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All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Smart Sensors' Role in Integrated System Health Management

During the last decade, there has been a major effort in the aerospace industry to reduce the cost per pond of payload and become competitive in the international market. Competition from Europe, Japan, and China has reduced this cost to almost a third from 1990 to 2000. This cost has leveled in recent years to an average price of around $12,000/pound of payload. One of NASA's goals is to promote the development of technologies to reduce this cost by a factor of 10 or more Exploration of space, specially manned exploration missions, involves very complex launch and flight vehicles, associated ground support systems, and extensive human support during all phases of the mission. When considering the Space Shuttle Program, we can see that vehicle and ground support systems' processing, operation, and maintenance represent a large percentage of the program cost and time. Reducing operating, processing and maintenance costs will greatly reduce the cost of Exploration programs. The Integrated System Health Management (ISHM) concept is one of the technologies that will help reduce these operating, processing and maintenance costs. ISHM is an integrated health monitoring system applicable to both flight and ground systems. It automatically and autonomously acquires information from sensors and actuators and processes that information using the ISHM-embedded knowledge. As a result, it establishes the health of the system based on the acquired information and its prior knowledge. When this concept is fully implemented, ISHM systems shall be able to perform failure prediction and remediation before actual hard failures occurs, preventing its costly consequences. Data sources, sensors, and their associated data acquisition systems, constitute the foundation of the system. A smart sensing architecture is required to support the acquisition of reliable, high quality data, required by the ISHM. A thorough definition of the smart sensor architectures, their embedded diagnostic agents, and communication protocols need to be established and standardized to allow the embedding and exchange of health information among sensors and ISHM. This workshop is aimed to foster the exchange of ideas and lessons learned between government, industry and academia to aid in the establishment of ISHM (and smart sensors) standards and guidelines as well as to identify present technology gaps that will have to be overcome to successfully achieve this goal.

Perotti, Jose M.↗
NASA NTRS1991

Fiber optic and laser sensors VIII; Proceedings of the Meeting, San Jose, CA, Sept. 17-19, 1990

This issue presents topics on the advances in fiber-optic sensor technology, fiber-optic gyroscope, fiber-optic position and pressure sensors, fiber-optic magnetic and temperature sensors, and generic fiber-optic sensors. Papers included are on a novel analog phase tracker for interferometric fiber-optic sensor applications, recent development status of fiber-optic sensors in China, the magnetic-field sensitivity of depolarized fiber-optic gyros, a depolarized fiber-optic gyro for future tactical applications, fiber-optic position transducers for aircraft controls, and a metal embedded optical-fiber pressure sensor. Attention is also given to a fiber-optic magnetic field sensor using spectral modulation encoding, a bare-fiber temperature sensor, an interferometric fiber-optic accelerometer, improvement of specular reflection pyrometer, a theoretical analysis of two-mode elliptical-core optical fiber sensors, and a fiber probe for ring pattern.

Depaula, Ramon P.↗
NASA NTRS2005

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↗
NASA NTRS1997

A Low-Power High-Speed Smart Sensor Design for Space Exploration Missions

A low-power high-speed smart sensor system based on a large format active pixel sensor (APS) integrated with a programmable neural processor for space exploration missions is presented. The concept of building an advanced smart sensing system is demonstrated by a system-level microchip design that is composed with an APS sensor, a programmable neural processor, and an embedded microprocessor in a SOI CMOS technology. This ultra-fast smart sensor system-on-a-chip design mimics what is inherent in biological vision systems. Moreover, it is programmable and capable of performing ultra-fast machine vision processing in all levels such as image acquisition, image fusion, image analysis, scene interpretation, and control functions. The system provides about one tera-operation-per-second computing power which is a two order-of-magnitude increase over that of state-of-the-art microcomputers. Its high performance is due to massively parallel computing structures, high data throughput rates, fast learning capabilities, and advanced VLSI system-on-a-chip implementation.

Fang, Wai-Chi↗
NASA NTRS2014

Drill Embedded Nanosensors For Planetary Subsurface Exploration

We have developed a carbon nanotube (CNT) sensor for water vapor detection under Martian Conditions and the miniaturized electronics can be embedded in the drill bit for collecting sensor data and transmit it to a computer wirelessly.This capability will enable the real time measurement of ice during drilling. With this real time and in-situ measurement, subsurface ice detection can be easy, fast, precise and low cost.

