System and method for progressive damage monitoring and failure event prediction in a composite structure
Inventors
Zalameda, Joseph N. • BURKE, ERIC R. • Horne, Michael R. • Madaras, Eric I.
Assignees
National Institute of Aerospace Associates • National Aeronautics and Space Administration NASA
Publication Number
US-10605783-B2
Publication Date
2020-03-31
Expiration Date
2036-08-16
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Abstract
A system for monitoring damage progression in a composite structure includes a load sensor, acoustic emission sensors, a camera, and a monitoring device. The load sensor measures an applied load to the structure. The sensors measure acoustic emission data indicative of possible damage to the structure. The camera captures image data of the structure in a designated portion of the electromagnetic spectrum. The monitoring device executes a method by which the acoustic emission data is synchronously collected with the image data and the applied load. The device automatically maps the acoustic emission data onto the image data to detect an area of damage progression in the composite structure. A failure event in the detected area of damage progression may be predicted using the mapped data, and a control action may be executed in response to the predicted failure event.
Core Innovation
A system and method are disclosed for wide area, in-situ measurement of progressive damage in a loaded composite structure and for predicting a failure event. The system includes a load sensor to measure an applied load, an array of acoustic emission sensors acoustically coupled to the composite structure to detect acoustic emissions indicative of damage, one or more cameras capturing image data in a designated portion of the electromagnetic spectrum, and a programmable monitoring device. The monitoring device synchronously collects acoustic emission data, image data, and applied load measurements, mapping acoustic emission data onto image data to detect damage progression areas and predict failure events.
The invention addresses the challenge of accurately detecting and tracking damage initiation and growth in composite structures under load, such as those in aircraft components. Existing inspection methods like acoustic emission testing detect damage onset but are limited in measuring damage shape, size, and depth, while other methods such as passive thermography, digital image correlation, and fiber optic sensing provide partial information but lack comprehensive capability for wide area, in-situ fatigue monitoring and failure prediction. The disclosed system integrates and synchronizes these data sources to overcome limitations and improve damage monitoring and failure event prediction.
Claims Coverage
The patent includes two independent claims covering a system and a method for monitoring damage progression and predicting failure in composite structures.
Load measurement and signaling
The system includes a load sensor operable for measuring applied load to the composite structure and outputting a load profile signal indicative of the measured load.
Acoustic emission sensing with spatial correlation
An array of acoustic emission sensors acoustically coupled to the composite structure, each having fixed two-dimensional coordinates, simultaneously measuring acoustic emission data representing events indicative of possible damage.
Synchronized imaging capturing damage signatures
A camera captures time-synchronized image data in a designated electromagnetic spectrum portion of the area of possible damage while the structure is under load, allowing detection of damage size and location.
Integrated monitoring device for data correlation and failure prediction
A monitoring device receives and synchronizes load profile signals, acoustic emission data, and image data, assigns energy indicators to acoustic events, automatically maps acoustic data onto image data generating clusters indicative of damage progression, predicts time of failure using size, location, and signal energy trends, and executes control actions including alerts.
Dynamic image resolution control
The monitoring device can control the camera’s resolution in targeted areas based on the severity of acoustic emission data.
Method for synchronous data collection and damage mapping
The method includes measuring acoustic emission data from sensors with fixed coordinates, synchronously collecting image data and load data, time-synchronizing these data sets, automatically mapping acoustic emission data onto image data to detect damage progression, assigning energy indicators, predicting failure time, and executing control actions such as alerts.
The independent claims cover a comprehensive system and method integrating load sensing, acoustic emission sensing with spatial mapping, time-synchronized imaging, and a monitoring device that correlates these data streams to detect damage progression and predict failure events with control actions, including dynamic control of imaging resolution.
Stated Advantages
Enables wide area, in-situ monitoring of damage progression in composite structures under load.
Improves accuracy in detecting damage size, location, and progression by synchronizing acoustic emission data with image data and applied load.
Allows prediction of failure events in real time using combined sensor data, facilitating timely control actions.
Supports dynamic control of imaging resolution based on severity of detected acoustic emissions, optimizing data collection.
Provides large area nondestructive evaluation capability for fatigue testing and damage tracking to aid design and validation of advanced composite structures.
Documented Applications
Real-time monitoring and failure prediction of composite aircraft components such as fuselage panels, wings, stabilizers, doors, and flight control surfaces.
Fatigue testing and validation of structural designs in advanced composite materials.
Use aboard various top-level platforms including aircraft, watercraft, spacecraft, land-based vehicles, and stationary structures for structural health monitoring.
Maintenance and inspection systems programmed with failure prediction models for alerting and guiding replacement or detailed inspection of composite structures.
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