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At least 289 records · Page 16

Evaluation of sensor placement algorithms for on-orbit identification of space platforms

Anticipating the construction of the international space station, on-orbit modal identification of space platforms through optimally placed accelerometers is an area of recent activity. Unwanted vibrations in the platform could affect the results of experiments which are planned. Therefore, it is important that sensors (accelerometers) be strategically placed to identify the amount and extent of these unwanted vibrations, and to validate the mathematical models used to predict the loads and dynamic response. Due to cost, installation, and data management issues, only a limited number of sensors will be available for placement. This work evaluates and compares four representative sensor placement algorithms for modal identification. Most of the sensor placement work to date has employed only numerical simulations for comparison. This work uses experimental data from a fully-instrumented truss structure which was one of a series of structures designed for research in dynamic scale model ground testing of large space structures at NASA Langley Research Center. Results from this comparison show that for this cantilevered structure, the algorithm based on Guyan reduction is rated slightly better than that based on Effective Independence.

Glassburn, Robin S.↗

Using Micro-Synchrophasor Data for Advanced Distribution Grid Planning and Operations Analysis

This report reviews the potential for distribution-grid phase-angle data that will be available from new micro-synchrophasors (µPMUs) to be utilized in existing distribution-grid planning and operations analysis. This data could augment the current diagnostic capabilities of grid analysis software, used in both planning and operations for applications such as fault location, and provide data for more accurate modeling of the distribution system. µPMUs are new distribution-grid sensors that will advance measurement and diagnostic capabilities and provide improved visibility of the distribution grid, enabling analysis of the grid’s increasingly complex loads that include features such as large volumes of distributed generation. Large volumes of DG leads to concerns on continued reliable operation of the grid, due to changing power flow characteristics and active generation, with its own protection and control capabilities. Using µPMU data on change in voltage phase angle between two points in conjunction with new and existing distribution-grid planning and operational tools is expected to enable model validation, state estimation, fault location, and renewable resource/load characterization. Our findings include: data measurement is outstripping the processing capabilities of planning and operational tools; not every tool can visualize a voltage phase-angle measurement to the degree of accuracy measured by advanced sensors, and the degree of accuracy in measurement required for the distribution grid is not defined; solving methods cannot handle the high volumes of data generated by modern sensors, so new models and solving methods (such as graph trace analysis) are needed; standardization of sensor-data communications platforms in planning and applications tools would allow integration of different vendors’ sensors and advanced measurement devices. In addition, data from advanced sources such as µPMUs could be used to validate models to improve/ensure accuracy, providing information on normally estimated values such as underground conductor impedance, and characterization of complex loads. Although the input of high-fidelity data to existing tools will be challenging, µPMU data on phase angle (as well as other data from advanced sensors) will be useful for basic operational decisions that are based on a trend of changing data.

25 ENERGY STORAGE↗

In-process monitoring and prediction of droplet quality in droplet-on-demand liquid metal jetting additive manufacturing using machine learning

Abstract In droplet-on-demand liquid metal jetting (DoD-LMJ) additive manufacturing, complex physical interactions govern the droplet characteristics, such as size, velocity, and shape. These droplet characteristics, in turn, determine the functional quality of the printed parts. Hence, to ensure repeatable and reliable part quality it is necessary to monitor and control the droplet characteristics. Existing approaches for in-situ monitoring of droplet behavior in DoD-LMJ rely on high-speed imaging sensors. The resulting high volume of droplet images acquired is computationally demanding to analyze and hinders real-time control of the process. To overcome this challenge, the objective of this work is to use time series data acquired from an in-process millimeter-wave sensor for predicting the size, velocity, and shape characteristics of droplets in DoD-LMJ process. As opposed to high-speed imaging, this sensor produces data-efficient time series signatures that allows rapid, real-time process monitoring. We devise machine learning models that use the millimeter-wave sensor data to predict the droplet characteristics. Specifically, we developed multilayer perceptron-based non-linear autoregressive models to predict the size and velocity of droplets. Likewise, a supervised machine learning model was trained to classify the droplet shape using the frequency spectrum information contained in the millimeter-wave sensor signatures. High-speed imaging data served as ground truth for model training and validation. These models captured the droplet characteristics with a statistical fidelity exceeding 90%, and vastly outperformed conventional statistical modeling approaches. Thus, this work achieves a practically viable sensing approach for real-time quality monitoring of the DoD-LMJ process, in lieu of the existing data-intensive image-based techniques.