Planetary exploration↗
NASA NTRS1995

Optical fiber sensors for damage analysis in aerospace materials

Under this grant, fiber optic sensors were investigated for use in the nondestructive evaluation of aging aircraft. Specifically, optical fiber sensors for detection and location of impacts on a surface, and for detection of corrosion in metals were developed. The use of neural networks was investigated for determining impact location by processing the output of a network of fiberoptic strain sensors distributed on a surface. This approach employs triangulation to determine location by comparing the arrival times at several sensors, of the acoustic signal generated by the impact. For this study, a neural network simulator running on a personal computer was used to train a network using a back-propagation algorithm. Fiber optic extrinsic Fabry-Perot interferometer (EFPI) strain sensors are attached to or embedded in the surface, so that stress waves emanating from an impact can be detected. The ability of the network to determine impact location by time-or-arrival of acoustic signals was assessed by comparing network outputs with actual experimental results using impacts on a panel instrumented with optical fiber sensors. Using the neural network to process the sensor outputs, the impact location can be inferred to centimeter range accuracy directly from the arrival time data. In addition, the network can be trained to determine impact location, regardless of material anisotropy. Results demonstrate that a back-propagation network identifies impact location for an anisotropic graphite/bismaleimide plate with the same accuracy as that for an isotropic aluminum plate. Two different approaches were investigated for the development of fiber optic sensors for corrosion detection in metals, both utilizing optical fiber sensors with metal coatings. In the first approach, an extrinsic Fabry-Perot interferometric fiber optic strain sensor was placed under tensile stress, and while in the resulting strained position, a thick coating of metal was applied. Due to an increase in the quantity of material, the sensor does not return to its original position upon removal of the applied stress, and some residual strain is maintained within the sensor element. As the metal thickness decreases due to corrosion, this strain is released, providing the sensing mechanism for corrosion detection. In the second approach, photosensitive optical fibers with long period Bragg gratings in the core were coated with metal. The Bragg gratings serve to couple core modes at discrete wavelengths to cladding modes. Since cladding modes interact with the metal coating surrounding the fiber cladding, the specific wavelengths coupled from core to cladding depend on the refractive index of the metal coating. Therefore, as the metal corrodes, the resulting change in index of the coating may be measured by measuring the change in wavelength of the coupled mode. Results demonstrate that both approaches can be successfully used to track the loss in metal coating on the optical fiber sensors due to corrosion.

Schindler, Paul↗
NASA NTRS2002

Structural Health Monitoring of Composite Wound Pressure Vessels

The increasing use of advanced composite materials in the wide range of applications including Space Structures is a great impetus to the development of smart materials. Incorporating these FBG sensors for monitoring the integrity of structures during their life cycle will provide valuable information about viability of the usage of such material. The use of these sensors by surface bonding or embedding in this composite will measure internal strain and temperature, and hence the integrity of the assembled engineering structures. This paper focuses on such a structure, called a composite wound pressure vessel. This vessel was fabricated from the composite material: TRH50 (a Mitsubishi carbon fiber with a 710-ksi tensile strength and a 37 Msi modulus) impregnated with an epoxy resin from NEWPORT composites (WDE-3D-1). This epoxy resin in water dispersed system without any solvents and it cures in the 240-310 degrees F range. This is a toughened resin system specifically designed for pressure applications. These materials are a natural fit for fiber sensors since the polyimide outer buffer coating of fiber can be integrated into the polymer matrix of the composite material with negligible residual stress. The tank was wound with two helical patterns and 4 hoop wraps. The order of winding is: two hoops, two helical and two hoops. The wall thickness of the composite should be about 80 mil or less. The tank should burst near 3,000 psi or less. We can measure the actual wall thickness by ultrasonic or we can burst the tank and measure the pieces. Figure 1 shows a cylinder fabricated out of carbon-epoxy composite material. The strain in different directions is measured with a surface bonded fiber Bragg gratings and with embedded fiber Bragg gratings as the cylinder is pressurized to burst pressures. Figure 2 shows the strain as a function of pressure of carbon-epoxy cylinder as it is pressurized with water. Strain is measured in different directions by multiple gratings oriented in both axial and hoops directions.

Joseph Grant↗
NASA NTRS1994

Shape Control of Plates with Piezo Actuators and Collocated Position/Rate Sensors

This paper treats the control problem of shaping the surface deformation of a circular plate using embedded piezo-electric actuator and collocated rate sensors. An explicit Linear Quadratic Gaussian (LQG) optimizer stability augmentation compensator is derived as well as the optimal feed-forward control. Corresponding performance evaluation formulas are also derived.

