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Virtual Sensor Test Instrumentation

Virtual Sensor Test Instrumentation is based on the concept of smart sensor technology for testing with intelligence needed to perform sell-diagnosis of health, and to participate in a hierarchy of health determination at sensor, process, and system levels. A virtual sensor test instrumentation consists of five elements: (1) a common sensor interface, (2) microprocessor, (3) wireless interface, (4) signal conditioning and ADC/DAC (analog-to-digital conversion/ digital-to-analog conversion), and (5) onboard EEPROM (electrically erasable programmable read-only memory) for metadata storage and executable software to create powerful, scalable, reconfigurable, and reliable embedded and distributed test instruments. In order to maximize the efficient data conversion through the smart sensor node, plug-and-play functionality is required to interface with traditional sensors to enhance their identity and capabilities for data processing and communications. Virtual sensor test instrumentation can be accessible wirelessly via a Network Capable Application Processor (NCAP) or a Smart Transducer Interlace Module (STIM) that may be managed under real-time rule engines for mission-critical applications. The transducer senses the physical quantity being measured and converts it into an electrical signal. The signal is fed to an A/D converter, and is ready for use by the processor to execute functional transformation based on the sensor characteristics stored in a Transducer Electronic Data Sheet (TEDS). Virtual sensor test instrumentation is built upon an open-system architecture with standardized protocol modules/stacks to interface with industry standards and commonly used software. One major benefit for deploying the virtual sensor test instrumentation is the ability, through a plug-and-play common interface, to convert raw sensor data in either analog or digital form, to an IEEE 1451 standard-based smart sensor, which has instructions to program sensors for a wide variety of functions. The sensor data is processed in a distributed fashion across the network, providing a large pool of resources in real time to meet stringent latency requirements.

Wang, Roy↗

Fiber Bragg Grating Sensor System for Monitoring Smart Composite Aerospace Structures

Lightweight, electromagnetic interference (EMI) immune, fiber-optic, sensor- based structural health monitoring (SHM) will play an increasing role in aerospace structures ranging from aircraft wings to jet engine vanes. Fiber Bragg Grating (FBG) sensors for SHM include advanced signal processing, system and damage identification, and location and quantification algorithms. Potentially, the solution could be developed into an autonomous onboard system to inspect and perform non-destructive evaluation and SHM. A novel method has been developed to massively multiplex FBG sensors, supported by a parallel processing interrogator, which enables high sampling rates combined with highly distributed sensing (up to 96 sensors per system). The interrogation system comprises several subsystems. A broadband optical source subsystem (BOSS) and routing and interface module (RIM) send light from the interrogation system to a composite embedded FBG sensor matrix, which returns measurand-dependent wavelengths back to the interrogation system for measurement with subpicometer resolution. In particular, the returned wavelengths are channeled by the RIM to a photonic signal processing subsystem based on powerful optical chips, then passed through an optoelectronic interface to an analog post-detection electronics subsystem, digital post-detection electronics subsystem, and finally via a data interface to a computer. A range of composite structures has been fabricated with FBGs embedded. Stress tensile, bending, and dynamic strain tests were performed. The experimental work proved that the FBG sensors have a good level of accuracy in measuring the static response of the tested composite coupons (down to submicrostrain levels), the capability to detect and monitor dynamic loads, and the ability to detect defects in composites by a variety of methods including monitoring the decay time under different dynamic loading conditions. In addition to quasi-static and dynamic load monitoring, the system can capture acoustic emission events that can be a prelude to structural failure, as well as piezoactuator-induced ultrasonic Lamb-waves-based techniques as a basis for damage detection.