Gaikwad, Aniruddha (ORCID:0000000285642621)↗

Summary of Michigan multispectral investigations program

The development of techniques to extend spectral signatures in space and time is reported. Signatures that were valid for 30 miles have been extended for 129 miles using transformation and sun sensor data so that a complicated multispectral recognition problem that required 219 learning sets can now be done with 13 learning sets.

Legault, R. R.↗

Passive microwave data for snow and ice research - Planned products from the DMSP SSM/I system

Recommendations which have been made for processing and distributing passive microwave data for snow and ice research obtained with the Defense Meteorological Satellite Program (DMSP) Special Sensor Microwave Imager (SSM/I) are discussed. The general objectives for SSM/I data are reviewed, and the sensor and data flow are described. The SSM/I sea ice products are discussed, and algorithm/product validation is addressed. Proposed services and implementation after SSM/I launch are summarized.

Weawer, Ronald↗

SeaWiFS technical report series. Volume 5: Ocean optics protocols for SeaWiFS validation

Protocols are presented for measuring optical properties, and other environmental variables, to validate the radiometric performance of the Sea-viewing Wide Field-of-view Sensor (SeaWiFS), and to develop and validate bio-optical algorithms for use with SeaWiFS data. The protocols are intended to establish foundations for a measurement strategy to verify the challenging SeaWiFS accuracy goals of 5 percent in water-leaving radiances and 35 percent in chlorophyll alpha concentration. The protocols first specify the variables which must be measured, and briefly review rationale. Subsequent chapters cover detailed protocols for instrument performance specifications, characterizing and calibration instruments, methods of making measurements in the field, and methods of data analysis. These protocols were developed at a workshop sponsored by the SeaWiFS Project Office (SPO) and held at the Naval Postgraduate School in Monterey, California (9-12 April, 1991). This report is the proceedings of that workshop, as interpreted and expanded by the authors and reviewed by workshop participants and other members of the bio-optical research community. The protocols are a first prescription to approach unprecedented measurement accuracies implied by the SeaWiFS goals, and research and development are needed to improve the state-of-the-art in specific areas. The protocols should be periodically revised to reflect technical advances during the SeaWiFS Project cycle.

Mueller, James L.↗

Water vapor column abundance retrievals during FIFE

A variation of the modified Langley plot algorithm is reported here and applied to the retrieval of atmospheric water column abundance from a filtered sunphotometer. In this new methodology an absorption data base (LOWTRAN 7) is used to compute a water abundance versus transmittance curve of growth, rather than the square-root dependence previously assumed. Validation of the technique is provided from an uncertainty analysis, and plans to further validate using Fourier transform spectrometers are detailed. The new sunphotometer technique is used to report local column water vapor during the First ISLSCP Field Experiment (FIFE), and comparisons are made with abundances retrieved via FIFE radiosonde observations. The sunphotometer data can best be utilized, however, to in turn validate data from airborne or in-orbit measurements of water vapor. With these flight sensors, horizontal and topographic variability within the scene can be viewed. An example of the airborne data set is given using an image from the airborne visible infrared imaging spectrometer, as acquired on August 31, 1990.

Bruegge, Carol J.↗

SeaWiFS technical report series. Volume 25: Ocean optics protocols for SeaWiFS validation, revision 1