Balakrishnan, A. V.↗
NASA NTRS1994

Shape Control of Plates with Piezo Actuators and Collocated Position/Rate Sensors

This paper treats the control problem of shaping the surface deformation of a circular plate using embedded piezo-electric actuators and collocated rate sensors. An explicit Linear Quadratic Gaussian (LQG) optimizer stability augmentation compensator is derived as well as the optimal feed-forward control. Corresponding performance evaluation formulas are also derived.

Balakrishnan, A. V.↗
NASA NTRS1990

Infrared response from metallic particles embedded in a single-crystal Si matrix - The layered internal photoemission sensor

Infrared radiation at wavelengths of 1-2 microns has been detected in a new device labeled the layered internal photoemission sensor. The device structure, which is grown by molecular beam epitaxy, incorporates epitaxial CoSi2 particles with dimensions of 10-50 nm. Radiation absorbed by these particles photoexcites carriers into a surrounding single-crystal silicon matrix. A peak quantum efficiency of 1.3 percent is measured, which is approximately six times higher than in planar CoSi2 Schottky diodes with 5-nm silicide thickness.

Fathauer, R. W.↗
NASA NTRS2005

LC Circuits for Diagnosing Embedded Piezoelectric Devices

A recently invented method of nonintrusively detecting faults in piezoelectric devices involves measurement of the resonance frequencies of inductor capacitor (LC) resonant circuits. The method is intended especially to enable diagnosis of piezoelectric sensors, actuators, and sensor/actuators that are embedded in structures and/or are components of multilayer composite material structures.

Chattin, Richard L.↗
NASA NTRS2018

An Efficient Inverse Finite Element Method for Shape and Stress Sensing of Laminated Composite and Sandwich Plates and Shells

The inverse Finite Element Method (iFEM) is a revolutionary methodology for real-time reconstruction of full-field structural displacements and stresses in structures that are instrumented with strain sensors. This inverse problem is commonly referred to as shape and stress sensing, which is well-recognized as an enabling technology for structural health monitoring systems. In this study, an improved iFEM formulation is proposed for shape and stress sensing of laminated composite and sandwich plates and shells. The formulation includes the kinematics of a shear deformation plate theory known as Refined Zigzag Theory (RZT) as its baseline. The present iFEM formulation is based upon the minimization of a weighted-least-squares functional that uses the complete set of section strains of RZT. The improved iFEM methodology is applicable for shape and stress sensing of thin and moderately thick plate and shell structures involving a relatively small number of strain gauges. The main advantage of the current formulation is that highly accurate through-the-thickness distributions of displacements, strains, and stresses are attainable using an element based on simple C0-continuous displacement interpolation functions. A three-node inverseshell element, named i3-RZT, is developed. Two example problems are examined in detail: (1) a simply supported rectangular laminated composite plate and (2) a wedge structure with a hole near one of the clamped ends. For both problems, the experimental strain data are generated numerically by the direct finite element analysis using high-fidelity discretizations. These strains are then regarded as the experimental strains obtained from surface mounted strain gauges or embedded fiber Bragg grating (FBG) sensors. The numerical results demonstrate the superior capability and potential applicability of the i3- RZT/iFEM methodology for performing accurate shape and stress sensing of complex composite structures.

Kefal, Adnan↗
NASA NTRS2008

Flexible Structural-Health-Monitoring Sheets

A generic design for a type of flexible structural-health-monitoring sheet with multiple sensor/actuator types and a method of manufacturing such sheets has been developed. A sheet of this type contains an array of sensing and/or actuation elements, associated wires, and any other associated circuit elements incorporated into various flexible layers on a thin, flexible substrate. The sheet can be affixed to a structure so that the array of sensing and/or actuation elements can be used to analyze the structure in accordance with structural-health-monitoring techniques. Alternatively, the sheet can be designed to be incorporated into the body of the structure, especially if the structure is made of a composite material. Customarily, structural-health monitoring is accomplished by use of sensors and actuators arrayed at various locations on a structure. In contrast, a sheet of the present type can contain an entire sensor/actuator array, making it unnecessary to install each sensor and actuator individually on or in a structure. Sensors of different types such as piezoelectric and fiber-optic can be embedded in the sheet to form a hybrid sensor network. Similarly, the traces for electric communication can be deposited on one or two layers as required, and an entirely separate layer can be employed to shield the sensor elements and traces.

