DOI QR코드

DOI QR Code

Ultrasonic wireless sensor development for online fatigue crack detection and failure warning

  • Yang, Suyoung (Department of Civil and Environmental Engineering, Korea Advanced Institute of Science and Technology) ;
  • Jung, Jinhwan (Department of Electrical Engineering, Korea Advanced Institute of Science and Technology) ;
  • Liu, Peipei (Department of Civil and Environmental Engineering, Korea Advanced Institute of Science and Technology) ;
  • Lim, Hyung Jin (Department of Civil and Environmental Engineering, Korea Advanced Institute of Science and Technology) ;
  • Yi, Yung (Department of Electrical Engineering, Korea Advanced Institute of Science and Technology) ;
  • Sohn, Hoon (Department of Civil and Environmental Engineering, Korea Advanced Institute of Science and Technology) ;
  • Bae, In-hwan (New Airport Hiway Co., Ltd)
  • Received : 2018.11.26
  • Accepted : 2019.01.21
  • Published : 2019.02.25

Abstract

This paper develops a wireless sensor for online fatigue crack detection and failure warning based on crack-induced nonlinear ultrasonic modulation. The wireless sensor consists of packaged piezoelectric (PZT) module, an excitation/sensing module, a data acquisition/processing module, a wireless communication module, and a power supply module. The packaged PZT and the excitation/sensing module generate ultrasonic waves on a structure and capture the response. Based on nonlinear ultrasonic modulation created by a crack, the data acquisition/processing module periodically performs fatigue crack diagnosis and provides failure warning if a component failure is imminent. The outcomes are transmitted to a base through the wireless communication module where two-levels duty cycling media access control (MAC) is implemented. The uniqueness of the paper lies in that 1) the proposed wireless sensor is developed specifically for online fatigue crack detection and failure warning, 2) failure warning as well as crack diagnosis are provided based on crack-induced nonlinear ultrasonic modulation, 3) event-driven operation of the sensor, considering rare extreme events such as earthquakes, is made possible with a power minimization strategy, and 4) the applicability of the wireless sensor to steel welded members is examined through field and laboratory tests. A fatigue crack on a steel welded specimen was successfully detected when the overall width of the crack was around $30{\mu}m$, and a failure warnings were provided when about 97.6% of the remaining useful fatigue lives were reached. Four wireless sensors were deployed on Yeongjong Grand Bridge in Souht Korea. The wireless sensor consumed 282.95 J for 3 weeks, and the processed results on the sensor were transmitted up to 20 m with over 90% success rate.

Keywords

Acknowledgement

Supported by : National Research Foundation (NRF), Ministry of Land, Infrastructure and Transport (MOLIT) of South Korea

