16.810 Engineering Design and Rapid Prototyping Lecture 9 Structural Testing Instructor(s) Prof. Olivier de Weck January 18, 2005 Outline ! Structural Testing ! ! ! ! Test Protocol for 16.810 (Discussion) ! ! ! 16.810 Why testing is important Types of Sensors, Procedures …. Mass, Static Displacement, Dynamics Application of distributed load Wing trailing edge displacement measurement First natural frequency testing 2 Data Acquisition and Processing for Structural Testing (1) Sensor Overview: Accelerometers, Laser sensors , Strain Gages , Force Transducers and Load Cells, Gyroscopes (2) Sensor Characteristics & Dynamics: FRF of sensors, bandwidth, resolution, placement issues (3) Data Acquistion Process: Excitation Sources, Non-linearity, Anti-Alias Filtering, Signal Conditioning (4) Data Post-Processing: FFT, DFT, Computing PSD's and amplitude spectra, statistical values of a signal such as RMS, covariance etc. (5) Introduction to System Identification ETFE, DynaMod Measurement Models 16.810 3 Why is Structural Testing Important? ! ! ! ! ! ! ! ! Product Qualification Testing Performance Assessment System Identification Design Verification Damage Assessment Aerodynamic Flutter Testing Operational Monitoring Material Fatigue Testing stimulus u(t) response x(t) Structural System DAQ DAQ = data acquisition DSP = digital signal processing 16.810 DSP Example: Ground Vibration Testing F-22 Raptor #01 during ground vibration tests at Edwards Air Force Base, Calif., in April 1999 4 I. Sensor Overview This Sensor morphology is useful for classification of typical sensors used in structural dynamics. Sensor Morphology Table Type Linear Bandwidth Low Medium High Derivative Position Rate Acceleration Reference Absolute Relative Quantity Force/Torque Displacement Impedance Low Example: uniaxial strain gage 16.810 Rotational High Need units of measurement: [m], [Nm],[µstrain],[rad] etc… 5 Sensor Examples for Structural Dynamics Example: fixed-fixed Goal: Explain what they measure and how they work beam with center load laser sensors excitation accelerometers gyroscopes strain gages mb m load cells shaker First flexible mode frequency: 16.810 l inductive sensors ground EI ω n = 14 3 l ( m + 0.375mb ) 6 Strain Gages Strain: ∆l ε= lo Strain gages measure strain (differential displacement) over a finite area via a change in electrical resistance R=lρ [Ω] Current Nominal length lo: lo With applied strain: Implementation: Wheatstone bridge circuit bond to test article GND V+ Vin Io = lo ρ Vin Iε = (lo + ∆l ) ρ strain gages feature polyimide-encapsulated constantan grids with copper-coated solder tabs. Mfg: 16.810 7 Accelerometers Accelerometers measure linear acceleration in one, two or three axes. We distinguish: !! x(t ) → s 2 X ( s ) − sx (0) − dx(0) dt (generally neglect initial conditions) • single vs. multi axis accelerometers • DC versus non-DC accelerometers mag Recorded voltage Vout (t ) = K a !! x(t ) + V0 +40dB/dec rolloff Accelerometer response to base motion ω Can measure: linear, centrifugal and gravitational acceleration Use caution when double-integrating acceleration to get position (drift) Single-Axis Accelerometer must be aligned with sensing axis. C1 a C2 Example: Kistler Piezobeam (not responsive at DC) Manufacturers: Kistler, Vibrometer, Summit,... 16.810 Example: Summit capacitive accelerometer (DC capable) 8 Laser Displacement Sensors sensor x target Records displacement directly via slant range measurement. [VDC] V out Typical Settings +7 I: 2µm-60 ms II: 15µm-2ms III: 50µm-0.15ms x (t ) → X ( s ) 0 Resolution tradeoff spatial vs. temporal Distance x is recorded via triangulation between the laser diode (emitter), the target and the receiver (position sensitive device - PSD). -7 Vibrometers include advanced processing and scanning capabilities. Manufacturers: Keyence, MTI Instruments,... 