The present invention relates to environmental testing of structures (sometimes referred to herein as “test articles”), and has particular applications in the testing of spacecraft and satellite components that experience extreme vibrations in their normal operating environments. The invention more particularly relates to the use of acoustic transducers (loudspeakers) capable of delivering large amounts of acoustic energy for such tests.
Satellite components need to be tested before they are assembled onto the satellite to ensure they will survive the vibration induced by the sound of a rocket launch. Most of the sound power experienced by a satellite during launch are at low frequencies, typically at wavelengths of around 2 to 12 feet. Many of the satellite components (such as solar panels, structural panels and dishes) that require testing are narrower than 2 feet, and often no more than 6 inches, in one direction that can be designated the z-direction, but are long in other directions, namely, in the x-y plane perpendicular to the z-direction. To effectively test components of these dimensions, acoustic energy must be uniformly delivered to the component under test over the entire extent of the component.
One known method of acoustic testing is the reverberant chamber method. Using this testing method, a test article is placed at a distance from the sound source in an environment which is as reverberant as possible. The acoustic energy in the reverberations is used to increase the sound level and spatial uniformity of the field. However, in order to achieve spatial uniformity, the test article must be sufficiently far from the sound source such that the reverberant contribution to the acoustic energy is larger than the acoustic energy in the direct sound. Also, for spatial uniformity, the chamber needs to be large (much larger than the test article), and thus conventional loudspeakers cannot be used.
Another downside to the reverberant chamber testing method is that the auto-correlation of the sound field is far wider than occurs during actual launch conditions. During an actual launch there are generally few surfaces near the satellite components of interest that reflect acoustic energy back onto the components. In other words, sound vibrations generated in the past contribute negligibly to the sound level at the present moment. To reproduce actual launch conditions, the auto-correlation of the sound field needs to be relatively narrow such that the only sound vibrations that effect the test article are direct, real time vibrations and not delayed vibrations.
Another conventional acoustic vibration testing method is direct field acoustic testing. Using this method, conventional loudspeakers are placed in a circle around the test article with the acoustic energy produced by the loudspeakers being directed at the test article from all sides. While direct field acoustic testing avoids the wide auto-correlation issues associated with reverberant chamber testing, achievable sound pressure levels in the volume of space where the test article is positioned are limited. Also, the sound pressure fields produced by this test configuration generally require microphone placements that surround the test article, and therefore the microphones must be moved in order to get the test article in and out of the test setup.
The present invention is directed to a system and method for acoustic vibration testing of test articles such as satellite components that takes advantage of the narrow dimensions of the components of a satellite that most often require testing. The system and method of the invention allow sound pressure levels to be achieved within a usable volume of space for testing purposes that are substantially higher than can be achieved using conventional vibration test methodologies. The elevated sound pressure levels can be achieved without an overly wide auto-correlation of the sound field, that is, an auto-correlation that does not accurately represent actual exposure during use. The acoustic vibration testing system and method of the invention further allows for advantageous placements of the microphones needed to monitor the test conditions, simplifying test set-up and procedures.
The system and method of the invention is particularly adapted to vibration testing test articles having a maximum dimension in one direction. In accordance with the invention, a rigid boundary wall is provided that extends in an x-y plane. A test article is placed next to the rigid boundary wall such that it lies within a defined boundary-adjacent test zone that extends in an x-y plane in front of the boundary wall. The depth of the boundary-adjacent test zone will correlate to the shortest wavelength of the acoustic energy to which a test article is to be subjected. The shorter this wavelength is the narrower the boundary-adjacent test zone. Test articles are chosen having a maximum depth throughout the x-y plane that allows the test article to fit substantially entirely within the boundary adjacent test zone.
Acoustic energy is directed at the test article positioned in the boundary-adjacent test zone. This is done from a location in front of the boundary wall that is displaced from the test zone. The acoustic energy can be produced from one or multiple sources. The rigid boundary wall bounding the boundary-adjacent test zone causes an increase in the sound pressure levels within the boundary-adjacent test zone, thus amplifying the intensity of the vibrations to which the test article in the test zone is subjected. Using the system and method of the invention, sound pressure levels can be achieved within a narrow but useful boundary-adjacent test zone that greatly exceed the sound pressure levels achieved using conventional direct field testing methods.
To be effective, the rigid boundary wall should have a very low absorption factor, generally no greater than about 0.5 and preferably no greater than 0.2, and still more preferably no greater than 0.1. Except for the boundary wall, the testing is preferably conducted in a lateral free field test environment to achieve a relatively narrow auto-correlation of the sound pressure fields in the test zone. As used herein “lateral free field” or simply “free field” shall be understood to mean environmental conditions where reflections from wall surfaces (other than the boundary wall described herein) are negligible. It is permissible and even beneficial to have reflective floor surfaces and permissible but not always beneficial to have reflective ceiling surfaces. (Reflective ceiling surfaces would be beneficial if the stack of loudspeakers used in the test reached the ceiling.)
Environmental testing is the controlled replication in laboratory environmental conditions (heat, humidity, electromagnetic emission, vibration, sound, etc.) that a test structure will experience in actual use to ensure that the test structure will perform correctly when used outside the lab. The device(s) which replicate the environmental conditions are referred to as the input transducers because they provide the inputs to the environmental system. Where the environmental conditions sought to be replicated are sound vibrations, the input transducers are transducers capable of generating acoustic energy, i.e., loudspeakers.
Replication in a laboratory environment of the extremely high levels of acoustic energy to which some test structures, such as spacecraft or satellites, may be subjected presents particular challenges. Typically, such tests involve the use of one or multiple loudspeakers arranged so that their acoustic outputs are directed at the target structure or test article, with the delivery of acoustic energy from the loudspeaker(s) to the target structure being controlled by either a SIMO or MIMO controller.