Moslehi, Behzad↗

Distribution Transformer Health Monitoring using Smart Meter Data

The distribution electric grid has become a highly complex and intelligent network with changing load and customer types. This has generated unprecedented challenges and opportunities for utility companies–opportunities especially in the area of asset health/performance management. Moreover, several utilities are increasingly moving from the traditional reactive and time-based asset monitoring approach to a more proactive condition based method. However, this needs to be done in a low-cost and efficient manner. Here, this paper explores how existing sensor infrastructure such as smart meters can be utilized to provide utility operators with more visibility into the health and operation of their assets. The paper focuses primarily on service transformers.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Intelligent Wireless Sensor Networks for System Health Monitoring

Wireless sensor networks (WSN) based on the IEEE 802.15.4 Personal Area Network (PAN) standard are finding increasing use in the home automation and emerging smart energy markets. The network and application layers, based on the ZigBee 2007 Standard, provide a convenient framework for component-based software that supports customer solutions from multiple vendors. WSNs provide the inherent fault tolerance required for aerospace applications. The Discovery and Systems Health Group at NASA Ames Research Center has been developing WSN technology for use aboard aircraft and spacecraft for System Health Monitoring of structures and life support systems using funding from the NASA Engineering and Safety Center and Exploration Technology Development and Demonstration Program. This technology provides key advantages for low-power, low-cost ancillary sensing systems particularly across pressure interfaces and in areas where it is difficult to run wires. Intelligence for sensor networks could be defined as the capability of forming dynamic sensor networks, allowing high-level application software to identify and address any sensor that joined the network without the use of any centralized database defining the sensors characteristics. The IEEE 1451 Standard defines methods for the management of intelligent sensor systems and the IEEE 1451.4 section defines Transducer Electronic Datasheets (TEDS), which contain key information regarding the sensor characteristics such as name, description, serial number, calibration information and user information such as location within a vehicle. By locating the TEDS information on the wireless sensor itself and enabling access to this information base from the application software, the application can identify the sensor unambiguously and interpret and present the sensor data stream without reference to any other information. The application software is able to read the status of each sensor module, responding in real-time to changes of PAN configuration, providing the appropriate response for maintaining overall sensor system function, even when sensor modules fail or the WSN is reconfigured. The session will present the architecture and technical feasibility of creating fault-tolerant WSNs for aerospace applications based on our application of the technology to a Structural Health Monitoring testbed. The interim results of WSN development and testing including our software architecture for intelligent sensor management will be discussed in the context of the specific tradeoffs required for effective use. Initial certification measurement techniques and test results gauging WSN susceptibility to Radio Frequency interference are introduced as key challenges for technology adoption. A candidate Developmental and Flight Instrumentation implementation using intelligent sensor networks for wind tunnel and flight tests is developed as a guide to understanding key aspects of the aerospace vehicle design, test and operations life cycle.

networks↗

Physical Intelligent Sensors

This paper proposes the development of intelligent sensors as part of an integrated systems approach, i.e. one treats the sensors as a complete system with its own sensing hardware (the traditional sensor), A/D converters, processing and storage capabilities, software drivers, self-assessment algorithms, communication protocols and evolutionary methodologies that allow them to get better with time. Under a project being undertaken at the NASA s Stennis Space Center, an integrated framework is being developed for the intelligent monitoring of smart elements. These smart elements can be sensors, actuators or other devices. The immediate application is the monitoring of the rocket test stands, but the technology should be generally applicable to the Integrated Systems Health Monitoring (ISHM) vision. This paper outlines progress made in the development of intelligent sensors by describing the work done till date on Physical Intelligent Sensors (PIS). The PIS discussed here consists of a thermocouple used to read temperature in an analog form which is then converted into digital values. A microprocessor collects the sensor readings and runs numerous embedded event detection routines on the collected data and if any event is detected, it is reported, stored and sent to a remote system through an Ethernet connection. Hence the output of the PIS is data coupled with confidence factor in the reliability of the data which leads to information on the health of the sensor at all times. All protocols are consistent with IEEE 1451.X standards. This work lays the foundation for the next generation of smart devices that have embedded intelligence for distributed decision making capabilities.

Bandhil, Pavan↗

Investigation of Superluminescent Diodes for Smart Lighting Systems. Final Report