16.810 CL range x [m] Advantages: contact-free measurement Disadvantages: need reflective, flat target limited resolution ~ 1µm 9 Force Transducers / Load Cells Force Transducers/Load Cells are capable of measuring Up to 6 DOF of force on three orthogonal axes, and the moment (torque) about each axis, to completely define the loading at the sensor's location The high stiffness also results in a high resonant frequency, allowing accurate sensor response to rapid force changes. Load cells are electro-mechanical transducers that translate force or weight into voltage. They usually contain strain gages internally. Fz Mz My Fy Mx Fx Manufacturers: JR3, Transducer Techniques Inc. ... 16.810 10 Other Sensors ! Fiber Optic strain sensors (Bragg Gratings) input I optical fiber λ transmitted reflection Broad spectrum input light s reflected only at a specific wavelength determined by the grating spacing which varies with strain. • Ring Laser Gyroscopes (Sagnac Effect) • PVDF or PZT sensors 16.810 11 II. Sensor Characteristics & Dynamics Goal: Explain performance characteristics (attributes of real sensors) saturation limit S When choosing a sensor for a non-linear particular application we must specify the following requirements: Sensor Performance Requirements: linear Y • Dynamic Range and Span • Accuracy and Resolution • Absolute or Relative measurement • Sensor Time Constant • Bandwidth • Linearity • Impedance • Reliability (MTBF) Constraints: Power: 28VDC, 400 Hz AC, 60 Hz AC Cost, Weight, Volume, EMI, Heat 16.810 S(X) dynamic range X Calibration is the process of obtaining the S(X) relationship for an actual sensor. In the physical world S depends on things other than X. Consider modifying input Y (e.g. Temp) E.g. Load cell calibration data: X= mass (0.1 , 0.5 1.0 kg…) S= voltage (111.3 , 563.2, 1043.2 mV) 12 Sensor Frequency Response Function x(t) m k s 2 X ( s) cs + k = 2 Ga ( s ) = 2 s X b ( s ) ms + cs + k c Ideal Accelerometer FRF from Base Motion xb(t) 2 Example: Accelerometer m = 4.5 g k = 7.1e+05 N/m c= 400 Ns/m Magnitude [dBl 0 -2 -6 -8 -10 -12 -14 -16 -18 0 10 Typically specify bandwidth as follows: Example: Kistler 8630B Accelerometer Frequency Response +/-5%: 0.5-2000 Hz 16.810 bandwidth -4 101 102 103 104 105 Frequency [Hz] Note: Bandwidth of sensor should be at least 10 times higher than highest frequency of signal s(t) 13 Sensor Time Constant How quickly does the sensor respond to input changes ? Second-Order Instruments First-Order Instruments dy a1 + ao y = bou dt Dividing by ao gives: a1 dy bo +y= u a dt a "0 "o τ K In s-domain: Y ( s) K = U ( s) τ s + 1 τ : time constant K: static sensitivity 16.810 2 d y dy a2 2 + a1 + ao y = bo u dt dt Essential parameters are: bo K# ao static sensitivity In s-domain: ao a2 a1 ζn # 2 ao a2 natural frequency damping ratio ωn # Y ( s) K = 2 U ( s ) s + 2ζ nω n s + ω n2 Time constant here is: τ = 1 ζω n Time for a 1/e output change 14 Sensor Range & Resolution saturation Dynamic range= ratio of largest to smallest dynamic input a sensor measures dB=20*log(N) output Hysteresis due to internal sensor friction High operating limit range (=span) threshold input resolution Low operating limit Resolution = smallest input increment that gives rise to a measurable output change. Resolution and accuracy are NOT the same thing ! 16.810 Threshold= smallest measurable input 15 Accuracy Measurement theory = essentially error theory Accuracy=lack of errors Total error = random errors & systematic errors (IMPRECISION) •Temperature fluctuations •external vibrations •electronic noise (amplifier) ±3σ uncertainty limits (BIAS) • Invasiveness of sensor • Spatial and temporal averaging • human bias • parallax errors • friction, magnetic forces (hysteresis) bias 3σ accuracy quoted as: “4.79 ± 0.54 µε” µε 4.25 4.32 4.79 4.91 5.33 Reading Best True Value (unknown) Estimate Probable error accuracy: ep=0.674σ σ “4.79 ± 0.12 µε” Note: Instrument standard used for calibration should be ~ 10 times more