In referring to the accompanying drawings, it is noted that all figures are illustrative of structures and sound fields that are placed or occur in space defined by perpendicular x, y and z axes. Only the x and z axes are shown. The y axis, which together with the x axis defines the x-y plane described herein, is perpendicular to the drawing page.
In the set-up shown in
The effect of the boundary wall 15 shown in
Also, it is seen from the plot in
In regards to the placement of the one or more loudspeakers in front of the boundary wall, it is observed that loudspeakers have a maximum SPL that they can produce at a given distance. They also have a characteristic coverage angle outside of which the sound level drops off. In practicing the method of the invention, the loudspeaker should be close enough to the boundary 15 to produce the necessary SPL, but not so close that the edges of the test article end up outside of the loudspeaker coverage pattern. Preferably the loudspeakers will be at a distance from the boundary wall that is least wavelength at the shortest wavelength of interest, and no more than one wavelength at the longest wavelength of interest.
It will be appreciated that yet additional loudspeakers could be added to the loudspeaker arrangements described above for further enlarging the coverage area of the test zone and/or increasing SPL levels within the test zone. The number and orientation of the loudspeakers can be chosen to achieve a test zone of a desired size and one that has a substantially uniform SPL level throughout the zone.
In setting up a test in accordance with the invention, a test space must first be selected. Again, this will preferably be a space that provides a lateral free field test environment, as such a test environment will allow for a relatively narrow auto-correlation of the sound pressure fields in the test zone for the test article. This test space must either have a pre-existing rigid wall that can act as a boundary wall within the space, or such a wall will need to be introduced into the space.
The size of the boundary wall, that is, the degree to which it extends in the x-y plane, will suitably be chosen based on the long dimensions of the largest test articles to be tested. The boundary wall is ideally flat without any significant perturbations on the wall that would produce undesirable disruption of the sound field produced by the loudspeakers. (Small perturbations which do not exceed the wavelength of the smallest wavelength of the acoustic energy to which a test article is to be subjected will have no significant effect on the sound field in front of the wall.) However, it is not intended that the invention be limited to a perfectly flat wall. Rather, while not ideal, some degree of curvature or other irregularity in its reflective surface could be allowed, so long as SPL levels can be kept reasonably uniform throughout most of the test zone. Such surfaces, which can be described as generally extending an x-y plane, are considered to be within the scope of the invention.
A further aspect of setting up a test in accordance with the invention involves selecting one or more loudspeakers for the test space. As above-described, the number of loudspeakers chosen will depend on the size of articles to be tested, for example, the longest dimension of the solar panels of a satellite. The loudspeakers are positioned in front of the boundary wall, preferably at a distance that is least ½ wavelength at the shortest wavelength of interest and no more than one wavelength at the longest wavelength of interest. For satellite component testing, suitable loudspeakers would suitably deliver most all of their acoustic energy within a frequency range of about 30 Hz to about 500 Hz, and the distance between the loudspeaker and the boundary wall being no less than 1⅛ feet (0.34 meters) and no more than 37 feet (11.4 meters). In this application, equalization can be used to create an acoustic energy profile for the loudspeaker's output that can be matched to published frequency vibration profiles for the vibrations normally experienced by the satellite components in live conditions, typically in ⅓ octaves over the applicable frequency range.
In still a further aspect of the test set-up, microphones are deployed outside the boundary adjacent test zone for the test article to monitor SPL levels within the boundary adjacent test zone as the tests are conducted. The remote positioning of the monitoring microphone or microphones is possible because of the above-described characteristics of the sound field produced by the loudspeaker or loudspeakers in front of the barrier wall, namely, the existence of a secondary zone within the sound field removed from the wall that exhibits the same SPL levels as the boundary adjacent test region where the test article is to be tested. The monitoring microphone(s) are placed in this remote secondary zone, which can be located by taking SPL measurements within the sound field when the positioned loudspeakers are turned on. It is noted that the remote secondary test zone in which the monitoring microphone is placed need not exhibit the same SPL levels as the boundary-adjacent test zone so long as there is a correlation between the SPL levels in the two zones of the sound field that is understood and can be used to determine SPL levels in the test zone.
The present invention is an improvement over both the reverberant test method and direct field test methods earlier described. Advantages over the reverberant test method are several and include: i) the test article can be closer to the sound source, ii) the test chamber can be significantly smaller, iii) the auto-correlation of the sound field will be more realistic, iv) the acoustic environment of the test article is more like boundary loading experienced during the actual conditions being simulated such as a satellite launch, and v) conventional loudspeakers can be used for the test. Advantages over the other direct field test methods include that loudspeakers on one side of the test article can be eliminated, displaced microphone locations that experience the same sound pressure levels as the test article are available, and the acoustic environment of the test article is more like boundary loading experienced during the actual conditions being simulated, e.g., during a launch.
While the present invention has been described in considerable detail in the foregoing specification and accompanying drawings, it is not intended that the invention be limited to such detail, except as may be necessitated by the following claims.
This application is a continuation of International (PCT) Application No. PCT/US2019/022143 filed Mar. 13, 2019, which claims the benefit of U.S. Provisional Patent Application No. 62/643,109 filed Mar. 14, 2018. The foregoing applications are incorporated herein by reference.
Number | Date | Country | |
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62643109 | Mar 2018 | US |
Number | Date | Country | |
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Parent | PCT/US2019/022143 | Mar 2019 | US |
Child | 17013335 | US |