The solid-state lighting ecosystem has evolved very rapidly over the last few years, with significant improvements in the technical performance of light-emitting diodes (LEDs) and the commoditization of LED-based lighting fixtures. As the performance of conventional lighting products begins to saturate, there is growing market interest in “Lighting as a Service” applications that will leverage advanced systems to impart new functionalities to lighting and improve energy efficiency, human health, and productivity. These “Smart Lighting” systems will include high-performance light sources, specialized sensors, and dynamic controls to deliver high quality, energy efficient, color tunable lighting with customized spatial light delivery and integrated visible light communication capability. To achieve these capabilities, smart lighting systems will place greater demands on the performance of light sources. Highly efficient sources with additional functionalities compared to conventional LEDs, such as small form factor, large modulation bandwidth, and spatially coherent output beams, will be required. While laser diodes have been proposed as potential sources for smart lighting systems, they also exhibit several properties that pose challenges, such as temporal coherence, extremely high spatial coherence, and ultra-narrow linewidths. To address these issues, we propose an investigation of an alternative device architecture known as a superluminescent diode (SLD). SLDs are similar in form to ridge laser diodes and share many of the same characteristics, such as stimulated emission operation, spatially coherent output, small form factor, and the potential for large modulation bandwidth. However, the operating principle for SLDs is distinct from laser diodes in that SLDs lack a strong cavity feedback mechanism, resulting in spatially coherent but temporally incoherent light output. Thus, SLDs may address the issues with laser diodes for lighting, while simultaneously maintaining some of the desirable characteristics of both laser diodes and LEDs. The objectives of this proposal are to design, grow, and fabricate blue (450 nm) SLDs on polar c-plane and nonpolar m-plane free-standing GaN substrates, and to evaluate their potential as sources in smart lighting systems through basic device characterization and detailed investigations of their efficiency droop and modulation bandwidth. The primary scientific aims of this work are to understand the fundamental role of optical gain in the superluminescent (non-lasing) regime on efficiency droop and modulation bandwidth in III-nitride emitters and to understand the effects of higher optical gain on SLD performance by comparing polar c-plane and nonpolar m-plane SLDs. The University of New Mexico (UNM) will collaborate with Sandia National Laboratories (SNL) and the Center for Integrated Nanotechnologies to design, fabricate, grow, and characterize the SLDs. UNM will perform the design and epitaxial growth, while SNL will focus on the fabrication and device characterization. The novelty of the proposed work includes the first comprehensive theoretical and experimental investigations of efficiency droop and the first investigation of modulation bandwidth in GaN-based emitters operating in the superluminescent regime. Moreover, the comparison of c-plane and m-plane SLDs will enable the first analysis of the effects of higher optical gain on the device performance. The development of high-performance GaN-based SLDs may enable efficiency gains and improved functionality in next-generation smart lighting systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Fiber optic sensor technology - An opportunity for smart aerospace structures

Fiber optic sensors provide the opportunity for fabricating materials with internal sensors which can serve as lifetime health monitors, analogous to a central nervous system. The embedded fiber optic sensors can be interrogated by various techniques to measure internal strain, temperature, pressure, acoustic waves and other parameters indicative of structural integrity. Experiments have been conducted with composite samples with embedded sensors to measure strain using optical time domain reflectometry, modal interference and an optical phase locked loop. Fiber optic sensors have been developed to detect acoustic emission and impact damage and have been demonstrated for cure monitoring. These sensors have the potential for lifetime monitoring of structural properties, providing real time nondestructive evaluation.

Heyman, J. S.↗

Propulsion IVHM Extreme Environment Instrumentation Power IVHM

This paper presents propulsion and instrumentation power for integrated vehicle health management technologies. The topics include: 1) Propulsion IVHM Capabilities Research; 2) Projects: X-33 Post-Test Diagnostic System; 3) X-34 NITEX; 4) Advanced Health Monitoring Systems; 5) Active Vibration Monitoring System; 6) Smart Self Healing Propulsion Systems; 7) Extreme Environment Sensors; and 8) Systems Engineering and Integration.