accurate than the sensor itself (National Standards Practice) 16.810 16 Linearity “Independent Linearity”: Usually have largest errors at full scale deflection of sensor +/- A percent of reading or +/- B percent of full scale, whichever is greater B% of full scale A% of reading Output Static Sensitivity = dS dX mV kg (slope of calibration curve) least squares fit Input Point at which A% of reading = B% of full scale input 16.810 Increasing values decreasing values Full scale 17 Placement Issues Need to consider the dynamics of the structure to be tested before choosing where to place sensors: I 0 0 q= 2 q + T u Φ βu −2 Z Ω −Ω%&%% $ $% ' %&% ' A B y = β y Φ 0 q + [ 0] u " $%&%' D C Observability determined by product of mode shape matrix Φ and output influence coefficients βy Example: TPF SCI Architecture Mode at 100 Hz unobservable if sensor placed at this “node” Observability gramian: Wo → AT Wo + Wo A + C T C = 0 Other considerations: • Pole-zero pattern if sensor used for control (collocated sensor-actuator pair) • Placement constraints (volume, wiring, surface properties etc…) 16.810 18 Invasiability / Impedance How does the measurement/sensor influence the physics of the system ? Remember Heisenberg’s uncertainty principle: x ∆x ∆p ≥ ( sensor qi1 ⋅ qi 2 = P [W] Power 2 P = q i1 drain: F Impedance characterizes “loading” effect of sensor on the system. Sensor extracts power/energy -> Consider “impedance” and “admittance” k ks Want to Generalized measure F input impedance: Error due to measurement: “measured” qi1 Z gi # qi 2 qi1m = Z go Effort variable = Flow variable 1 qi1u Z gi + 1 Z gi Force Velocity Z gi ∝ k s “undisturbed” Load Cell: High Impedance = ks large vs. Strain Gage: Low Impedance= ks small Conclusion: Impedance of sensors lead to errors that must be modeled in a high accuracy measurement chain (I.e. include sensor impedance/dynamics) 16.810 19 III. Data Acquisition Process Typical setup X physical variable Excitation X Transducer Goal: Explain the measurement chain Excitation source provides power to the structural system such that a dynamic response is observable in the first place Transducer “transforms” the physical variable X to a measured signal Amplifier Amplifier is used to increase the measurement signal strength Filter Filter is used to reject unwanted noise from the measurement signal A/D Converter Analog to Digital converter samples the continuous measurement signal in time and in amplitude S DSP Display 16.810 S signal variable Digital Signal Processing turns raw digital sensor data into useful dynamics information 20 System Excitation Types Type B: Broadband Noise (Electromechanical Shakers) Type A 0 -2 0 2 Type B Type A : Impulsive Excitation (Impulse Hammers) Overview of Excitation Types 2 16.810 Type C 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 Time [sec] 4 5 0 -2 0 2 Type D Type D: Environmental (Slewing, Wind Gusts, Road, Test track, Waves) 2 0 -2 0 2 Type C: Periodic Signals (Narrowband Excitation) 1 0 -2 0 21 Excitation Sources u (t ) = F (t ) = Foδ (t ) Wide band excitation at various energy levels can be applied to a structure using impulse force hammers. They generate a nearly perfect impulse. t u(t) y(t) G(ω) Impulse Response h(t) Broadband y (t ) = ∫ u (τ )h(t − τ )dτ (convolution integral) −∞ Y (ω ) = U (ω ) H (ω ) " Fo ⋅1 G (ω ) = H (ω ) (no noise) The noise-free response to an ideal impulse contains all the information about the LTI system dynamics Shaker can be driven by periodic or broadband random current from a signal generator. S yy (ω ) = G ( jω ) Suu (ω )G ( jω ) H Input PSD Record Syy,Suu and solve for G Output PSD 16.810 22 Excitation Amplitude / Non-Linearity Plots Courtesy Mitch Ingham damping frequency Example from MODE Experiment in µ-dynamics (torsion mode): non-linear PZT Excitation Conclusion: Linearity is only preserved for relatively small amplitude excitation (geometrical or material non-linearity, friction, stiction etc…) Excitation amplitude selection is a tradeoff between introducing non-linearity (upper bound) and achieving good signal-to-noise ratio (SNR) (lower bound). 