This report presents protocols for measuring optical properties, and other environmental variables, to validate the radiometric performance of the Sea-viewing Wide Field-of-view Sensor (SeaWiFS), and to develop and validate bio-optical algorithms for use with SeaWiFS data. The protocols are intended to establish foundations for a measurement strategy to verify the challenging SeaWiFS uncertainty goals of 5 percent in water-leaving radiances and 35 percent in chlorophyll alpha concentration. The protocols first specify the variables which must be measured, and briefly review the rationale for measuring each variable. Subsequent chapters cover detailed protocols for instrument performance specifications, characterizing and calibrating instruments, methods of making measurements in the field, and methods of data analysis. These protocols were developed at a workshop sponsored by the SeaWiFS Project Office (SPO) and held at the Naval Postgraduate School in Monterey, California (9-12 April 1991). This report began as the proceedings of the workshop, as interpreted and expanded by the authors and reviewed by workshop participants and other members of the bio-optical research community. The protocols are an evolving prescription to allow the research community to approach the unprecedented measurement uncertainties implied by the SeaWiFS goals; research and development are needed to improve the state-of-the-art in specific areas. These protocols should be periodically revised to reflect technical advances during the SeaWiFS Project cycle. The present edition (Revision 1) incorporates new protocols in several areas, including expanded protocol descriptions for Case-2 waters and other improvements, as contributed by several members of the SeaWiFS Science Team.

Hooker, Stanford B.↗

Prognostics Approach for Power MOSFET Under Thermal-Stress

The prognostic technique for a power MOSFET presented in this paper is based on accelerated aging of MOSFET IRF520Npbf in a TO-220 package. The methodology utilizes thermal and power cycling to accelerate the life of the devices. The major failure mechanism for the stress conditions is dieattachment degradation, typical for discrete devices with leadfree solder die attachment. It has been determined that dieattach degradation results in an increase in ON-state resistance due to its dependence on junction temperature. Increasing resistance, thus, can be used as a precursor of failure for the die-attach failure mechanism under thermal stress. A feature based on normalized ON-resistance is computed from in-situ measurements of the electro-thermal response. An Extended Kalman filter is used as a model-based prognostics techniques based on the Bayesian tracking framework. The proposed prognostics technique reports on preliminary work that serves as a case study on the prediction of remaining life of power MOSFETs and builds upon the work presented in [1]. The algorithm considered in this study had been used as prognostics algorithm in different applications and is regarded as suitable candidate for component level prognostics. This work attempts to further the validation of such algorithm by presenting it with real degradation data including measurements from real sensors, which include all the complications (noise, bias, etc.) that are regularly not captured on simulated degradation data. The algorithm is developed and tested on the accelerated aging test timescale. In real world operation, the timescale of the degradation process and therefore the RUL predictions will be considerable larger. It is hypothesized that even though the timescale will be larger, it remains constant through the degradation process and the algorithm and model would still apply under the slower degradation process. By using accelerated aging data with actual device measurements and real sensors (no simulated behavior), we are attempting to assess how such algorithm behaves under realistic conditions.

Power MOSFET PHM↗

Characterizing Current THD’s Dependency on Solar Irradiance and Supraharmonics Profiling for a Grid-Tied Photovoltaic Power Plant

The rapidly increasing distributed energy resources (DERs) in power systems are now getting interconnected to set community grid structures, where power quality will be a major concern. The grid-to-grid (G2G) bidirectional power transfer among the distribution microgrid will not be considered commercially feasible unless the upstream harmonics are under the limits. The aggregation of such harmonics, measured as total harmonic distortion (THD), is feared to be beyond tolerable limits with the progression of rooftop grid-tied PV-like installations. Hence, this THD needs to be characterized with DER generation end variables. In this work, the photovoltaic (PV) DERs’ dependency on environment variables such as irradiance was profiled in the context of generating and injecting harmonics into the grid. A mathematical model of a grid-tied three-phase PV DER was developed as part of this correlation characterization, matching the fundamental unit structure of a 1.4 MW solar canopy located on the Florida International University (FIU) Miami campus. To determine the qualitative association with produced THD patterns, the model was evaluated with various irradiance settings. A real-time digital simulation (RTDS) platform was used to verify it. Following this confirmation, sets of data from power quality meters at the point of common coupling and FIU field sensors were utilized to validate further the correlation model. The results showed that the grid current’s THD exhibited a high correlation with the irradiance profile and its variation over time. The early morning and late afternoon periods of the day, associated with a low irradiance, constantly had higher harmonics generated from the PV DER. The midday THD was rather rational with partial shadings, hence a geolocation-dependent factor. These findings were verified by an RTDS and validated by real field data. In quantifying the THD injected by a single DER at a high-frequency (2–150 kHz) supraharmonics (SH) level, a 3% peak increment in magnitude was observed from the high-fixed to the low-fixed irradiance profile. The correlation characteristics depicted that the hybrid microgrid suffered from a daytime-dependent harmonic insertion from the grid-tied DER. This is a global problem unless specific measures are taken to mitigate the harmonics. The electrically notorious higher-frequency SH was found to increase proportionally. The G2G power transfer can be limited because of the higher THD in the early morning and late afternoon, which will also worsen because the numbers of grid-tied PV DERs (i.e., rooftop solar and industrial solar) are likely to increase rapidly soon. The community grid structure can thus have a controlled harmonics filtration setup purposefully designed to address the findings of this work, which also fall within the scope of our future research.