Zakrajsek, June↗

NASA Wearable Technology CLUSTER 2013-2014 Report

Wearable technology has the potential to revolutionize the way humans interact with one another, with information, and with the electronic systems that surround them. This change can already be seen in the dramatic increase in the availability and use of wearable health and activity monitors. These devices continuously monitor the wearer using on-­‐body sensors and wireless communication. They provide feedback that can be used to improve physical health and performance. Smart watches and head mounted displays are also receiving a great deal of commercial attention, providing immediate access to information via graphical displays, as well as additional sensing features. For the purposes of the Wearable Technology CLUSTER, wearable technology is broadly defined as any electronic sensing, human interfaces, computing, or communication that is mounted on the body. Current commercially available wearable devices primarily house electronics in rigid packaging to provide protection from flexing, moisture, and other contaminants. NASA mentors are interested in this approach, but are also interested in direct integration of electronics into clothing to enable more comfortable systems. For human spaceflight, wearable technology holds a great deal of promise for significantly improving safety, efficiency, autonomy, and research capacity for the crew in space and support personnel on the ground. Specific capabilities of interest include: Continuous biomedical monitoring for research and detection of health problems. Environmental monitoring for individual exposure assessments and alarms. Activity monitoring for responsive robotics and environments. Multi-modal caution and warning using tactile, auditory, and visual alarms. Wireless, hands-free, on-demand voice communication. Mobile, on-demand access to space vehicle and robotic displays and controls. Many technical challenges must be overcome to realize these wearable technology applications. For example, to make a wearable device that is both functional and comfortable for long duration wear, developers must strive to reduce electronic mass and volume while also addressing constraints imposed by the body attachment method. Depending on the application, the device must be placed in a location that the user can see and reach, and that provides the appropriate access to air and the wearer's skin. Limited power is available from body-­‐worn batteries and heat must be managed to prevent discomfort. If the clothing is to be washed, there are additional durability and washability hurdles that traditional electronics are not designed to address. Finally, each specific capability has unique technical challenges that will likely require unique solutions. In addition to the technical challenges, development of wearable devices is made more difficult by the diversity of skills required and the historic lack of collaboration across domains. Wearable technology development requires expertise in textiles engineering, apparel design, software and computer engineering, electronic design and manufacturing, human factors engineering, and application-­‐specific fields such as acoustics, medical devices, and sensing. Knowledge from each of these domains must be integrated to create functional and comfortable devices. For this reason, the diversity of knowledge and experience represented in the Wearable Technology is critical to overcoming the fundamental challenges in the field.

Simon, Cory↗

Damage Detection Response Characteristics of Open Circuit Resonant (SansEC) Sensors

The capability to assess the current or future state of the health of an aircraft to improve safety, availability, and reliability while reducing maintenance costs has been a continuous goal for decades. Many companies, commercial entities, and academic institutions have become interested in Integrated Vehicle Health Management (IVHM) and a growing effort of research into "smart" vehicle sensing systems has emerged. Methods to detect damage to aircraft materials and structures have historically relied on visual inspection during pre-flight or post-flight operations by flight and ground crews. More quantitative non-destructive investigations with various instruments and sensors have traditionally been performed when the aircraft is out of operational service during major scheduled maintenance. Through the use of reliable sensors coupled with data monitoring, data mining, and data analysis techniques, the health state of a vehicle can be detected in-situ. NASA Langley Research Center (LaRC) is developing a composite aircraft skin damage detection method and system based on open circuit SansEC (Sans Electric Connection) sensor technology. Composite materials are increasingly used in modern aircraft for reducing weight, improving fuel efficiency, and enhancing the overall design, performance, and manufacturability of airborne vehicles. Materials such as fiberglass reinforced composites (FRC) and carbon-fiber-reinforced polymers (CFRP) are being used to great advantage in airframes, wings, engine nacelles, turbine blades, fairings, fuselage structures, empennage structures, control surfaces and aircraft skins. SansEC sensor technology is a new technical framework for designing, powering, and interrogating sensors to detect various types of damage in composite materials. The source cause of the in-service damage (lightning strike, impact damage, material fatigue, etc.) to the aircraft composite is not relevant. The sensor will detect damage independent of the cause. Damage in composite material is generally associated with a localized change in material permittivity and/or conductivity. These changes are sensed using SansEC. The unique electrical signatures (amplitude, frequency, bandwidth, and phase) are used for damage detection and diagnosis. An operational system and method would incorporate a SansEC sensor array on select areas of the aircraft exterior surfaces to form a "Smart skin" sensing surface. In this paper a new method and system for aircraft in-situ damage detection and diagnosis is presented. Experimental test results on seeded fault damage coupons and computational modeling simulation results are presented. NASA LaRC has demonstrated with individual sensors that SansEC sensors can be effectively used for in-situ composite damage detection of delamination, voids, fractures, and rips. Keywords: Damage Detection, Composites, Integrated Vehicle Health Monitoring (IVHM), Aviation Safety, SansEC Sensors