16.810 23 Signal Conditioning and Noise n(t) u(t) Test Article y(t) K Consider Signal to Noise Ratio (SNR) = +∞ Power Content in Signal Power Content in Noise Y ( s ) = KG ( s )U ( s ) + N ( s ) Look at PSD’s: Solve for system dynamics via Cross-correlation uy G ( jω ) ≅ Suy (ω ) 16.810 S yy (ω ) = S yy (ω ) ∫S −∞ nn (ω ) dω Snn = KG ( jω ) + S yy (ω ) Suu 2 Decrease noise effect by: Noise •Increasing Suu (limit non-linearity) contribution •Increasing K (also increases Snn) •Decreasing Snn (best option) Suu (ω ) Quality estimate via coherence function When we amplify the signal, we introduce measurement noise n(t), which corrupts the measurement y(t) by some amount. Cyu(ω) 24 A/D Quantization Time quantization: f s x(t) analog signal digital signal Sampling Frequency: tk = k ⋅ ∆T x(t) t Amplitude quantization: #bits & range 1 ∆T ˆ x(k) A/D Figure courtesy Alissa Clawson Signal Amplitude [bits] Example: 8 bits 1 bit for 1 sign 27 = 128 levels ∆T fs = original and quantized actuator signals: X 600 400 200 0 -200 -400 0 0.5 1 1.5 2 2.5 2 2.5 noise signal 200 100 0 -100 -200 0 0.5 1 1.5 time [sec] Nyquist Theorem: In order to recover a signal x(t) exactly it is necessary to sample the signal at a rate greater than twice the highest frequency present. Rule of thumb: Sample 10 times faster than highest frequency of interest ! 16.810 25 Anti-AliasingLPFFiltering VERY IMPORTANT ! x(t) Filtering should be done on the ωf ≤ analog signal, e.g. 4-th order Butterworth ˆ x(k) A/D 2π f s 2 No Anti-Aliasing 1.5 Sample signal x(t) Want f < 50 Hz 1 5 Signal analog sampled 0.5 0 -5 0 0 5 10 15 20 25 30 35 40 45 50 Anti-Aliasing filter 2nd-order with 40 Hz corner frequency 1.5 Fs=100Hz 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 1 Amplitudes =[1 1.5 1.5 0.75 ]; frequencies =[2 10 30 85 ]; 0.5 0 85 Hz signal is “folded” down 0 from the Nyquist frequency (50 Hz) to 15 Hz 5 10 15 20 25 30 35 Frequency [Hz] Solution: Use a low pass filter (LPF) which avoids signal corruption by frequency components above the Nyquist frequency 16.810 40 45 50 Small attenuation 26 IV. Data Post-Processing Goal: Explain what we do after data is obtained Stationary processes (E[x], E[x2],…) are time invariant Analyze in frequency-domain Transient processes Analyze in time-domain (Ts, Percent overshoot etc.) Impulse response Fourier transform of h(t)->H(ω) The FFT (Fast Fourier Transform) is the workhorse of DSP (Digital Signal Processing). 16.810 27 Metrics for steady state processes Mean Value: Steady State Process Example x 10-6 T /2 1 µ x = E[ x] = x(t )dt ∫ T −T / 2 2.5 2 Signal x [m] 1.5 (central tendency metric) 1 0.5 Discrete: 0 -0.5 ∑x k =1 k σ x2 = E[( x − µ x ) 2 ] = -1.5 E[ x 2 ] − µ x2 -2 1 Rarely interested in higher moments. 16.810 N Variance: -1 0 1 µx = N 2 3 Time [sec] 4 5 6 (dispersion metric) Root-mean-square (RMS) = Equal to σx only for zero mean E[ x 2 ] 28 Metrics for transient processes -3 Step Response signal example 4.5 x 10 P.O. Signal x(t) [m] 4 Example: Step Response (often used to evaluate performance of a controlled structural system) 3.5 Peak Time: 3 2.5 πα ωn 4 Ts = ζω n Tp = Settling Time: 2 Evaluate in time domain 1.5 1 Ts 0.5 0 Tp 0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018 0.02 16.810 P.O. = 100 exp ( −πζα ) Damping α term: ζ<1 = 1 1−ζ 2 1 −ζω nt −1 1 x(t ) = xo 1 − e sin(ω nα t + tan αζ α Time t [sec] If assume one dominant pair of complex poles: Percent Overshoot: 29 Metrics for impulse response/decay from Initial Conditions Example: Decay process or impulse response Oscillatory Exponential Decay 60 x(t=0)=60 (Initial Condition) Impulse response (time domain) Signal Strength 50 x(t ) = 40 50e −t +∞ ∫ u (τ )h(t − τ )dτ −∞ (convolution operation) 30 