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NASA NTRS2012

Turbine Engine Disk Rotor Health Monitoring Assessment Using Spin Tests Data

Detecting rotating engine component malfunctions and structural anomalies is increasingly becoming a crucial key feature that will help boost safety and lower maintenance cost. However, achievement of such technology, which can be referred to as a health monitoring remains somewhat challenging to implement. This is mostly due to presence of scattered loading conditions, crack sizes, component geometry and material properties that hinders the simplicity of imposing such application. Different approaches are being considered to assist in developing other means of health monitoring or nondestructive techniques to detect hidden flaws and mini cracks before any catastrophic events occur. These methods extend further to assess material discontinuities and other defects that have matured to the level where a failure is very likely. This paper is focused on presenting data obtained from spin test experiments of a turbine engine like rotor disk and their correlation to the development of a structural health monitoring and fault detection system. The data collected includes blade tip clearance, blade tip timing measurements and shaft displacements. The experimental results are collected at rotational speeds up to 10,000 Rpm and tests are conducted at the NASA Glenn Research Center s Rotordynamics Laboratory via a high precision spin system. Additionally, this study offers a closer glance at a selective online evaluation of a rotating disk using advanced capacitive, microwave and eddy current sensor technology.

Abdul-Aziz, Ali↗

NASA NTRSDate not supplied

Structural Health Monitoring of Vertical Lift Structures Operating in an Urban Environment

Verifying the structural integrity of aeronautical vehicles is of critical importance for the safety of passengers and crew. When operating in a densely populated urban area, pedestrian safety and collateral damage to buildings and other infrastructure also become important concerns. Damage modes, including fatigue from an increased frequency of take-off and landing cycles and a higher probability of impacts from bird strikes, also pose different failure risks as compared to commercial long-haul aircraft and thus require a change in structural health monitoring philosophy. This presentation will review the state of the art in structural health monitoring with an eye toward applications for vertical lift systems operated in the urban environment. Structural health monitoring methods including eddy current, fiber optic, ultrasonic plate wave, surface acoustic wave and electrical impedance tomography will be explored for use in on-board monitoring of impact and overstrain events as well as damage detection and characterization. Infusion of the data into an early warning system to help ensure damage will not propagate to failure during flight will also be discussed.

Russell A Wincheski↗

NASA NTRS2013

In situ health monitoring of piezoelectric sensors

An in situ health monitoring apparatus may include an exciter circuit that applies a pulse to a piezoelectric transducer and a data processing system that determines the piezoelectric transducer's dynamic response to the first pulse. The dynamic response can be used to evaluate the operating range, health, and as-mounted resonance frequency of the transducer, as well as the strength of a coupling between the transducer and a structure and the health of the structure.

Jensen, Scott L.↗

NASA NTRS2005

INDUCTIVE SYSTEM HEALTH MONITORING WITH STATISTICAL METRICS

Model-based reasoning is a powerful method for performing system monitoring and diagnosis. Building models for model-based reasoning is often a difficult and time consuming process. The Inductive Monitoring System (IMS) software was developed to provide a technique to automatically produce health monitoring knowledge bases for systems that are either difficult to model (simulate) with a computer or which require computer models that are too complex to use for real time monitoring. IMS processes nominal data sets collected either directly from the system or from simulations to build a knowledge base that can be used to detect anomalous behavior in the system. Machine learning and data mining techniques are used to characterize typical system behavior by extracting general classes of nominal data from archived data sets. In particular, a clustering algorithm forms groups of nominal values for sets of related parameters. This establishes constraints on those parameter values that should hold during nominal operation. During monitoring, IMS provides a statistically weighted measure of the deviation of current system behavior from the established normal baseline. If the deviation increases beyond the expected level, an anomaly is suspected, prompting further investigation by an operator or automated system. IMS has shown potential to be an effective, low cost technique to produce system monitoring capability for a variety of applications. We describe the training and system health monitoring techniques of IMS. We also present the application of IMS to a data set from the Space Shuttle Columbia STS-107 flight. IMS was able to detect an anomaly in the launch telemetry shortly after a foam impact damaged Columbia's thermal protection system.