14 SOLAR ENERGY↗

OCTS and SeaWiFS Bio-Optical Algorithm and Product Validation and Intercomparison in US Coastal Waters

Monitoring the health of US coastal waters is an important goal of the National Oceanic and Atmospheric Administration (NOAA). Satellite sensors are capable of providing daily synoptic data of large expanses of the US coast. Ocean color sensors, in particular, can be used to monitor the water quality of coastal waters on an operational basis. To appraise the validity of satellite-derived measurements, such as chlorophyll concentration, the bio-optical algorithms used to derive them must be evaluated in coastal environments. Towards this purpose, over 21 cruises in diverse US coastal waters have been conducted. Of these 21 cruises, 12 have been performed in conjunction with and under the auspices of the NASA/Sensor Intercomparison and Merger for Biological and Interdisciplinary Oceanic Studies (SIMBIOS) Project. The primary goal of these cruises has been to obtain in-situ measurements of downwelling irradiance, upwelling radiance, and chlorophyll concentrations in order to evaluate bio-optical algorithms that estimate chlorophyll concentration. In this Technical Memorandum, we evaluate the ability of five bio-optical algorithms, including the current Sea-Viewing Wide Field-of-view Sensor (SeaWiFS) algorithm, to estimate chlorophyll concentration in surface waters of the South Atlantic Bight (SAB). The SAB consists of a variety of environments including coastal and continental shelf regimes, Gulf Stream waters, and the Sargasso Sea. The biological and optical characteristics of the region is complicated by temporal and spatial variability in phytoplankton composition, primary productivity, and the concentrations of colored dissolved organic matter (CDOM) and suspended sediment. As such, the SAB is an ideal location to test the robustness of algorithms for coastal use.

Brown, Christopher W.↗

Thermal Hydraulic Experimental Test Article (FY2020 Status Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA will be installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2. The design work for the facility has been completed. Since the FY19 THETA status report, the THETA primary system components have been assembled and tested using de-ionized water. Some results of this testing at select Richardson and Reynolds numbers are included herein. The custom THETA sodium flowmeter (permanent magnet submersible sodium flowmeter) has been built and calibrated using sodium in an auxiliary facility against a NIST traceable vortex shedder type flowmeter. The permanent magnet flowmeter showed excellent performance, following the theoretical equation for measured voltage quite well, with an error < 3.5% at flow rates ranging from 3-24 GPM at temperatures up to 400 °C. The secondary sodium system for heat rejection from intermediate heat exchanger has been analyzed according to ASME code. All secondary side piping, fittings and a U-stamped air-to-sodium heat exchanger have been procured.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Thermal Hydraulic Experimental Test Article - Report of THETA Commissioning for METL Testing

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA has been installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2 and Figure 3. Since the FY20 THETA status report, [1], further water shakedown testing was performed, some final welding modifications were performed, all system components were sanitized, dry assembled, and commissioned before installing into METL test vessel #4. The THETA submersible electromagnetic flowmeter was welded closed to hermetically seal internal components from sodium followed by a helium leak check for the final time