References

  1. Amura, M and Meo, M. (2012), "Prediction of residual fatigue life using nonlinear ultrasound", Smart Mater. Struct., 21(4), 045001.
  2. Caizzone, S., DiGampaolo, E. and Marrocco, G. (2014), "Wireless crack monitoring by stationary phase measurements from coupled RFID tags", IEEE Trans. Antenn. Propagat., 62(12), 6412-6419. https://doi.org/10.1109/TAP.2014.2360553
  3. Cantrell, J.H. and Yost, W.T. (2001), "Nonlinear ultrasonic characterization of fatigue microstructures", Int. J. Fatig., 23, 487-490. https://doi.org/10.1016/S0142-1123(01)00162-1
  4. Chan, T.H., Li, Z. and Ko, J.M. (2004), "Evaluation of typhoon induced fatigue damage using health monitoring data for the Tsing Ma Bridge", Struct. Eng. Mech., 17(5), 655-670. https://doi.org/10.12989/sem.2004.17.5.655
  5. Chen, H.L.R. and Choi, J.H. (2006), "Fatigue crack growth and remaining life estimation of AVLB components", Struct. Eng. Mech., 23(6), 651-674. https://doi.org/10.12989/sem.2006.23.6.651
  6. Chen, J., Yuan, S., Qiu L., Cai, J. and Yang, W. (2016), "Research on a lamb wave and particle filter-based on-line crack propagation prognosis method", Sens., 16(3), 320. https://doi.org/10.3390/s16030320
  7. Chintalapudi, K., Fu, T., Paek, J., Kothari, N., Rangwala, S., Cafferey, J. and Masri, S. (2006), "Monitoring civil structures with a wireless sensor network", IEEE Intern. Comput., 10(2), 26-34. https://doi.org/10.1109/MIC.2006.38
  8. De Lima, W. and Hamilton, M. (2003), "Finite-amplitude waves in isotropic elastic plates", J. Sound Vibr., 265(4), 819-839. https://doi.org/10.1016/S0022-460X(02)01260-9
  9. Duffour, P., Morbidini, M. and Cawley, P. (2006), "A study of the vibro-acoustic modulation technique for the detection of cracks in metals", J. Acoust. Soc. Am., 119(3), 1463-1475. https://doi.org/10.1121/1.2161429
  10. Fierro, G.P.M. and Meo, M. (2015), "Residual fatigue life estimation using a nonlinear ultrasound modulation method", Smart Mater. Struct., 24(2), 025040.
  11. Forrest, P.G. (2013), Fatigue of Metals, Elsevier.
  12. Gholizadeh, S., Leman, Z. and Baharudin, B. (2015), "A review of the application of acoustic emission technique in engineering", Struct. Eng. Mech., 54(6), 1075. https://doi.org/10.12989/sem.2015.54.6.1075
  13. Grosse, C.U., Glaser, S.D. and Knuger, M. (2010), "Initial development of wireless acoustic emission sensor Motes for civil infrastructure state monitoring", Smart Struct. Syst., 6(3), 197-209. https://doi.org/10.12989/sss.2010.6.3.197
  14. Hamia, R., Cordier, C. and Dolabdjian, C. (2014), "Eddy-current non-destructive testing system for the determination of crack orientation", Ndt E Int., 61, 24-28. https://doi.org/10.1016/j.ndteint.2013.09.005
  15. Ihn, J.B. and Chang, F.K. (2004), "Detection and monitoring of hidden fatigue crack growth using a built-in piezoelectric sensor/actuator network: I. Diagnostics", Smart Mater. Struct., 13(3), 609. https://doi.org/10.1088/0964-1726/13/3/020
  16. Jang, S., Jo, H., Cho, S., Mechitov, K., Rice, J.A., Sim, S.H. and Agha, G. (2010), "Structural health monitoring of a cable-stayed bridge using smart sensor technology: Deployment and evaluation", Smart Struct. Syst., 6(5-6), 461-480. https://doi.org/10.12989/sss.2010.6.5_6.461
  17. Jhang, K.Y. (2009), "Nonlinear ultrasonic techniques for nondestructive assessment of micro damage in material: a review", Int. J. Prec. Eng. Manufact., 10(1), 123-135. https://doi.org/10.1007/s12541-009-0019-y
  18. Kilic, G. (2014), "Wireless sensor network protocol comparison for bridge health assessment", Structu. Eng. Mech., 49(4), 509-521. https://doi.org/10.12989/sem.2014.49.4.509
  19. Kim, Y., Lim, H.J. and Sohn, H. (2018), "Nonlinear ultrasonic modulation based failure warning for aluminum plates subject to fatigue loading", Int. J. Fatig., 114, 130-137. https://doi.org/10.1016/j.ijfatigue.2018.05.014
  20. Knopp, J.S., Aldrin, J.C. and Jata, K.V. (2009), "Computational methods in eddy current crack detection at fastener sites in multi-layer structures", Nondestruct. Test. Evaluat., 24(1-2), 103-120. https://doi.org/10.1080/10589750802195519