Iverson, David L.↗

NASA NTRS1993

Health monitoring of Japanese payload specialist: Autonomic nervous and cardiovascular responses under reduced gravity condition (L-0)

In addition to health monitoring of the Japanese Payload Specialists (PS) during the flight, this investigation also focuses on the changes of cardiovascular hemodynamics during flight which will be conducted under the science collaboration with the Lower Body Negative Pressure (LBNP) Experiment of NASA. For the Japanese, this is an opportunity to examine firsthand the effects of microgravity of human physiology. We are particularly interested in the adaption process and how it relates to space motion sickness and cardiovascular deconditioning. By comparing data from our own experiment to data collected by others, we hope to understand the processes involved and find ways to avoid these problems for future Japanese astronauts onboard Space Station Freedom and other Japanese space ventures. The primary objective of this experiment is to monitor the health condition of Japanese Payload Specialists to maintain a good health status during and after space flight. The second purpose is to investigate the autonomic nervous system's response to space motion sickness. To achieve this, the function of the autonomic nervous system will be monitored using non-invasive techniques. Data obtained will be employed to evaluate the role of autonomic nervous system in space motion sickness and to predict susceptibility to space motion sickness. The third objective is evaluation of the adaption process of the cardiovascular system to microgravity. By observation of the hemodynamics using an echocardiogram we will gain insight on cardiovascular deconditioning. The last objective is to create a data base for use in the health care of Japanese astronauts by obtaining control data in experiment L-O in the SL-J mission.

Sekiguchi, Chiharu↗

NASA NTRS1991

Definition, technology readiness, and development cost of the orbit transfer vehicle engine integrated control and health monitoring system elements

An Integrated Control and Health Monitoring (ICHM) system was conceived for use on a 20 Klb thrust baseline Orbit Transfer Vehicle (OTV) engine. Considered for space used, the ICHM was defined for reusability requirements for an OTV engine service free life of 20 missions, with 100 starts and a total engine operational time of 4 hours. Functions were derived by flowing down requirements from NASA guidelines, previous OTV engine or ICHM documents, and related contracts. The elements of an ICHM were identified and listed, and these elements were described in sufficient detail to allow estimation of their technology readiness levels. These elements were assessed in terms of technology readiness level, and supporting rationale for these assessments presented. The remaining cost for development of a minimal ICHM system to technology readiness level 6 was estimated. The estimates are within an accuracy range of minus/plus 20 percent. The cost estimates cover what is needed to prepare an ICHM system for use on a focussed testbed for an expander cycle engine, excluding support to the actual test firings.

Cannon, I.↗

NASA NTRS2011

Hardware Specific Integration Strategy for Impedance-Based Structural Health Monitoring of Aerospace Systems

The Integrated Vehicle Health Management (IVHM) Project, sponsored by NASA's Aeronautics Research Mission Directorate, is conducting research to advance the state of highly integrated and complex flight-critical health management technologies and systems. An effective IVHM system requires Structural Health Monitoring (SHM). The impedance method is one such SHM technique for detection and monitoring complex structures for damage. This position paper on the impedance method presents the current state of the art, future directions, applications and possible flight test demonstrations.

Owen, Robert B.↗

NASA NTRS2012

Investigation of a Moire Based Crack Detection Technique for Propulsion Health Monitoring

The development of techniques for the health monitoring of the rotating components in gas turbine engines is of major interest to NASA s Aviation Safety Program. As part of this on-going effort several experiments utilizing a novel optical Moir based concept along with external blade tip clearance and shaft displacement instrumentation were conducted on a simulated turbine engine disk as a means of demonstrating a potential optical crack detection technique. A Moir pattern results from the overlap of two repetitive patterns with slightly different periods. With this technique, it is possible to detect very small differences in spacing and hence radial growth in a rotating disk due to a flaw such as a crack. The experiment involved etching a circular reference pattern on a subscale engine disk that had a 50.8 mm (2 in.) long notch machined into it to simulate a crack. The disk was operated at speeds up to 12 000 rpm and the Moir pattern due to the shift with respect to the reference pattern was monitored as a means of detecting the radial growth of the disk due to the defect. In addition, blade displacement data were acquired using external blade tip clearance and shaft displacement sensors as a means of confirming the data obtained from the optical technique. The results of the crack detection experiments and its associated analysis are presented in this paper.

