SBIR-STTR Award

We propose SHM technology integrated with multi-scale, multi-physics analysis to demonstrate the technical feasibility of, an integrated hybrid SHM system that utilizes networks of fiber optic (FO) sensors and piezoelectric (PZT) actuators to monitor loads and detect damage state on both non-rotating and rotating structural components for the V-22 platform. In Phase I, a prototype of the hybrid SHM system will be demonstrated to monitor actual environment loading history and track damage states (and evolution of such damage) on a metallic and composite coupon. The hardware/software for data acquisition of the hybrid SHM system is proposed to be small/lightweight, packaged as a single unit and eventually integrated with the current V-22 Vibration/Structural Life and Engine Diagnostics (VSLED) system. An ultrasonic based wireless SHM system is proposed by ASC team to detect damages in structural components which can be easily integrated to current V-22s VSLED system. The proposed approach adds

Benefit:
This effort offers the US Navy and providers of engineering services a real-time/ultra-rapid structural health monitoring system to enable zero maintenance and improved life prediction of V22 rotating and non-rotating components. This technology will overcome the limitations of conventional, costly, time-consuming, operator dependent, off-line down-time non-destructive examination of large area structures. Once the methodology is verified and incorporated into a working model, a prototype portable, compact, mildly invasive SHM system can be manufactured and tested on real air vehicle components during operation. The demonstrated/verified SHM technology can be applied fleet-wide to military rotorcraft/aircraft/spacecraft and commercial aircraft alike. Verified detection and tracking of structural damage as well as monitoring the actual environment and loading conditions the structure experiences will lead to improved reliability of critical life limited structures, reduced operating cost, and reduced maintenance cost by replacing the part when it needs to be replaced based on condition. When fully matured, the developed SHM product will be integrated with the aircraft and will be capable to sense/transmit data on board for post processing and provide real time event and damage detection.

Keywords:
3) Integrated H/S, 3) Integrated H/S, 1) Hybrid sensor system, 6) Event type and detection, 5) Damage type and detection, 2) DPS, and 8) Probability of Detection (POD), 7) Data management, 4) Light weight/compact DAQ

There is no single Structural Heath Monitoring (SHM) system available today which is capable to perform complete, on board (i.e. real-time) and validated structural evaluation of e.g. manned craft extensible to unmanned vessels of interest to the US Navy. This deficiency is related to both extrinsic factors including the variable operational and loading conditions, complex geometries/materials, synchronous activation of several damage mechanisms, as well as intrinsic ones including limitations in the hardware/software tools used and inability to define clearly what could be a measurable parameter to reliably describe evolving operational states. The primary objective of this program is therefore to offer the US Navy a Health Monitoring System (HMS) to enable real-time/ultra-rapid recording, diagnostics and prognostic capabilities to identify maintenance/repair issues as well as to provide post-mission forensic analysis and playback of related data. The proposed technology has the potential to overcome the limitations of current costly, time-consuming, operator dependent, and downtime-requiring HMS approaches. The demonstrated/verified HMS technology can be applied fleet-wide to military and commercial applications. In this program the research and development team will focus in detecting and monitoring fatigue events and associated damage causes (i.e. cracks, debondings, delaminations etc.) in both metallic and composite structural components. The team will identify and analyze different fatigue types including quasi-static harmonic, random, low and high cycle fatigue2. The main technical objective of this Phase II program will be to minimize code development and associated component integration to increase the HMS TRL from 4 to 7 so that it can be implemented in actual ship structural components. The team will use its existing SHM system and various legacy models to demonstrate the capabilities to detect fatigue events. The team will also demonstrate both physics-based and statistical/probabilistic models to demonstrate prognostic capabilities. The proposed design for the data acquisition system will be small and lightweight, packaged as a single unit and eventually integrated with other combatant craft systems. The technical objective that will be developed will include detail description of the algorithms developed to detect key events and monitor damage. The proposed HMS will be capable of accommodating multiple sensing systems namely strain gauges, fiber optics and piezoelectric transducers. The diagnostic and prognostic capable HMS system will be performing data analysis at the edge followed by prognostics by leveraging verified models. The final objective of this Phase II program will be to demonstrate the developed capabilities f on an actual ship under operation.

Benefit:
The primary objective of this program is to offer the US Navy and providers of engineering services a near-real-time/ultra-rapid Health Monitoring System (HMS) to enable recording, diagnostics and prognostic capabilities to identify maintenance/repair issues as well as to provide post-mission forensic analysis and playback of related data. The effort will also benefit the program with a reliable and robust integrated diagnostic hardware/software SHM system that will be implemented when demonstrating the capabilities. Performed analysis will aid NAVSEA to understand the reliability and access the remaining useful life (RUL) of selected structural component. Finally the effort will benefit NAVSEA to implement developed prototype on a full-scale testing system. The program will target selected government agencies and major companies that would benefit from the technology whether applied to naval ships, aircraft, or automobiles. With regard to the US Navy, multiple programs would benefit from the proposed technology. The identification and interaction with specific programs/PEOs would be carried out with the guidance of the TPOC and TechOpps. Similar programs will be fashioned and implemented in parallel for the Army, Air Force and Marine Corps. Regarding major OEMs, the logical choice for outreach would be Lockheed Martin (LM) and Northrop Grumman (NG). In both cases, internal corporate SBIR advocates, senior engineers and Business Development officers will be identified and informed about the capabilities and benefits of the technology. Primary target for LM would be its partner, Fincantieri-Marinette Marine (Cengiz Atam POC). Outreach to NG will focus on personnel and programs related Ingles Shipyard. Ideally introductions will be established by the TPOC and Navy PEOs. This process would be shepherded by AlphaSTAR, in conjunction with TechOpps, to other divisions within LM and NG that address aircraft, rotorcraft, UAVs, and USVs. Primary FEA solvers (Dassault, ANSYS, MSC, Siemens) will be contacted and informed how their specific tools could be used to support analysis of platform health. The program will also identify key personnel and organizations that are open to discussions regarding matching funds for Phase II plus or Phase III research. This latter effort will involve developing a case by case business model for each outreach effort that will show a clear benefit and return on investment for the participant.

Keywords:
(1) Diagnostic-Prognostic SHM, (6) Remaining Use-ful Life, (7) Condition Based Maintenance (CBM), (4) Digital Twin Data Driven Analysis, (5) Machine Learning/Artificial Intelligence, (2) Multi Modal Big Data Processing and Data Discovery, (3) NDI Sensor Data-fusion and Cross Verification, (8) Fatigue Crack Monitoring