Dudley, Kenneth L.↗

Damage Detection Sensor System for Aerospace and Multiple Applications

The damage detection sensory system is an intelligent damage detection ‘skin’ that can be embedded into rigid or flexible structures, providing a lightweight capability for in-situ health monitoring for applications such as spacecraft, expandable or inflatable structures, extravehicular activities (EVA) suits, smart wearables, and other applications where diagnostic impact damage monitoring might be critical. The sensor systems can be customized for detecting location, damage size, and depth, with velocity options and can be designed for particular environments for monitoring of impact or physical damage to a structure. The operation of the sensor detection system is currently based on the use of parallel conductive traces placed on a firm or flexible surface. Several detection layers can be implemented, where alternate layers are arranged in orthogonal direction with respect to the adjacent layers allowing for location and depth calculations. Increased flexibility of the damage detection sensor system designs will also be introduced.

Williams, M.↗

NASA Prototype All Composite Tank Cryogenic Pressure Tests to Failure with Structural Health Monitoring

This Paper will describe the results of pressurization to failure of 100 gallon composite tanks using liquid nitrogen. Advanced methods of health monitoring will be compared as will the experimental data to a finite element model. The testing is wholly under NASA including unique PZT (Lead Zirconate Titanate) based active vibration technology. Other technologies include fiber optics strain based systems including NASA AFRC technology, Acoustic Emission, Acellent smart sensor, this work is expected to lead to a practical in-Sutu system for composite tanks.

tanks↗

Kennedy Space Center's Partnership with Graftel Incorporated

NASA Kennedy Space Center (KSC) has recently partnered with Graftel Incorporated under an exclusive license agreement for the manufacture and sale of the Smart Current Signature Sensor. The Smart Current Signature Sensor and software were designed and developed to be utilized on any application using solenoid valves. The system monitors the electrical and mechanical health of solenoids by comparing the electrical current profile of each solenoid actuation to a typical current profile and reporting deviation from its learned behavior. The objective of this partnership with Graftel is for them to develop the technology into a hand-held testing device for their customer base in the Nuclear Power Industry. The device will be used to perform diagnostic testing on electromechanical valves used in Nuclear Power plants. Initially, Graftel plans to have working units within the first year of license in order to show customers and allow them to put purchase requests into their next year's budget. The subject technology under discussion was commercialized by the Kennedy Space Center Technology Programs and Partnerships Office, which patented the technology and licensed it to Graftel, Inc., a company providing support, instrumentation, and calibration services to the nuclear community and private sector for over 10 years. For the nuclear power industry, Graftel designs, manufacturers, and calibrates a full line of testing instrumentation. Grafters smart sensors have been in use in the United States since 1993 and have proved to decrease set-up time and test durations. The project was funded by Non-Destructive Engineering, and it is felt that this technology will have more emphasis on future vehicles. Graftel plans to market the Current Signature Sensor to the Electric Utility industry. Graftel currently supplies product and services to the Nuclear Power Industry in the United States as well as internationally. Product and services sold are used in non-destructive testing for valves, penetrations and other applications. Graftel also supplies testing services to an industrial customer base. The customer base includes 90 percent of the U.S. Nuclear plants and plants in Brazil, Europe, and Asia. Graftel works internationally with two representative groups and employees and has ten people at the principle location and a group of contract engineers around the country.

