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Applicability of Loads Estimation Techniques Using Sparse Acceleration Sensor Data to Spacecraft Structural Health Monitoring

The use of structural health monitoring systems on spacecraft structures can play a crucial role in ensuring the safety, reliability, and longevity of the structure by gathering and analyzing onboard sensor data. Of specific importance is monitoring for excessive loading at critical interfaces as any off-nominal structural excitations experienced by spacecraft structures can cause early unpredicted high structural life consumption or damage. The availability and cost of flight-certified sensors along with the size of spacecraft structures and allowable payload mass drives the need for a method to estimate loads using sparsely-located sensors. Numerous approaches such as physics-based, statistical learning, and physics-enhanced statistical learning algorithms have gained popularity among structural prognostics applications. However, developing noise-robust prediction models to assess loads and structural life predictions from a sparse multi-sensor data acquisition system can be a challenging task. This paper discusses the evaluation of physics-based versus machine-learning algorithms for predicting loads and structural life at mission critical locations on the spacecraft structure using a finite element loads analysis with the application of simulated noise and noise reduction techniques. To estimate the loads from accelerations, the physics-based algorithm leverages a loads transformation matrix from a Craig-Bampton reduced finite element model. A System Equivalent Reduction Expansion Process (SEREP) and a pseudo-inverse approach are considered to expand from the onboard sensor degrees of freedom to the Craig-Bampton model degrees of freedom. The machine learning algorithm provides a data driven solution/mapping of the sensor accelerations to the loads at the mission critical locations using a high dimensionality analysis. Although these strategies produce comparable loads prediction without noise, the limitations of these strategies with incorporating simulated noise and noise reduction techniques with low signal to noise ratio signals are evaluated. The study demonstrates the immense potential of statistical learning algorithms for sparse structural prognostic models and enhancing signal denoising techniques. These findings also highlight the need for noise-resilient prognostic models and low-noise data acquisition systems onboard spacecraft structures.

Spacecraft Structural Health Monitoring

Acceleration and Velocity Sensing from Measured Strain

A simple approach for computing acceleration and velocity of a structure from the strain is proposed in this study. First, deflection and slope of the structure are computed from the strain using a two-step theory. Frequencies of the structure are computed from the time histories of strain using a parameter estimation technique together with an Autoregressive Moving Average model. From deflection, slope, and frequencies of the structure, acceleration and velocity of the structure can be obtained using the proposed approach. shape sensing, fiber optic strain sensor, system equivalent reduction and expansion process.

shape sensing

Wing Shape Sensing from Measured Strain

A new two step theory is investigated for predicting the deflection and slope of an entire structure using strain measurements at discrete locations. In the first step, a measured strain is fitted using a piecewise least squares curve fitting method together with the cubic spline technique. These fitted strains are integrated twice to obtain deflection data along the fibers. In the second step, computed deflection along the fibers are combined with a finite element model of the structure in order to extrapolate the deflection and slope of the entire structure through the use of System Equivalent Reduction and Expansion Process. The theory is first validated on a computational model, a cantilevered rectangular wing. It is then applied to test data from a cantilevered swept wing model.

system equivalent reduction and expansion process

Wing Shape Sensing from Measured Strain

A new two-step theory is investigated for predicting the deflection and slope of an entire structure using strain measurements at discrete locations. In the first step, a measured strain is fitted using a piecewise least-squares curve fitting method together with the cubic spline technique. These fitted strains are integrated twice to obtain deflection data along the fibers. In the second step, computed deflection along the fibers are combined with a finite element model of the structure in order to interpolate and extrapolate the deflection and slope of the entire structure through the use of the System Equivalent Reduction and Expansion Process. The theory is first validated on a computational model, a cantilevered rectangular plate wing. The theory is then applied to test data from a cantilevered swept-plate wing model. Computed results are compared with finite element results, results using another strainbased method, and photogrammetry data. For the computational model under an aeroelastic load, maximum deflection errors in the fore and aft, lateral, and vertical directions are -3.2%, 0.28%, and 0.09%, respectively; and maximum slope errors in roll and pitch directions are 0.28% and -3.2%, respectively. For the experimental model, deflection results at the tip are shown to be accurate to within 3.8% of the photogrammetry data and are accurate to within 2.2% in most cases. In general, excellent matching between target and computed values are accomplished in this study. Future refinement of this theory will allow it to monitor the deflection and health of an entire aircraft in real time, allowing for aerodynamic load computation, active flexible motion control, and active induced drag reduction.

shape sensing

Wing Shape Sensing from Measured Strain

A new two-step theory is investigated for predicting the deflection and slope of an entire structure using strain measurements at discrete locations. In the first step, a measured strain is fitted using a piecewise least-squares curve fitting method together with the cubic spline technique. These fitted strains are integrated twice to obtain deflection data along the fibers. In the second step, computed deflection along the fibers are combined with a finite element model of the structure in order to interpolate and extrapolate the deflection and slope of the entire structure through the use of the System Equivalent Reduction and Expansion Process. The theory is first validated on a computational model, a cantilevered rectangular plate wing. The theory is then applied to test data from a cantilevered swept-plate wing model. Computed results are compared with finite element results, results using another strain-based method, and photogrammetry data. For the computational model under an aeroelastic load, maximum deflection errors in the fore and aft, lateral, and vertical directions are -3.2 percent, 0.28 percent, and 0.09 percent, respectively; and maximum slope errors in roll and pitch directions are 0.28 percent and -3.2 percent, respectively. For the experimental model, deflection results at the tip are shown to be accurate to within 3.8 percent of the photogrammetry data and are accurate to within 2.2 percent in most cases. In general, excellent matching between target and computed values are accomplished in this study. Future refinement of this theory will allow it to monitor the deflection and health of an entire aircraft in real time, allowing for aerodynamic load computation, active flexible motion control, and active induced drag reduction..

system equivalent reduction and expansion process

Acceleration and Velocity Sensing from Measured Strain

A simple approach for computing acceleration and velocity of a structure from the strain is proposed in this study. First, deflection and slope of the structure are computed from the strain using a two-step theory. Frequencies of the structure are computed from the time histories of strain using a parameter estimation technique together with an autoregressive moving average model. From deflection, slope, and frequencies of the structure, acceleration and velocity of the structure can be obtained using the proposed approach. Simple harmonic motion is assumed for the acceleration computations, and the central difference equation with a linear autoregressive model is used for the computations of velocity. A cantilevered rectangular wing model is used to validate the simple approach. Quality of the computed deflection, acceleration, and velocity values are independent of the number of fibers. The central difference equation with a linear autoregressive model proposed in this study follows the target response with reasonable accuracy. Therefore, the handicap of the backward difference equation, phase shift, is successfully overcome.

shape sensing