Woike, Mark R.↗

NASA NTRS2009

Health Monitoring of a Rotating Disk Using a Combined Analytical-Experimental Approach

Rotating disks undergo rigorous mechanical loading conditions that make them subject to a variety of failure mechanisms leading to structural deformities and cracking. During operation, periodic loading fluctuations and other related factors cause fractures and hidden internal cracks that can only be detected via noninvasive types of health monitoring and/or nondestructive evaluation. These evaluations go further to inspect material discontinuities and other irregularities that have grown to become critical defects that can lead to failure. Hence, the objectives of this work is to conduct a collective analytical and experimental study to present a well-rounded structural assessment of a rotating disk by means of a health monitoring approach and to appraise the capabilities of an in-house rotor spin system. The analyses utilized the finite element method to analyze the disk with and without an induced crack at different loading levels, such as rotational speeds starting at 3000 up to 10 000 rpm. A parallel experiment was conducted to spin the disk at the desired speeds in an attempt to correlate the experimental findings with the analytical results. The testing involved conducting spin experiments which, covered the rotor in both damaged and undamaged (i.e., notched and unnotched) states. Damaged disks had artificially induced through-thickness flaws represented in the web region ranging from 2.54 to 5.08 cm (1 to 2 in.) in length. This study aims to identify defects that are greater than 1.27 cm (0.5 in.), applying available means of structural health monitoring and nondestructive evaluation, and documenting failure mechanisms experienced by the rotor system under typical turbine engine operating conditions.

Abdul-Aziz, Ali↗

NASA NTRS2014

Tunable Laser Development for In-flight Fiber Optic Based Structural Health Monitoring Systems

The objective of this task is to investigate, develop, and demonstrate a low-cost swept lasing light source for NASA DFRC's fiber optics sensing system (FOSS) to perform structural health monitoring on current and future aerospace vehicles. This is the regular update of the Tunable Laser Development for In-flight Fiber Optic Based Structural Health Monitoring Systems website.

Composite Materials↗

NASA NTRS1995

A vehicle health monitoring system for the Space Shuttle Reaction Control System during reentry

A general two tier framework for vehicle health monitoring of Guidance Navigation and Control (GN&C) system actuators, effectors, and propulsion devices is presented. In this context, a top level monitor that estimates jet thrust is designed for the Space Shuttle Reaction Control System (RCS) during the reentry phase of flight. Issues of importance for the use of estimation technologies in vehicle health monitoring are investigated and quantified for the Shuttle RCS demonstration application. These issues include rate of convergence, robustness to unmodeled dynamics, sensor quality, sensor data rates, and information recording objectives. Closed loop simulations indicate that a Kalman filter design is sensitive to modeling error and robust estimators may reduce this sensitivity. Jet plume interaction with the aerodynamic flowfield is shown to be a significant effect adversely impacting the ability to accurately estimate thrust.

Rosello, Anthony David↗

NASA NTRS2019

Acoustic Emission-Based Health Monitoring of Space Launch System Structures

This report documents the technical accomplishments of the project, “Acoustic Emission- Based Health Monitoring of Space Launch System Structures,” sponsored by the National Aeronautics and Space Administration (Award No. NNM13AA12G). As the project title suggests, the goal of the project was to develop a structural health monitoring (SHM) system for Space Launch System (SLS) vehicles based on acoustic emission (AE) or AE-like signals. Such a system will enhance SLS reliability by identifying the damage locations and type of damage when the damage is initiated. This SHM system would also lead to reduced maintenance costs by enabling ground support equipment to inspect only SLS elements or parts that are likely to be damaged. Finally, it will facilitate lean designs that meet tolerance levels specified by barely detectable damage. By avoiding excess conservatism in this manner, this SHM system will further reduce manufacturing costs of SLS vehicles.