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Thermal Hydraulic Experimental Test Article (FY21 Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA has been installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2 and Figure 3. Since the FY20 THETA status report, further water shakedown testing was performed, some final welding modifications were performed, all system components were sanitized, dry assembled, and commissioned. The THETA submersible electromagnetic flowmeter was welded closed to hermetically seal internal components from sodium followed by a helium leak check for the final time. Following installation of THETA into vessel #4, all data acquisition and control systems were brought online and commissioned at room temperature in the argon gas space of the empty vessel. The vessel zone 1 heaters were reinstalled and the flange was then insulated. The vessel 4 heaters were brought to a temperature of 100 °C and the THETA pump was jogged at 600 RPM to ensure it was functioning correctly. The secondary, AC Conduction based electromagnetic pump from CMI Novacast (product number CA-15) was ordered and will be delivered in late calendar year 2021. The custom designed permanent magnet based secondary flowmeter was designed, a drawing package and manufacturing specification created and quote requested from a machine shop. The intermediate heat exchanger design was completed and a drawing package is currently in progress. During the middle of calendar year 2021 the Building 308 sodium scrubber system was shut down in order to replaced some corroded piping and facilitate improvements on the system, thus requiring the sodium in METL to remain frozen. This has imposed a delay in filling vessel 4 with sodium to begin THETA testing. Sodium testing is expected to begin in early fiscal year 2022 as all THETA primary systems are operational.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Thermal Hydraulic Experimental Test Article - Status Report FY20 Q2

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (like a redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA will be installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2. The design work for the facility has been completed, most primary component have been fabricated, primary components are being assembled in preparation for initial testing, and procurement is continuing with the secondary system components. Since the FY19 THETA status report, The THETA primary system components are at Argonne National Laboratory (ANL) and have been dry assembled. The secondary sodium system for heat rejection from intermediate heat exchanger has all been analyzed according to ASME code. All secondary side piping, fittings and a U-stamped air-to-sodium heat exchanger has been procured.

42 ENGINEERING↗

Aeroheating Thermal Model Correlation for Mars Global Surveyor (MGS) Solar Array

The Mars Global Surveyor (MGS) Spacecraft made use of aerobraking to gradually reduce its orbit period from a highly elliptical insertion orbit to its final science orbit. Aerobraking produces a high heat load on the solar arrays, which have a large surface area exposed to the airflow and relatively low mass. To accurately model the complex behavior during aerobraking, the thermal analysis needed to be tightly coupled to the spatially varying, time dependent aerodynamic heating. Also, the thermal model itself needed to accurately capture the behavior of the solar array and its response to changing heat load conditions. The correlation of the thermal model to flight data allowed a validation of the modeling process, as well as information on what processes dominate the thermal behavior. Correlation in this case primarily involved detailing the thermal sensor nodes, using as-built mass to modify material property estimates, refining solar cell assembly properties, and adding detail to radiation and heat flux boundary conditions. This paper describes the methods used to develop finite element thermal models of the MGS solar array and the correlation of the thermal model to flight data from the spacecraft drag passes. Correlation was made to data from four flight thermal sensors over three of the early drag passes. Good correlation of the model was achieved, with a maximum difference between the predicted model maximum and the observed flight maximum temperature of less than 5%. Lessons learned in the correlation of this model assisted in validating a similar model and method used for the Mars Odyssey solar array aeroheating analysis, which were used during onorbit operations.

Amundsen, Ruth M.↗

Validation of Machine Learning Algorithms for Hyperspectral Inversion of Common Water Quality Indicators

The upcoming transition to a diverse suite hyperspectral airborne and orbiting optical sensors will provide an unprecedented opportunity to measure inland water quality characteristics at a fidelity not previously achievable. This presentation will assess prototype deep learning models trained on synthetic hyperspectral data and validated with collocated in-situ measurements. Synthesized data is becoming increasingly popular for use in data-driven approaches to complex problems, and can compliment real data to increase performance on complex and unusual phenomenon, reduce or test bias, and experiment to demonstrate explainability. We will present insights from hyperspectral inversions of Chlorophyl-a, Phycocyanin, and concentration of non-algal particles using selected orbiting and airborne sensors over diverse, optically complex aquatic scenarios. We analyze how various optical water types affect fidelity of results and where improvements can be made as we prototype for globally operational water quality algorithms which can be leveraged by upcoming hyperspectral missions such as the Surface Biology and Geology (SBG) mission.

Surface Biology and Geology (SBG)↗

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