Sensor Technologies For Structural Health Monitoring

Sensor Technologies for Structural Health
Monitoring
Course Introduction
• Introduction (Major, MS or PhD, Research

experience, Research interests)
• Survey of Academic Background

 Matlab Programming
 Data acquisition (hardware, Labview)
 Structural Dynamics
 Finite Element Analysis
 Fracture and fatigue
• Syllabus and tentative schedule

What is Structural Health Monitoring?
Definition:
In-service evaluation of structural health status
by measuring key structural and environmental
parameters on a continuous base at real-time.
Purposes of SHM: Detect structure damages

• Safety, Safety, Safety
• Provide maintenance and rehabilitation advices
• Improve design guidelines
• Disaster mitigation
Current Safety Assurance Practices
• Design with large safety factors-overdesign

• Design for damage tolerance
– Life prediction (material damage, fracture mechanics)
– Quality control (material processing, manufacturing,
assembly)
– Accurate specification of operational conditions
• Periodic Inspection
– Manual
– Nondestructive Evaluation (visual, ultrasound, eddy
current)
Infamous Disasters due to Structural
Failures
Question: IF all structures are designed

properly, do we still need Structural Health
Monitoring?
Why Do Disaster Happen?
• Design uncertainties
– Loading conditions
• Manufacturing uncertainties
• Material variations
• Environmental effects
• Aging Infrastructures
– Civil infrastructures
– Spacecrafts
– Airplanes
Conventional Structural Systems
Conventional Structural
Systems are dumb, very dumb
– Designed to achieve a set of
intended functions under pre-
selected loads and forces.
– Large safety factor is employed
to account for the uncertainty in
external loads
– Unable to adapt to structural
changes and to varying usage
patterns and loading
conditions.
Design, Build, and Cross-your-fingers Both pictures were taken from

the 1995 Kobe Earthquake
Future Structural Systems
“Smart” Structures-
structures that are able to
sense and response/adapt to
changes in their environment
Characteristics of SS
– Integrated with many sensors
and control devices through
information network
– To achieve an enhanced
performance at a reduced life-
cycle cost
Image courtesy of USA Today & Ken P. Chong at NSF

Biological Analogy to Smart Structural
System
A smart structural system can be considered as a mimicking
of biological systems, possessing its own sensory and
nervous systems, brain, and muscular system, with the goal
of being autonomous and adaptable as living things
Information
Sensors Processing (brain)
(visual, olfactory,
hearing,
mechanosensory) Actuators
(Muscular)
Courtesy of T. Kobori, Kajima Corp.

Core Components of Smart Structural
System
Core components of a smart

structural system (equipping
structures with an integrated system of the
Networked Information
following elements to make them adaptive to Sensors Processing
environment changes): Smart
– Sensor (network) SSS
– Data/information processing Materials
Control & Structural

and interpretation Actuator System
– Controller and Actuating Device

(sometimes called effector)
Smart Structural System
• A smart structural system is roughly defined as a system
with sensors, data processing unit, control and actuating
devices, and therefore is adaptive to the change in
external operating conditions.
Control effect under the November 19,

1991 Chiba City Coast earthquake
(Tokyo, Magnitude: 4.9)
Typical SHM System
Data Processing
Sensor
System
System
Self-healing
Simulation Model
Maintenance
Prognosis
Scheduling
Health Evaluation
System
Life Prediction
Model
Benefits of SHM
• Better safety ensurance

• Cost-saving
– Cost of inspection (e.g. 40% saving on
airplane inspection)
– Early detection
• Autonomous damage detection for
disaster mitigation
Applications of SHM
Aerospace Structures (Airframe, engine

components, composite materials, etc.)
Civil Structures (Bridge, Dam, Skyscraper,
Earthquake impact, etc.)
Mechanical Systems (bearing, engine, etc.)
Human (elderly, people with health problems,
fatigue of mission critical personnel, etc.)
Structural Damages
Definition: any structural condition that is

different from its normal/design condition
Examples of Structural Damages

Typical Damages in Airplanes
• Fatigue cracking, particularly in joints at

countersunk hole edges
• Corrosion, particularly inside joints and closed
compartments
• Paint damage as an impact event signal
• Debonding, due to corrosion in joints
• Impact damages in composite materials
• Manufacturing damages in composite materials
• Debonding in stiffened composite panels
Four Levels of Damage Detection
1. Detection of whether damage is present

in the structure;
2. Identification of the location of the
damage;
3. Quantification of the severity of the
damage;
4. Evaluation of remaining structural integrity
and risk assessment.
Damage Detection Requirement for
Airplanes
Detection Sensitivity
• 1-2mm cracks in Aluminum sheet
• 5 mm cracks in a metallic frame
• 100 mm cracks in a large area
• 10% of sheet thickness in corrosion
• 15X15mm debonding
Detection reliability: 90% reliability with 95%

confidence level
Damage Detection Mechanisms
• Local & direct measurement

– Check for damage types (crack, corrosion,
delamination)
– Acoustic Emission
• Global & indirect measurement

– Measure structural behavior
SHM Mechanisms
Usage based SHM: measure the usage of the structure

and determine if abnormal usage occurred
Vibration-based SHM
– Natural frequency and frequency response functions
– Mode shape and mode shape curvature
– Damping
– Wave propagation (guided wave, ultrasonic, etc.)
Strain-based SHM
– Strain-energy distribution
SHM Techniques for Airplanes
Sensors Used for SHM
Vibration measurement sensors

– Accelerometer
– Deflection/bending sensor
– Strain gauge
– Acoustic sensor
Environmental sensors
– Pressure sensor
– Temperature sensor
– Moisture sensor
– Corrosion sensor
Different Stages of Fatigue Damages For
Metallic Materials
• Substructural and microstructural damages

• Microscopic cracks
• Formation of dominate cracks
• Stable propagation of dominated cracks
• Structural instability and/or complete fracture
Question: at what stages should we detect the

fatigue damages to save repair cost?
Aging Civil Aircraft

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Sensor Technologies for Structural Health

• Introduction (Major, MS or PhD, Research

• Survey of Academic Background

• Syllabus and tentative schedule

Purposes of SHM: Detect structure damages

• Design with large safety factors-overdesign

Question: IF all structures are designed

Design, Build, and Cross-your-fingers Both pictures were taken from

Image courtesy of USA Today & Ken P. Chong at NSF

Courtesy of T. Kobori, Kajima Corp.

Core components of a smart

environment changes): Smart

– Sensor (network) SSS

– Data/information processing Materials

Control & Structural

– Controller and Actuating Device

Control effect under the November 19,

• Better safety ensurance

Aerospace Structures (Airframe, engine

Definition: any structural condition that is

Examples of Structural Damages

• Fatigue cracking, particularly in joints at

1. Detection of whether damage is present

Detection reliability: 90% reliability with 95%

• Local & direct measurement

• Global & indirect measurement

Usage based SHM: measure the usage of the structure

Vibration measurement sensors

• Substructural and microstructural damages

Question: at what stages should we detect the

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