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Monitoring Technology
September 2013
NASA Focused Structural Health Monitoring
National Aeronautics and Space Administration
Space
pace Shuttle
Shutt
h tlle
hutt
Orbiter
er
International
ternation
iona
al
Launchh Space
Spacce
c e
Vehicles
es Stationn
NASA
Vehicle
e Structural Composite
Compos
os
sittte
e
Pressure
Pressur
rre
e Health Crew
w
Systems
Sy ms
ms Module
Modu
Modul
ulle
Monitoring
Technology
Reentrrry
Reentry y Uninhabitedd
Vehicles
Vehicle
es Aerial Vehicles
es
Space Vehicles
es
3
Topics
National Aeronautics and Space Administration
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
AE
July 7, 2003
Sensors Accelerometers
J1 1 2 3 4 5 6 7
J2
J3
Triax Panel 5 Panel 6 Panel 7 Panel 8 Panel 9 Panel 10 8
400.00
Acoustic Emission Sensor Data Impact on Panel #8:
Broken Panel
350.00 1 2
331.71
310.81
300.00 3 4
254.73
250.00
5 6 236.03
Peak g’s
200.00
7 8
150.00 136.60
100.00
67.55
61.33 42.68
32.35 52.54 57.01
50.00 22.89 18.40 32.57 31.47 38.43 35.89
24.18 23.88 33.00 47.53 29.19 25.76
26.60 22.15
18.17 14.39 30.75
7.9 37.2 37.2
6.7 7.3 7.3 7.9 24.3 24.3 24.2
Air Blast Test 20.9 20.9
0.00
Accelerations
WLEIDS Operations
National Aeronautics and Space Administration
9
Space Shuttle / ISS
Evolution of Micro-WIS Systems
ISS assembly Columbia Shuttle fleet DIDS
Purpose IVHM Thermal Models Cargo Loads MPS Feedline Wing Leading ISS Impact/Leak
Cert Life Dynamics Edge Impacts Monitoring
Extension
Dimensions 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”
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
13
Distributed Impact Detection System Concept
National Aeronautics and Space Administration
Impact
Structural
Waves
Piezoelectric
Sensors
DIDS Wireless
Sensor Units
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
• Temperature range: -50°C to +100°C
SSC • 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
DIDS Receiver • Kynar heat shrink Sensor Cable
connected to SSC • Length: 2 Meters
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
Example of installation behind ISS equipment ramp
(Fit Check in B9 US Lab Mockup)
18
SHM Aerospace Vehicle Applications
National Aeronautics and Space Administration
Space Shuttle
le
International
ternation
iona
al
Launchh Space
Spacce
c e
Vehicles
es Stationn
NASA
Vehicle
e Structural Composite
Compoosittte
o e
Pressure
Pressur
rre
e Health Crew
w
Systems
Syst ms s Module
Modu
Modul
ule
Monitoring
Technology
Reentrrry
Reentry y UAVs
Vs
Vehicles
Ve hicle
es
Space Vehicles
hi les
19
Fiber Optic Sensing System (FOSS)
Background
National Aeronautics and Space Administration
20
Fiber Optic Sensing System (FOSS)
Operation Overview
National Aeronautics and Space Administration
• Fiber count 8
• Max sensing length / fiber 40 ft
• Max sensors / fiber 2000
• Total sensors / system 16000
• Max sample rate (flight) 100 sps
• Max sample rate (ground) 60 sps
• Power (flight) 28VDC @ 4.5 Amps
Flight System
• Power (ground) 110 VAC
• User Interface Ethernet
• Weight (flight, non-optimized) 27 lbs
• Weight (ground, non-optimized) 20 lbs
• Size (flight, non-optimized) 7.5 x 13 x 13 in
• Size (ground, non-optimized) 7 x 12 x 11 in
Ground System
Environmental qualification specifications for
flight system
• Shock 8g
• Vibration 1.1 g-peak sinusoidal curve
• Altitude 60kft at -56C for 60 min
• Temperature -56 < T < 40C
Predator -B in Flight 22
Fiber Bragg Grating – Optical Frequency Domain
Reflectometry
FBG-OFDR can dramatically improve structural and system
National Aeronautics and Space Administration
25
Uninhabited Aerial Vehicles
Global Observer UAS - Aerovironment
• Proof-load testing of components and large-scale structures
Whiffletree
Loading System
1.2
Predicted vertical wing displacement
Actual: Photogrammetry in GRF
1 100% DLL
Actual: Photogrammetry in RRF
1 2
0.6 FWD
3 4 AFT
50% DLL
0.4
30% DLL
0.2
0 0% DLL
Over the entire wing span, the predicted displacements of
fiber 3 closely match the actual for every load condition.