Qing, Xinlin↗
NASA NTRS1995

Method and apparatus for measuring temperatures in fabrics and flexible thermal insulations

A temperature sensor uses a type R thermocouple wire element in a ceramic sheath to sense temperatures up to 3,200 deg F., and is particularly suitable for flexible insulations. The sensor includes a thermocouple wire embedded in a sheath having two sections disposed at right angles to each other. The junction of the thermocouple is located at one end of one of the sections and the lead wires extend from the other section. The section which includes the junction is secured to a flexible surface with ceramic cement.

Kourtides, Demetrius A.↗
NASA NTRS2001

Using Neural Networks in Decision Making for a Reconfigurable Electro Mechanical Actuator (EMA)

The objectives of this project were to demonstrate applicability and advantages of a neural network approach for evaluating the performance of an electro-mechanical actuator (EMA). The EMA in question was intended for the X-37 Advanced Technology Vehicle. It will have redundant components for safety and reliability. The neural networks for this application are to monitor the operation of the redundant electronics that control the actuator in real time and decide on the operating configuration. The system we proposed consists of the actuator, sensors, control circuitry and dedicated (embedded) processors. The main purpose of the study was to develop suitable hardware and neural network capable of allowing real time reconfiguration decisions to be made. This approach was to be compared to other methods such as fuzzy logic and knowledge based systems considered for the same application. Over the course of the project a more general objective was the identification of the other neural network applications and the education of interested NASA personnel on the topic of Neural Networks.

Latino, Carl D.↗
NASA NTRSDate not supplied

TPSAS-NF1676L-27788-DND

NASA Advanced Composites Project (ACP) - Reduce timeline required for development and certification of advanced composite structures by 30 percent Manufacturing Defects - Detrimentally affect quality of parts - Lead to higher cost and cause significant delay Developed guided wave-based technique for detection of manufacturing defects in carbon fiber reinforced polymer (CFRP) composites Extended guided wave - based technique for in-situcure monitoring of composites using high temperature piezoelectric transducers Incorporated embedded fiber Bragg grating (FBG) sensors for guided wave sensing during cure.

Tyler B Hudson↗
NASA NTRS2003

A Framework for Intelligent Rocket Test Facilities with Smart Sensors

A long-term center goal at the John C. Stennis Space Center (SSC) is the formulation and implementation of a framework for an Intelligent Rocket Test Facility (IRTF), which incorporates distributed smart sensor elements. The IRTF is to provide reliable, high-confident measurements. Specific objectives include: 1. Definition of a framework and architecture that supports implementation of highly autonomous methodologies founded on basic physical principles and embedded knowledge. 2. Modeling of autonomous sensors and processes as self-sufficient, evolutionary elements. 3. Development of appropriate communications protocols to enable the complex interactions that must take place to allow timely and high-quality flow of of information among all the autonomous elements of the system. 4. Development of lab-scale prototypes of key system elements. Though our application is next-generation rocket test facilities, applications for the approach are much wider and include monitoring of shuttle launch operations, air and spacecraft operations and health monitoring, and other large-scale industrial system operations such as found in processing and manufacturing plans. Elements of prototype IRTF have been implemented in preparation for advanced development and validation using rocket test stand facilities as SSC. This work has identified issues that are important to further development of complex network and should be of interest to other working with sensor networks.

Figueroa, Fernando↗
NASA NTRSDate not supplied

Assured Performance of Additively Manufactured and Composite Parts through Embedded Sensing and Life Cycle Monitoring: An Enabler for in-Space Use

Lightweight composites have a range of applications in aerospace where operational costs and mission (payload) capabilities depend significantly on component weight. Additive manufacturing of the composite components expands the design and production space allowing for complex part geometries. A limiting factor to the utilization of the composites in high value applications, such as aerospace generally, and particularly for in-space applications, is the ability to determine the part quality both at the time of production as well as through the lifetime of the component. Work on monitoring the performance of additively manufactured and autoclaved composites that encompasses the design and manufacturing as well as use in operational environments will be discussed. Optimization of the component design for manufacturability, the use of process monitoring sensors during the component build as well as embedding of carbon nanotube yarn based structural sensors will be described.

Additive Manufacturing↗