastrophic failures. However,
there is no single Nondestructive Monitoring method available that is capable of assessing the early stages of crack
growth in such components. While vibration based damage identification techniques are used, they cannot detect cracks
until they reach a considerable size, which makes detection of the onset of cracking extremely difficult. Acoustic
Emission (AE) can detect and monitor early stage crack growth, however excessive background noise can mask acoustic
emissions produced by crack initiation. Fusion of the two mentioned techniques can increase the accuracy of
measurement and minimize false alarms. However, a monitoring system combining both techniques could prove too
large and heavy for the already restricted space available in aircrafts.
In the present work, we will present a newly developed integrated Acoustic Emission/Vibration (AE/VIB) combined
sensor which can operate in the temperature range of -55°F to 257°F and in high EMI environment. This robust AE/VIB
sensor has a frequency range of 5 Hz-2 kHz for the vibration component and a range of 200-400 kHz for the acoustic
emission component. The sensor weight is comparable to accelerometers currently used in flying aircraft. Traditional
signal processing approaches are not effective due to high signal attenuation and strong background noise conditions,
commonly found in aircraft drive train systems. As an alternative, we will introduce a new Supervised Pattern
Recognition (SPR) methodology that allows for simultaneous processing of the signals detected by the AE/VIB sensor
and their classification in near-real time, even in these adverse conditions. Finally, we will discuss the architecture
developed to produce a fully autonomous monitoring tool based on the fusion of the AE and Vibration techniques.
This paper discusses the conceptual development of a continuously monitored intelligent system for underground infrastructure. The proposed sensors are based on advanced coupling and refinement of several technologies: electrically conducting composite pipe (ECCP), electrochemical impedance spectroscopy (EIS) and time domain reflectometry (TDR). A significant benefit gleaned from the combination of these technologies is that the resulting system may be used on non-metallic, as well as, metallic pipes. In addition, the synergism of the technologies obtains the maximum information regarding defect location and characterization. The monitoring signal, waveguides, and damage sensor are also discussed, as well as, the data fusion, dynamic modeling and simulation requirements for the intelligent monitoring system.
KEYWORDS: Metals, Sensors, Acoustic emission, Signal processing, Software development, Neural networks, Warfare, Picture Archiving and Communication System, Control systems, Data acquisition
This paper presents the latest results obtained from Acoustic Emission (AE) monitoring and detection of cracks and/or damage in diaphragm couplings, which are used in some aircraft and engine drive systems. Early detection of mechanical failure in aircraft drive train components is a key safety and economical issue with both military and civil sectors of aviation. One of these components is the diaphragm-type coupling, which has been evaluated as the ideal drive coupling for many application requirements such as high speed, high torque, and non-lubrication. Its flexible axial and angular displacement capabilities have made it indispensable for aircraft drive systems. However, diaphragm-type couplings may develop cracks during their operation. The ability to monitor, detect, identify, and isolate coupling cracks on an operational aircraft system is required in order to provide sufficient advance warning to preclude catastrophic failure. It is known that metallic structures generate characteristic Acoustic Emission (AE) during crack growth/propagation cycles. This phenomenon makes AE very attractive among various monitoring techniques for fault detection in diaphragm-type couplings. However, commercially available systems capable of automatic discrimination between signals from crack growth and normal mechanical noise are not readily available. Positive classification of signals requires experienced personnel and post-test data analysis, which tend to be a time-consuming, laborious, and expensive process. With further development of automated classifiers, AE can become a fully autonomous fault detection technique requiring no human intervention after implementation. AE has the potential to be fully integrated with automated query and response mechanisms for system/process monitoring and control.