  21. Kwon, S.D., Park, J. and Law, K. (2013), "Electromagnetic energy harvester with repulsively stacked multilayer magnets for low frequency vibrations", Smart Mater. Struct., 22(5), 055007.
  22. Li, N., Sun, J., Jiao, J., Wu, B. and He, C. (2016), "Quantitative evaluation of micro-cracks using nonlinear ultrasonic modulation method", Ndt E Int., 79, 63-72. https://doi.org/10.1016/j.ndteint.2015.12.003
  23. Lim, H.J., Kim, Y., Koo, G., Yang, S., Sohn, H., Bae, I.H. and Jang, J.H. (2016), "Development and field application of a nonlinear ultrasonic modulation technique for fatigue crack detection without reference data from an intact condition", Smart Mater. Struct., 25(9), 095055.
  24. Lim, H.J., Sohn, H. and Liu, P. (2014), "Binding conditions for nonlinear ultrasonic generation unifying wave propagation and vibration", Appl. Phys. Lett., 104(21), 214103.
  25. Liu, P., Lim, H.J., Yang, S., Sohn, H., Lee, C.H., Yi, Y. and Bae, I.H. (2017), "Development of a "stick-and-detect" wireless sensor node for fatigue crack detection", Structural Health Monitor., 16(2), 153-163. https://doi.org/10.1177/1475921716666532
  26. Liu, Y., He, C., Huang, C., Khan, M.K. and Wang, Q. (2014), "Very long life fatigue behaviors of 16Mn steel and welded joint", Struct. Eng. Mech., 52(5), 889-901. https://doi.org/10.12989/sem.2014.52.5.889
  27. Lynch, J.P., Law, K.H., Kiremidjian, A.S., Carryer, E., Farrar, C.R., Sohn, H. and Wait, J.R. (2004), "Design and performance validation of a wireless sensing unit for structural monitoring applications", Struct. Eng. Mech., 17(3-4), 393-408. https://doi.org/10.12989/sem.2004.17.3_4.393
  28. Lynch, J.P., Wang, Y., Loh, K.J., Yi, J.H. and Yun, C.B. (2006), "Performance monitoring of the Geumdang Bridge using a dense network of high-resolution wireless sensos", Smart Mater. Struct., 15(6), 1561. https://doi.org/10.1088/0964-1726/15/6/008
  29. Mainwaring, A., Culler, D., Polastre, J., Szewczyk, R. and Anderson, J. (2002), "Wireless sensor networks for habitat monitoring", Proceedings of the 1st ACM International Workshop on Wireless Sensor Networks and Applications, Atlanta, Georgia, U.S.A., September.
  30. Marin, A., Kishore, R., Schaab, D.A., Vuckovic, D. and Priya, S. 2016), "Micro wind turbine for powering wireless sensor nodes", Energy Harvest. Syst., 3(2), 139-152. https://doi.org/10.1515/ehs-2013-0004
  31. McCullagh J, Galchev T, Peterson R, et al. (2014), "Long-term testing of a vibration harvesting system for the structural health monitoring of bridges", Sens. Actuat. A: Phys., 217, 139-150. https://doi.org/10.1016/j.sna.2014.07.003
  32. Mi, B., Michaels, J.E. and Michaels, T.E. (2006), "An ultrasonic method for dynamic monitoring of fatigue crack initiation and growth", J. Acoust. Soc. Am., 119(1), 74-85. https://doi.org/10.1121/1.2139647
  33. Mix, P.E. (2005), Introduction to Nondestructive Testing: A Training Guide, John Wiley & Sons.
  34. Nair, A. and Cai, C. (2010), "Acoustic emission monitoring of bridges: Review and case studies", Eng. Struct., 32(6), 1704-1714. https://doi.org/10.1016/j.engstruct.2010.02.020
  35. Nallasivam, K., Talukdar, S. and Dutta, A. (2008), "Fatigue life prediction of horizontally curved thin walled box girder steel bridges", Struct. Eng. Mech., 28(4), 387-410. https://doi.org/10.12989/sem.2008.28.4.387
  36. Rabiei, M. and Modarres, M. (2013), "Quantitative methods for structural health management using in situ acoustic emission monitoring", Int. J. Fatig., 49, 81-89. https://doi.org/10.1016/j.ijfatigue.2012.12.001
  37. Roberts, T. and Talebzadeh, M. (2003), "Acoustic emission monitoring of fatigue crack propagation", J. Constr. Steel Res., 59(6), 695-712. https://doi.org/10.1016/S0143-974X(02)00064-0
  38. Rokhlin, S. and Kim, J.Y. (2003), "In situ ultrasonic monitoring of surface fatigue crack initiation and growth from surface cavity", Int. J. Fatig., 25(1), 41-49. https://doi.org/10.1016/S0142-1123(02)00055-5