-0.2
2
0 0.1
0 1 0.2
0 2 0
0.3
3 04
0.4 0.5
0 5 0.6
0 6 0.7
0 7 0.8
0 8 0.9
0 9 1
Wing Span (normalized) 27
UAVs - Global Observer UAS (AV)
Flight Testing of Strain and 2D Shape Sensing
National Aeronautics and Space Administration
28
Predator-B UAS - Flight Testing
Strain and 2D Shape Sensing
National Aeronautics and Space Administration
IIkhana
khana iin
nFFlight
light
Personal Observations
• The Shuttle never returned in the
same condition as when it launched
• Flight operations always reveals the
unexpected and make known the
unknowns STS Landing at
• NASAs SHM fiber optic sensors are Edwards AFB
much lighter than conventional strain
gage sensors Post-flight
Inspection
• FOSS-OFDR provides massive
amounts of quantitative structural
performance information in real time
and for post test analysis
• This quantitative information can
overcome some of the unknown
unknowns that may allow you to fly
another day
Dream Chaser Re-entry (artist conception)
Monitoring of MMOD Impact Damage to TPS
NASA Dryden / CSIRO Australia collaboration
National Aeronautics and Space Administration
Objective
• Detect & evaluate Micrometeoroid and
Orbital Debris (MMOD) impact damage to
Thermal Protection Systems (TPS) using
embedded acoustic and thermal sensor
networks
Vehicle Re-entry (artist
Principles conception)
• Detect and locate impacts using acoustic
emission sensor networks
• Evaluate severity of damage with optical
fiber thermal sensor network
• Utilize centralised or self-organising
operation with local network architecture
on modular tiled structure Heat shield with TPS TPS health monitoring system
Novel aspects
• Development of switched optical fiber
sensor network to enhance robustness
• Capable of central control or autonomous
self-organising operation.
• Functional damage evaluation – monitor
effect on thermal properties.
Two TPS modules Heat shield Test Setup at Dryden
33
Vehicle Pressure Systems
Embedded Strain - The Multidisciplinary Challenge
National Aeronautics and Space Administration
34
Vehicle Pressure Systems
Composite Overwrapped Pressure Vessels (COPVs)
Objectives
National Aeronautics and Space Administration
6000 6000
F1eG161 F1eG343
5000 F1eG174 F1eG356 5000
F1eG187 F1eG369
4000 F1eG201 F1eG382 4000
Strain (με)
3000 3000
Strain (με)
2000 2000
1000 1000
0 0
-1000 -1000
0 500 1000 1500 2000 2500 3000 3500 0 1000 2000 3000
TT (sec) TT (sec)
H_5
H_7
90°
0°
180°
270°
37
FOSS Current and Future Work
Flight Demonstration on a Launch Vehicle (KSC-Launch Services)
National Aeronautics and Space Administration
TPS
SHHealth
ealttth
h
Monitoring
ngg Strain
n
Embedded
mbedded
dedd Temperature
emperature and
and
Strain
n Cryogenic
c
Liquid Level
el
Magnetic Field
d
2D Shape
pe
Na
Applied Loads
Ap ds
3D
D Shape
pe
38
Cryogenic Liquid Level-Sensing
National Aeronautics and Space Administration
FOSS Approach
Cryogenic
• While using a uniquely developed
fiber optic structure (CryoFOSS),
the transitional phase can be
mapped more accurately
• Using a single continuous grating
fiber, a high degree of spatial Cryogenic
Cryogenic 1st Gen
Container located at
resolution can be achieved, as low MSFC (below deck)
Container CryoFOSS
Test Results
as 1/16”
39
LH2 Testing of CryoFOSS at MSFC
Objective
National Aeronautics and Space Administration
41
Magnetic Field Sensing
NASA Dryden / UCLA collaboration
wObjective
National Aeronautics and Space Administration