This disclosure generally relates to equipment and methods for non-destructive evaluation and testing of structures.
Non-destructive evaluation of structures involves thoroughly examining a structure without harming the structure or requiring its significant disassembly. Non-destructive evaluation is commonly used in the aircraft industry to inspect aircraft structures for any type of internal or external damage to or flaws in the structure. Non-destructive evaluation is also used in the initial fabrication of the aircraft's structural components. It is used to assure that a part was fabricated correctly and that foreign material is not embedded within the part. Inspection may be performed during manufacturing of a structure and/or after a structure has been put in service
Known NDE techniques include laser shearography and electronic speckle pattern interferometry (ESPI). Laser shearography and ESPI use correlated laser light and interferometry to create a real-time image showing small strain changes on a surface that indicate sub-surface damage or flaws. The strain changes are created using a partial vacuum (in a hood or chamber), heat, or physical loading of the structure. The main drawback of these methods is their high cost. The same cost issue is true of laser Doppler technology, which creates a laser impact event and observes the surface waves using interferometry methods. Low-frequency ultrasound or bond testing is a commonly used inspection method which is less expensive, but is time consuming and is a contact method. Low-frequency ultrasound or bond testing introduces a mechanical wave into the part being examined, which mechanical wave is then received by a sensor that monitors changes in the induced wave as the probe is scanned by hand over an area. The change is displayed either by the movement of a meter needle or by a flying dot on a screen. This change represents the stiffness in the localized area under the sensor. This process is repeated until the inspector has mapped out the damage boundary. There are more sophisticated systems that will provide an image of the area under test, but they are more expensive, require more skill from the operator, and take more time to set up.
Rapid, automated and large-area inspection methods are needed for in-service inspection of sandwich structures. When honeycomb sandwich (both metal and non-metal) structure has been impacted during service, it is susceptible to some degree of damage. Often the mechanic will perform a “tap test” to listen for a difference in the sound of the suspected damage area, yet it takes a certified inspector to determine the extent of the damage, if any, using fairly sophisticated electronic equipment (a bondtester, etc.) to make that determination. This requires time and the availability of a certified operator of the equipment, which in turn drives up the cost of the inspection/repair.
For strain measurement applications such as structural testing, strain gauges require very high man-hours to prepare and apply and the full field strain system is very expensive. Structural testing of composite materials often involves attachment of many strain gauges and some NDE sensors for tracking damage growth. High-speed video is often used right before final failure to collect important data on the modes of failure.
Any advance in technology which could be employed to overcome some or all of the foregoing drawbacks would be desirable.
The subject matter disclosed herein is directed in part to methods for enhancing the visualization of small strains or wave patterns in a structure using a video-based motion amplification means. In particular, the video-based methods disclosed herein can be employed for NDE of aircraft structures (such as honeycomb/sandwich structures) under loading to detect sub-surface damage. In some NDE embodiments disclosed in detail below, common digital video images of structures under applied load are processed using motion magnification techniques to show minute surface strains that indicate sub-surface damage. The use of motion magnification software enables a video-based method of NDE that is rapid, low cost, area-based, and non-contact.
In accordance with some embodiments disclosed hereinafter, a mechanical stress (quasi-static or dynamic) or thermal stress is introduced into the local area where damage is suspected. A standard (or high speed for some dynamic stress approaches) video recording is made of the area under test. The video is processed using a motion amplification algorithm which magnifies extremely small motions. The motion amplification can reveal strains (for static or thermal loading) or wave patterns (for dynamic loading) generated on the surface of the part. If there is damage or structural change, the resulting surface strains will indicate it, or the surface waves in that area will change in phase, amplitude, or both, and will be indicated in the video images. Sub-surface damage can be quickly and easily indicated. These methods can be performed in real-time, creating a strain-sensitive viewer to find and quantify damage to aircraft structure.