  39. Ruiz-Carcel, C., Hernani-Ros, E., Cao, Y. and Mba, D. (2014), "Use of spectral kurtosis for improving signal to noise ratio of acoustic emission signal from defective bearings", J. Fail. Analy. Prevent., 14(3), 363-371. https://doi.org/10.1007/s11668-014-9805-7
  40. Sankararaman, S., Ling, Y. and Mahadevan, S. (2011), "Uncertainty quantification and model validation of fatigue crack growth prediction", Eng. Fract. Mech., 78, 1487-1504. https://doi.org/10.1016/j.engfracmech.2011.02.017
  41. Sazonov, E., Krishnamurthy, V. and Schilling, R. (2010), "Wireless intelligent sensor and actuator network-a scalable platform for time-synchronous applications of structural health monitoring", Struct. Health Monitor., 9, 465-476. https://doi.org/10.1177/1475921710370003
  42. Sohn, H., Lim, H.J., DeSimio, M.P., Brown, K. and Derriso, M. (2014), "Nonlinear ultrasonic wave modulation for online fatigue crack detection", J. Sound Vibr., 333(5), 1473-1484. https://doi.org/10.1016/j.jsv.2013.10.032
  43. Sohn, H., Lim, H.J., Kim, J.M., et al. (2016), "Self-sufficient and self-contained sensing for local monitoring of in-situ bridge structures", Proceedings of the 8th European Workshop on Structural Health Monitoring, Bilbao, Spain, July.
  44. Su, Z., Zhou, C., Hong, M., Cheng, L., Wang, Q. and Qing, X. (2014), "Acousto-ultrasonics-based fatigue damage characterization: Linear versus nonlinear signal features", Mech. Syst. Sign. Proc., 45(1), 225-239. https://doi.org/10.1016/j.ymssp.2013.10.017
  45. Sunny, A.I., Tian, G.Y., Zhang, J. and Pal, M. (2016), "Low frequency (LF) RFID sensors and selective transient feature extraction for corrosion characterization", Sens. Actuat. A: Phys., 241, 34-43. https://doi.org/10.1016/j.sna.2016.02.010
  46. Tanner, N.A., Wait, J.R., Farrar, C.R. and Sohn, H. (2003), "Structural health monitoring using modular wireless sensors", J. Intellig. Mater. Syst. Struct., 14(1), 43-56. https://doi.org/10.1177/1045389X03014001005
  47. Van Den Abeele, K.A., Johnson, P.A. and Sutin, A. (2000), "Nonlinear elastic wave spectroscopy (NEWS) techniques to discern material damage, part I: Nonlinear wave modulation spectroscopy (NWMS)", J. Res. Nondestruct. Evaluat., 12(1), 17-30. https://doi.org/10.1080/09349840009409646
  48. Wijetunge, S., Gunawardana, U. and Liyanapathirana, R. (2010), "Wireless sensor networks for structural health monitoring: Considerations for communication protocol design", Proceedings of the 2010 IEEE 17th International Conference on IEEE, Doha, Qatar, April.
  49. Wu, W. and Ni, C. (2004), "Probabilistic models of fatigue crack propagation and their experimental verification", Probabilist. Eng. Mech., 19(3), 247-257. https://doi.org/10.1016/j.probengmech.2004.02.008
  50. Yang, S., Jung, S.Y., Kim, K., Liu, P., Lee, S., Kim, J. and Sohn, H. (2018), "Development of a tunable low-frequency vibration energy harvester and its application to a self-contained wireless fatigue crack detection sensor", Struct. Health Monitor., 1475921718786886.
  51. Zaitsev, V.Y., Nazarov, V.E. and Talanov, V.I. (2006), "Nonclassical'manifestations of microstructure-induced nonlinearities: New prospects for acoustic diagnostics", Phys.-Uspekhi, 49(1), 89-94.
  52. Zhang, J. and Tian, G.Y. (2016), "UHF RFID tag antenna-based sensing for corrosion detection & characterization using principal component analysis", IEEE Trans. Antenn. Propagat., 64(10), 4405-4414. https://doi.org/10.1109/TAP.2016.2596898
  53. Zilberstein, V., Schlicker, D., Walrath, K., Weiss, V. and Goldfine, N. (2001), "MWM eddy current sensors for monitoring of crack initiation and growth during fatigue tests and in service", Int. J. Fatig., 23, 477-485. https://doi.org/10.1016/S0142-1123(01)00154-2

Cited by

  1. Investigation on modulation of multi-frequency ultrasonic waves in structures with quadratic nonlinearity vol.28, pp.1, 2021, https://doi.org/10.12989/sss.2021.28.1.043