Adams, D. O.↗

NASA NTRS2012

Sensor-Only System Identification for Structural Health Monitoring of Advanced Aircraft

Environmental conditions, cyclic loading, and aging contribute to structural wear and degradation, and thus potentially catastrophic events. The challenge of health monitoring technology is to determine incipient changes accurately and efficiently. This project addresses this challenge by developing health monitoring techniques that depend only on sensor measurements. Since actively controlled excitation is not needed, sensor-to-sensor identification (S2SID) provides an in-flight diagnostic tool that exploits ambient excitation to provide advance warning of significant changes. S2SID can subsequently be followed up by ground testing to localize and quantify structural changes. The conceptual foundation of S2SID is the notion of a pseudo-transfer function, where one sensor is viewed as the pseudo-input and another is viewed as the pseudo-output, is approach is less restrictive than transmissibility identification and operational modal analysis since no assumption is made about the locations of the sensors relative to the excitation.

Kukreja, Sunil L.↗

NASA NTRS2000

Development of Wireless Subsurface Microsensors for Health Monitoring of Thermal Protection Systems

Low cost access to space is a primary goal for both NASA and the U.S. aerospace industry. Integrated subsystem health diagnostics is an area where major improvements have been identified for potential implementation into the design of new reusable launch vehicles (RLVS) in order to reduce life cycle costs, increase safety margins and improve mission reliability. A number of efforts are underway to use existing and emerging technologies to establish new methods for vehicle health monitoring on operational vehicles as well as X-vehicles. This paper summarizes a joint effort between several NASA centers and industry partners to develop rapid wireless diagnostic tools for failure management and long-term TPS performance monitoring of thermal protection systems (TPS) on future RLVS. An embedded wireless microsensor suite is being designed to allow rapid subsurface TPS health monitoring and damage assessment. This sensor suite will consist of both passive overlimit sensors and sensors for continuous parameter monitoring in flight. The on-board diagnostic system can be used to radio in maintenance requirements before landing and the data could also be used to assist in design validation for X-vehicles. For a 3rd generation vehicle, wireless diagnostics should be at a stage of technical development that will allow use for intelligent feedback systems for guidance and navigation control applications and can also serve as feedback for TPS that can intelligently adapt to its environment.

Pallix, Joan↗

NASA NTRS2013

Structural health monitoring system/method using electroactive polymer fibers

A method for monitoring the structural health of a structure of interest by coupling one or more electroactive polymer fibers to the structure and monitoring the electroactive responses of the polymer fiber(s). Load changes that are experienced by the structure cause changes in the baseline responses of the polymer fiber(s). A system for monitoring the structural health of the structure is also provided.

Scott-Carnell, Lisa A.↗

NASA NTRS2019

Health Monitoring in Small Satellite Design

Presentation/lecture on systems health monitoring (diagnostics, prognostics, decision-making) with applications to the design phase of small satellite components and systems.

Okolo, Wendy A.↗

NASA NTRS1997

Automated Internet-Based Control of Spacecraft Groundstations: Beacon-Based Health Monitoring Concept

This report serves as an update about the activities of Stanford University's Space Systems Development Laboratory (SSDL) in their beacon-based health monitoring experiment. Section 1 describes the goals of the project and the organization of the team. Section 2 provides an overview of the major components of the system, describing the general approach of automated health monitoring and the beacon signal relay. It also provides background about the SAPPHIRE spacecraft and ASSET operations system, which will be used for the experiment. Specific details about implementation and status of each element of the experiment are found in Section 3. Section 4 describes the experiment and future work, and references are contained in Section 5.

Cantwell, Brian↗

NASA NTRS2000

A Future Vision of a Data Acquisition: Distributed Sensing, Processing, and Health Monitoring

This paper presents a vision fo a highly enhanced data acquisition and health monitoring system at NASA Stennis Space Center (SSC) rocket engine test facility. This vision includes the use of advanced processing capabilities in conjunction with highly autonomous distributed sensing and intelligence, to monitor and evaluate the health of data in the context of it's associated process. This method is expected to significantly reduce data acquisitions costs and improve system reliability. A Universal Signal Conditioning Amplifier (USCA) based system, under development at Kennedy Space Center, is being evaluated for adaptation to the SSC testing infrastructure. Kennedy's USCA architecture offers many advantages including flexible and auto-configuring data acquisition with improved calibration and verifiability. Possible enhancements at SSC may include multiplexing the distributed USCAs to reduce per channel cost, and the use of IEEE-485 to Allen-Bradley Control Net Gateways for interfacing with the resident control systems.

Figueroa, Fernando↗