This paper presents the research and development of an Acoustic Health Monitoring (AHM) system that uses Guided Lamb Wave (GLW) technology to determine the thickness of railroad tank car shells for identification of wall loss due to corrosion. In recent regulatory changes, the emphasis has shifted from the traditional hydrotest to more modern methods for assuring tank car integrity. The new generation of maintenance programs will rely heavily on nondestructive testing, and will use damage tolerance concepts and risk analysis to establish inspection frequencies and items to inspect. It is the responsibility of the owners to set up experience-based maintenance programs that are suitable for the working conditions of their own particular fleets. Development of an ideal AHM system for railroad cars would be an instrument that incorporates Acoustic Emission (AE) and GLW technology. The combination of active and passive acoustic technologies integrated into a single system would be a highly efficient means of determining the structural integrity of tank cars. The integration of the GLW technology will allow identification of corrosion wall loss in a zone between two sensors, rather than at a single point (traditional ultrasonic thickness measurements). Thus, a much larger area of the structure can be inspected for approximately the same inspection cost. With a suitable integration of this new technology into the overall inspection and corrosion management program, the fleet can be more efficiently maintained and the risk of accidental release through progressive corrosion damage can be significantly reduced.
KEYWORDS: Principal component analysis, Acoustic emission, Picture Archiving and Communication System, Pattern recognition, Statistical analysis, Manufacturing, Data acquisition, Signal generators, Control systems, Inspection
In order to develop an effective and accurate way to monitor and control the quality of fiberglass products, Acoustic Emission (AE) signals, generated during compression of fiberglass samples, were studied and analyzed using neural network based pattern recognition software. Distinguishable patterns were found in samples manufactured under different conditions and compositions, which resulted in different product quality. AE waveform features, such as absolute energy, average frequency, duration, and rise time were analyzed and the features showed strong dependence on the sample tested. This made sample classification possible and definitive and therefore a classifier was developed and applied to data collected from additional test samples. Finally, an AE system for the evaluation of fiberglass insulation was designed and built. It is expected that the developed system will be used as a quality control tool in industrial production of fiberglass insulating material. In this paper we will discuss the AE data collection and analysis, classifier development, and give an overview of the inspection system developed.
This paper presents the results obtained during the development of a semi-real-time monitoring methodology based on Neural Network Pattern Recognition of Acoustic Emission (AE) signals for early detection of cracks in couplings used in aircraft and engine drive systems. AE signals were collected in order to establish a baseline of a gear-testing fixture background noise and its variations due to rotational speed and torque. Also, simulated cracking signals immersed in background noise were collected. EDM notches were machined in the driving gear and the load on the gearbox was increased until damaged was induced. Using these data, a Neural Network Signal Classifier (NNSC) was implemented and tested. The testing showed that the NNSC was capable of correctly identifying six different classes of AE signals corresponding to different gearbox operation conditions. Also, a semi-real-time classification software was implemented. This software includes functions that allow the user to view and classify AE data from a dynamic process as they are recorded at programmable time intervals. The software is capable of monitoring periodic statistics of AE data, which can be used as an indicator of damage presence and severity in a dynamic system. The semi-real-time classification software was successfully tested in situations where a delay of 10 seconds between data acquisition and classification was achieved with a hit rate of 50 hits/second per channel on eight active AE channels.
With the increasing use of advanced composite materials in aircraft, automobiles, military hardware, and aerospace composites (such as rocket motorcases) a sizable need for composite health assessment measures exist, particularly where there is risk of failure due to high mechanical and thermal stresses. For most epoxy-based laminate composites, even low-momentum impacts can lead to "barely visible impact damage" (BVD), corresponding to a significant weakening of the composite. This weakening can lead to sudden and catastrophic failure when the material is subjected to normal operating loads. Following the explosion of Delta 241 (IIR-1) on Jaunary 17th, 1997, the failure investigation board concluded that an entire fleet of Graphite Epoxy Motorcases (GEMs) should be instrumented with a health monitoring system. This system would provide continuous structural health data on the GEM from initial acceptance testing through final erection on the launch pad. The result presented here contribute significantly to the understanding of the acoustic properties of the GEM casing, and make a substantial advancement in the theoretical phase of the source location algorithm development. When the system is complete it will continuously monitor the structural health of the GEMs, communicate wirelessly with base stations, operate autonomously for extended periods, and fit unobtrusively on the GEM itself.