Other systems disclosed herein use motion magnification techniques to highlight local failure events during structural testing, thereby providing a low-cost, wide-area method for monitoring structural testing. High-speed video is often used right before final failure to collect important data on the modes of failure. The high-speed video of current and even archived tests would provide imaging of the strains at the point of failure. When applied to structural testing, the additional data provided using motion magnification may reduce the number of tests required and improve structural models. The time-consuming sensor set-ups could be reduced as well.
Motion magnification technology can be used to process video images in real-time at an inspection site or to process archival video image data. In preferred embodiments, the motion magnification software will operate in real-time to enable high-speed video imaging of the structure alongside the magnified strain, for both NDE and testing applications. Reviewing archival high-speed video data could indicate more specific damage growth phenomena that would improve structural models and overall understanding of failure mechanisms.
One aspect of the subject matter disclosed in detail below is a method for non-destructive evaluation of an area on a structure, the method comprising: introducing stress into a local area of a structure where hidden damage may be present; recording a video of the stressed local area; processing the video using motion amplification to magnify small motions in the stressed local area; and observing the processed video. In accordance with various embodiments, the loading is produced by evacuating a volume adjacent to the local area; by transferring heat into or out of the local area; or by mechanically generating structural waves in the local area. The method may further comprise: identifying a flaw or damage in the local area and then capturing a screenshot from the processed video which shows the identified flaw or damage; and marking a location of the identified flaw or damage on the structure. In addition, the method may further comprise concurrently displaying the video and the processed video on respective portions of a screen of a display unit.
Another aspect is a method for highlighting local failure events during structural testing, the method comprising: placing a structure in a materials testing machine; actuating the materials testing machine to apply a load to the structure; recording a video of the loaded structure; processing the video using motion amplification to magnify small motions in the loaded structure; and observing the processed video. This method may further comprise correlating an image from the processed video with other sensor data, a finite element model or structural code.
A further aspect of the subject matter disclosed in detail below is a test set-up for non-destructive evaluation of a structure, comprising: a structure to be evaluated; means for introducing stress into the structure; a computer system; a video camera aimed at the structure or portion thereof and connected to the computer system; and a display unit connected to the computer system, the display unit comprising a screen. The computer system is programmed to perform the following operations: receiving a video of the structure from the camera; processing the video using motion amplification to magnify small motions in the structure; and causing the display unit to display the processed video on at least a first portion of the screen. The computer system may be further programmed to cause the display unit to display the unprocessed video on a second portion of the screen and/or to control the state of the means for introducing stress into the structure.
In accordance with some embodiments, the means for introducing stress into the structure comprise: (a) means for enclosing a volume that surrounds the structure or is adjacent to a portion of the structure; (b) a vacuum pump connected to the enclosed volume by a conduit; and (c) a control valve installed in the conduit between the enclosed volume and the vacuum pump, the control valve having open and closed states, the enclosed volume and the vacuum pump being in fluid communication when the control valve is in the open state and not in fluid communication when the control valve is in the closed state. In accordance with further embodiments, the means for introducing stress into the structure comprise a flash or controllable heat lamp or a mechanical driver or a fatigue or static loading test machine.
Other aspects of systems and methods that utilize motion magnification for non-destructive evaluation or testing of structures are disclosed below.
Reference will hereinafter be made to the drawings in which similar elements in different drawings bear the same reference numerals.
Embodiments of systems and methods for using motion magnification technology to perform non-destructive evaluation of structures will now be described. Thereafter systems and methods for using motion magnification technology to monitor structural testing will be described.
To prove the concept of using motion magnification technology to perform non-destructive evaluation of structures, a test was conducted in which a ¾ inch×1 inch flaw was machined into a backside of a ⅛-inch-thick composite laminate. In the first part of the test, a light was placed behind the laminate and a video was recorded of an area on the front surface overlapping the machined flaw.
The specific set-up shown in
The set-up shown in
The vacuum hood 26 and external surface of the front skin 12b define an enclosed volume 16. The enclosed volume 16 and vacuum pump 30 are in fluid communication via the conduit 18 when the control valve 32 is in an open state. The enclosed volume 16 and vacuum pump 30 are not in fluid communication when the control valve 32 is in a closed state. When the enclosed volume 16 is in fluid communication with the vacuum pump 30, the latter can be operated to evacuate the enclosed volume 16 until at least an imperfect vacuum is formed (i.e., the vacuum pressure inside the enclosed volume 16 is much less than atmospheric pressure).
