Daniel F. Perey

Passive wireless SAW sensors for IVHM

NASA aeronautical programs require integrated vehicle health monitoring (IVHM) to ensure the safety of the crew and the vehicles. Future IVHM sensors need to be small, light weight, inexpensive, and wireless. Surface acoustic wave (SAW) technology meets all of these constraints. In addition it operates in harsh environments and over wide temperature ranges, and it is inherently radiation hardened. This paper presents a survey of research opportunities for universities and industry to develop new sensors that address anticipated IVHM needs for aerospace vehicles. Potential applications of passive wireless SAW sensors from ground testing to high altitude aircraft operations are presented, along with some of the challenges and issues of the technology.

Characterization of Effluents Given off by Wiring Insulation

When an insulated wire is heated, the insulation emits a variety of effluents. This paper discusses the basis of emissions of effluents from wiring insulation. Several species are emitted at relatively low temperatures, while others are emitted when the wire reaches higher temperatures. We isolate the emissions by relative molecular weight of the effluents and measure the effluent concentration both as a function of time (temperature held constant) and by wire temperature. We find that the Law of Mass Action describes and predicts the time‐dependence of the emission of a specific effluent caused by the heating. The binding energy is determined by performing an Arrhenius Plot on the temperature data. These dependencies are discussed and working equations are derived. Data collected from 20 gauge wire (MIL‐W‐22759/11‐20) is used to illustrate and confirm the validity of the theory.

Development of a Practical Broadband Active Vibration Control System

The goal of this work is to develop robust, lightweight, and low-power control units that can be used to suppress structural vibration in flexible aerospace structures. In particular, this paper focuses on active damping, which is implemented using compact decentralized control units distributed over the structure. Each control unit consists of a diamond-shaped piezoelectric patch actuator, three miniature accelerometers, and analog electronics. The responses from the accelerometers are added together and then integrated to give a signal proportional to velocity. The signal is then inverted, amplified, and applied to the actuator, which generates a control force that is out of phase with the measured velocity. This paper describes the development of the control system, including a detailed description of the control and power electronics. The paper also presents experimental results acquired on a Plexiglas window blank. Five identical control units installed around the perimeter of the window achieved 10 dB peak reductions and a 2.4 dB integrated reduction of the spatially averaged velocity of the window between 500 and 3000 Hz.

A Method For The Verification Of Wire Crimp Compression Using Ultrasonic Inspection

The development of a new ultrasonic measurement technique to assess wire crimp terminations is discussed. The amplitude change of a compressional ultrasonic wave propagating at right angles to the wire axis and through the junction of a crimp termination is shown to correlate with the results of a destructive pull test. The case of incomplete compression of crimped connections is ultrasonically tested, and the results are correlated with pull tests. Results show that the ultrasonic measurement technique consistently predicts good crimps when the ultrasonic transmission is above a certain threshold amplitude level. A quantitative measure of the quality of the crimped connection based on the ultrasonic energy transmitted is shown to respond accurately to crimp quality. A wave propagation model, describes the compressional ultrasonic wave propagation through the junction during the crimping process. This model is in agreement within 6% of the ultrasonic measurements. A prototype instrument for applying this technique while wire crimps are installed is also presented. The instrument is based on a two-jaw type crimp tool suitable for butt-splice type connections. A comparison of the results of two different instruments is presented and shows reproducibility between instruments within a 95% confidence bound.

Effluent Based Characterization of Aerospace Wiring

This paper discusses a wire insulation characterization method under development, which identifies the relative molecular weight and binding energy of effluents given off during wire heating and is aimed at nondestructively assessing wire insulation degradation. An overview of how this technique can be used to monitor wire insulation emissions is presented. A series of measurements made on wire specimens (MIL‐W‐22759/11‐20) with polytetraflouroethylene (PTFE or Teflon®) insulation is presented. A change of up to 55% in the emission concentration of a particular effluent was observed by repeated heating the wire specimens. Temperature measurements of the conductor and insulation were correlated to effluent emission concentrations. A basis for the changes in effluent concentration is also presented and leads to a determination of binding energies and associated time constants.

A digital, constant-frequency pulsed phase-locked-loop instrument for real-time, absolute ultrasonic phase measurements

A digitally controlled instrument for conducting single-frequency and swept-frequency ultrasonic phase measurements has been developed based on a constant-frequency pulsed phase-locked-loop (CFPPLL) design. This instrument uses a pair of direct digital synthesizers to generate an ultrasonically transceived tone-burst and an internal reference wave for phase comparison. Real-time, constant-frequency phase tracking in an interrogated specimen is possible with a resolution of 0.000 38 rad (0.022°), and swept-frequency phase measurements can be obtained. Using phase measurements, an absolute thickness in borosilicate glass is presented to show the instruments efficacy, and these results are compared to conventional ultrasonic pulse-echo time-of-flight (ToF) measurements. The newly developed instrument predicted the thickness with a mean error of -0.04 μm and a standard deviation of error of 1.35 μm. Additionally, the CFPPLL instrument shows a lower measured phase error in the absence of changing temperature and couplant thickness than high-resolution cross-correlation ToF measurements at a similar signal-to-noise ratio. By showing higher accuracy and precision than conventional pulse-echo ToF measurements and lower phase errors than cross-correlation ToF measurements, the new digitally controlled CFPPLL instrument provides high-resolution absolute ultrasonic velocity or path-length measurements in solids or liquids, as well as tracking of material property changes with high sensitivity. The ability to obtain absolute phase measurements allows for many new applications than possible with previous ultrasonic pulsed phase-locked loop instruments. In addition to improved resolution, swept-frequency phase measurements add useful capability in measuring properties of layered structures, such as bonded joints, or materials which exhibit non-linear frequency-dependent behavior, such as dispersive media.

Ultrasonic inspection to quantify failure pathologies of crimped electrical connections

Previous work has shown that ultrasonic inspection provides a means of assessing electrical crimp quality that ensures the electrical and mechanical integrity of an initial crimp before the installation process is completed. The amplitude change of a compressional ultrasonic wave propagating at right angles to the wire axis and through the junction of a crimp termination was shown to correlate with the results of destructive pull tests, which is a standard for assessing crimp wire junction quality. Of additional concern are crimps made at high speed assembly lines for wiring harnesses, which are used for critical applications, such as in aircraft. During high-speed assembly it is possible that many faulty crimps go undetected until long after assembly, and fail in service. The position and speed of the crimping jaw become factors as the high-speed crimp is formed. The work presented in this paper is designed to cover the more difficult and more subtle area of high-speed crimps by taking into account the rate change of the measurements. Building on the previous work, we present an analysis methodology, based on transmitted ultrasonic energy and timing of the first received pulse that is shown to correlate to the gauge of the crimp/ferrule combination and the position of the crimping jaw. Results demonstrating the detectability of a number of the crimp failure pathologies, such as missing strands, partially inserted wires and incomplete crimp compression, are presented. The ability of this technique to estimate crimp height, a mechanical measure of crimp quality, is discussed.