A test was recently conducted on August 1, 2000 at the FHwA Non-Destructive Evaluation Validation Center, sponsored by The New York State DOT, to evaluate a graphite composite laminate as an effective form of retrofit for reinforced concrete bridge beam. One portion of this testing utilized Acoustic Emission Monitoring for Evaluation of the beam under test. Loading was applied to this beam using a two-point loading scheme at FHwA's facility. This load was applied in several incremental loadings until the failure of the graphite composite laminate took place. Each loading culminated by either visual crack location or large audible emissions from the beam. Between tests external cracks were located visually and highlighted and the graphite epoxy was checked for delamination. Acoustic Emission data was collected to locate cracking areas of the structure during the loading cycles. To collect this Acoustic Emission data, FHwA and NYSDOT utilized a Local Area Monitor, an Acoustic Emission instrument developed in a cooperative effort between FHwA and Physical Acoustics Corporation. Eight Acoustic Emission sensors were attached to the structure, with four on each side, in a symmetrical fashion. As testing progressed and culminated with beam failure, Acoustic Emission data was gathered and correlated against time and test load. This paper will discuss the analysis of this test data.
Following the explosion of Delta 241 (IIR-1) on January 17th, 1997, the failure investigation board concluded that the Graphite Epoxy Motorcases (GEM's) should be inspected for damage just prior to launch. Subsequent investigations and feedback from industry led to an Aerospace Corporation proposal to instrument the entire fleet of GEM's with a continuous health monitoring system. The period of monitoring would extend from the initial acceptance testing through final erection on the launch pad. As this proposal demonstrates, (along with the increasing use of advanced composite materials in aircraft, automobiles, military hardware, and aerospace components such as rocket motorcases) a sizable need for composite health assessment measures exist. Particularly where continuous monitoring is required for the detection of damage from impacts and other sources of high mechanical and thermal stresses. Even low-momentum impacts can lead to barely visible impact damage (BVID), corresponding to a significant weakening of the composite. This damage, undetectable by visual inspection, can in turn lead to sudden and catastrophic failure when the material is subjected to a normal operating load. There is perhaps no system with as much potential for truly catastrophic failure as a rocket motor. We will present an update on our ongoing efforts with the United States Air Force Delta II Program Office, and The Aerospace Corporation. This will cover the development of a local, portable, surface-mounted, fiberoptic sensor based impact damage monitor designed to operate on a Delta II GEM during transport, storage, and handling. This system is designed to continuously monitor the GEMs, to communicate wirelessly with base stations and maintenance personnel, to operate autonomously for extended periods, and to fit unobtrusively on the GEM itself.
Many of today's methods of inspecting structures are very time consuming, labor intensive and in many cases (due to limited access), impractical. In addition, long shutdown times are required to perform the inspections, thus creating tremendous expenses associated with manpower, materials and lost production. With continuing advances in signal processing and communications a significant interest has been shown in developing new diagnostic technologies for monitoring the integrity of structures with known defects, or for detecting new defects, in real time with minimum human involvement. The continued use of aging structures, especially in regard to the airworthiness of aging aircraft, is a major area of concern. Recent developments in both active and passive Acoustic Emission monitoring as an advanced tool for 'Structural Health Management Systems (SHMS),' are illustrated by using two recently developed acoustic emission systems; the Acoustic Emission-Health and Usage Monitoring System (AE-HUMS) helicopter drivetrain health monitoring system, and the Acoustic Emission Flight Instrument System (AEFIS) composite health monitoring system. The data collected with these types of systems is processed with advanced data screening and classification techniques, which are employed to take full advantage of parametric and waveform-based acoustic emission.
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