The control valve 32 is under the control of a computer 20 programmed with motion magnification and image analysis software. The computer 20 controls the state of the control valve 32 for cycling or ramping the vacuum pressure inside the enclosed volume 16. The resulting vacuum pressures inside the enclosed volume 16 will exert stresses that introduce strains or waves in the front skin 12b in the local area overlying the hidden skin-core disbond 14.
The set-up shown in
In addition, the set-up shown in
The set-up further comprises a display unit 22 connected to the computer 20 and having a display screen. The computer 20 is programmed to perform the following operations: receiving the video image data from the video camera 24; processing the video image data using motion amplification to magnify motion in the structure; and causing the display unit 22 to display the unprocessed (i.e., raw) video (showing the area under inspection) on one side of the screen and the processed video (showing the hidden damage) on the other side of the screen in a side-by-side relationship.
In accordance with alternative embodiments, instead of attaching a vacuum hood 26 to a portion of the aircraft structure 12, the entire aircraft structure 12 can be placed inside of a vacuum chamber. If the vacuum pressure inside that vacuum chamber were then changed to produce vacuum loading, the video captured by the video camera 24 could be processed using motion magnification to display the entire aircraft structure 12, including all flaw areas at once.
NDE of an aircraft structure 12 (e.g., a honeycomb/sandwich structure) having an area in which hidden damage, such as a skin-core disbond 14, is suspected.
The set-up shown in
The set-up shown in
The set-up further comprises a display unit 22 connected to the computer 20. Again the computer 20 is programmed to receive the video image data from the camera 24; process the video image data using motion amplification; and cause (i.e., control or command) the display unit 22 to display the unprocessed video (showing the location under inspection) on one side of the screen and the processed video (showing differential motion due to thermal loading) on the other side in a side-by-side relationship.
The set-up shown in
Motion magnification technology can be used by commercial airlines for NDE or pre-NDE of sandwich structures on aircraft. In a pre-NDE method, the motion-magnified video recorded at an airport can be shown in real-time to a remote expert for rapid damage assessment. Motion magnification could be applied as an additional feature to any image-based NDE hardware for improved damage detection. Suppliers of sandwich structure could use it to check their product.
In an alternative application, motion magnification technology can be used for highlighting local failure events during structural testing.
In accordance with a further embodiment, video recordings of unplanned events (such as failure of aircraft, buildings, bridges, etc.) can be reviewed to provide improved failure analysis and pinpointing of failure initiation and progress. Initial and small motions and strains can be captured and analyzed for improved assessments.
While methods for enhancing the visualization of small strains or wave patterns in a structure using a video-based motion amplification means have been described with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the teachings herein. In addition, many modifications may be made to adapt the concepts and reductions to practice disclosed herein to a particular situation. Accordingly, it is intended that the subject matter covered by the claims not be limited to the disclosed embodiments.
As used in the claims, the term “computer system” should be construed broadly to encompass a system having at least one computer or processor, and which may have multiple computers or processors that communicate through a network or bus. As used in the preceding sentence, the terms “computer” and “processor” both refer to devices having a processing unit (e.g., a central processing unit) and some form of memory (i.e., computer-readable medium) for storing a program which is readable by the processing unit.
In construing the claim limitation “means for enclosing a volume that surrounds said structure or is adjacent to a portion of said structure”, the structures for performing the recited function include the vacuum hood and vacuum chamber disclosed herein and equivalents thereof.
The method claims set forth hereinafter should not be construed to require that the steps recited therein be performed in alphabetical order (any alphabetical ordering in the claims is used solely for the purpose of referencing previously recited steps) or in the order in which they are recited. Nor should they be construed to exclude any portions of two or more steps being performed concurrently or alternatingly.