Dunn, Carol Anne↗

Smart and Intelligent Sensors

John C. Stennis Space Center (SSC) provides rocket engine propulsion testing for NASA's space programs. Since the development of the Space Shuttle, every Space Shuttle Main Engine (SSME) has undergone acceptance testing at SSC before going to Kennedy Space Center (KSC) for integration into the Space Shuttle. The SSME is a large cryogenic rocket engine that uses Liquid Hydrogen (LH2) as the fuel. As NASA moves to the new ARES V launch system, the main engines on the new vehicle, as well as the upper stage engine, are currently base lined to be cryogenic rocket engines that will also use LH2. The main rocket engines for the ARES V will be larger than the SSME, while the upper stage engine will be approximately half that size. As a result, significant quantities of hydrogen will be required during the development, testing, and operation of these rocket engines.Better approaches are needed to simplify sensor integration and help reduce life-cycle costs. 1.Smarter sensors. Sensor integration should be a matter of "plug-and-play" making sensors easier to add to a system. Sensors that implement new standards can help address this problem; for example, IEEE STD 1451.4 defines transducer electronic data sheet (TEDS) templates for commonly used sensors such as bridge elements and thermocouples. When a 1451.4 compliant smart sensor is connected to a system that can read the TEDS memory, all information needed to configure the data acquisition system can be uploaded. This reduces the amount of labor required and helps minimize configuration errors. 2.Intelligent sensors. Data received from a sensor be scaled, linearized; and converted to engineering units. Methods to reduce sensor processing overhead at the application node are needed. Smart sensors using low-cost microprocessors with integral data acquisition and communication support offer the means to add these capabilities. Once a processor is embedded, other features can be added; for example, intelligent sensors can make a health assessment to inform the data acquisition client when sensor performance is suspect. 3.Distributed sample synchronization. Networks of sensors require new ways for synchronizing samples. Standards that address the distributed timing problem (for example, IEEE STD 1588) provide the means to aggregate samples from many distributed smart sensors with sub-microsecond accuracy. 4. Reduction in interconnect. Alternative means are needed to reduce the frequent problems associated with cabling and connectors. Wireless technologies offer the promise of reducing interconnects and simultaneously making it easy to quickly add a sensor to a system.

Lansaw, John↗

Wearable Health Monitoring Systems

The shrinking size and weight of electronic circuitry has given rise to a new generation of smart clothing that enables biological data to be measured and transmitted. As the variation in the number and type of deployable devices and sensors increases, technology must allow their seamless integration so they can be electrically powered, operated, and recharged over a digital pathway. Nyx Illuminated Clothing Company has developed a lightweight health monitoring system that integrates medical sensors, electrodes, electrical connections, circuits, and a power supply into a single wearable assembly. The system is comfortable, bendable in three dimensions, durable, waterproof, and washable. The innovation will allow astronaut health monitoring in a variety of real-time scenarios, with data stored in digital memory for later use in a medical database. Potential commercial uses are numerous, as the technology enables medical personnel to noninvasively monitor patient vital signs in a multitude of health care settings and applications.

Bell, John↗

Hybrid Piezoelectric/Fiber-Optic Sensor Sheets

Hybrid piezoelectric/fiber-optic (HyPFO) sensor sheets are undergoing development. They are intended for use in nondestructive evaluation and long-term monitoring of the integrity of diverse structures, including aerospace, aeronautical, automotive, and large stationary ones. It is anticipated that the further development and subsequent commercialization of the HyPFO sensor systems will lead to economic benefits in the form of increased safety, reduction of life-cycle costs through real-time structural monitoring, increased structural reliability, reduction of maintenance costs, and increased readiness for service. The concept of a HyPFO sensor sheet is a generalization of the concept of a SMART Layer(TradeMark), which is a patented device that comprises a thin dielectric film containing an embedded network of distributed piezoelectric actuator/sensors. Such a device can be mounted on the surface of a metallic structure or embedded inside a composite-material structure during fabrication of the structure. There is has been substantial interest in incorporating sensors other than piezoelectric ones into SMART Layer(TradeMark) networks: in particular, because of the popularity of the use of fiber-optic sensors for monitoring the "health" of structures in recent years, it was decided to incorporate fiber-optic sensors, giving rise to the concept of HyPFO devices.

Lin, Mark↗

Smart Networked Elements in Support of ISHM

At the core of ISHM is the ability to extract information and knowledge from raw data. Conventional data acquisition systems sample and convert physical measurements to engineering units, which higher-level systems use to derive health and information about processes and systems. Although health management is essential at the top level, there are considerable advantages to implementing health-related functions at the sensor level. The distribution of processing to lower levels reduces bandwidth requirements, enhances data fusion, and improves the resolution for detection and isolation of failures in a system, subsystem, component, or process. The Smart Networked Element (SNE) has been developed to implement intelligent functions and algorithms at the sensor level in support of ISHM.

Oostdyk, Rebecca↗