Laplace domain: Y ( s ) = H ( s )U ( s ) 20 (multiplication) 10 0 0 0.5 1 1.5 2 2.5 Time [sec] 3 3.5 4 Im Rate of decay depended on poles Re x(t ) = 50 exp(−t ) + 10 exp((−1 + 40 j )t ) 16.810 30 FFT and DFT Fourier series: Discrete Fourier Transform: N −1 X k = ∑ xr e Approximates the continuous Fourier transform: k , T T − i 2π f k tr r =0 fk = x (t ) = ∑ cn e iω n t tr = r T N X (ω ) = ∫ x(t )e −iωt dt 0 k = 0,1,..,N-1 r = 0,1,…,N-1 k and r are integers Note: N = # of data points T= time length of data Xk are complex The Power Spectral Density (PSD) Function gives the frequency content of the power in the signal: 2 ∆T Wk = X k ⋅ X kH N FFT - faster algorithm if N = power of 2 (512, 1024,2048,4096 …..) 16.810 31 Amplitude Spectra and PSD Example: processing of Laser displacement sensor data from SSL testbed -5 x 10 Time Domain Signal -6 x 10 4 8 6 2 1 6 PSD [m2/Hz] Amplitude [m] 3 Signal [m] -10 x 10 Power Spectral Density Amplitude Spectrum 4 2 4 2 0 5 10 15 Time [sec] 0 20 SUMMARY OF RESULTS MEAN of time signal: 2.0021e-005 RMS of time signal: 8.6528e-006 RMS of PSD (with fft.m): 8.6526e-006 RMS of AS (with fft.m): 8.6526e-006 RMS of cumulative RMS: 8.6526e-006 Dominant Frequency [Hz]: 40.8234 Dominant Magnitude [m]: 8.5103e-006 -6 x 10 8 8 6 6 4 2 0 2 0 2 10 10 Frequency [Hz] Cumulative RMS 4 2 0 10 16.810 2 10 10 Frequency [Hz] -6 x 10 Dominant Frequencies RMS [m] 0 2 10 10 10 Frequency [Hz] 32 Time domain: MATLAB coding Given signal x and time vector t , N samples, dt=const. dt=t(2)-t(1); % sampling time interval dt fmax=(1/(2*dt)); % upper frequency bound [Hz] Nyquist T=max(t); % time sample size [sec] N=length(t); % length of time vector (assume zero mean) x_mean=mean(x); % mean of signal x_rms=std(x); % standard deviation of signal Amplitude Spectrum: should match X_k = abs(fft(x)); % computes periodogram of x AS_fft = (2/N)*X_k; % compute amplitude spectrum k=[0:N-1]; % indices for FT frequency points f_fft=k*(1/(N*dt)); % correct scaling for frequency vector f_fft=f_fft(1:round(N/2)); % only left half of fft is retained AS_fft=AS_fft(1:round(N/2)); % only left half of AS is retained Power Spectral Density: PSD_fft=(2*dt/N)*X_k.^2; % computes one-sided PSD in Hertz PSD_fft=PSD_fft(1:length(f_fft)); % set to length of freq vector rms_psd=sqrt(abs(trapz(f_fft,PSD_fft))); % compute RMS of PSD 16.810 33 V. System Identification Goal: Explain example of data usage after processing Goal: Create a mathematical model of the system based on input and output measurements alone. Input time histories ui(t) , i=1,2,…n Transfer functions Estimator Output time histories xj(t) , j=1,2,…m ? State space system n(t) white noise input u(t) Gyu Gyu is the actual plant we are trying to identify in the presence of noise q! = Aq + Bu y = Cq + Du y(t) output 16.810 Transfer matrix: G(s) Want to obtain Gyu from: Y ( jω ) = G ( jω )U ( jω ) + V ( jω ) 34 Empirical Transfer Function Estimate (ETFE) Yk ( jω ) ˆ Gkl ( jω ) = U l ( jω ) Obtain an estimate of the transfer function from the I-th input to the j-th output Compute: N ( jω ) ˆ Gkl ( jω ) = Gkl ( jω ) + U l ( jω ) Estimated TF True TF Noise What are the consequences of neglecting the contributions by the noise term ? S yu = E[Y ( s )U * ( s )] SUU = E[UU *] , SYY = E[YY *] Quality Assessment of transfer function estimate via the coherence function: function 2 C yu = 16.810 S yu 2 S yy Suu C yu → 1 Implies small noise (Snn ~ 0) C yu → 0 Implies large noise Poor Estimate Typically we want Cyu > 0.8 35 Averaging data subdivided in Nd parts Y(t) Gˆ ( s) = T1 T2 T3 1 Nd ∑ 1 Nd ... TNd Nd Y ( s)U i (− s ) i =1 i ∑ i=1 U i (s) Nd 2 ETFE with 10 averages ETFE with no averaging 30 30 ETFE True System 20 ETFE 10 avg True System 20 10 10 0 Magnitude [dB] Magnitude [dB] 0 -10 -20 -30 -10 -20 -30 -40 -40 -50 -50 -60 12-state system -60 Error improves with: -70 Bias E[G − G ] ∝ 1 -70 -80 -2 10 16.810 -1 10 0 10 Frequency [Hz] 1 10 2 10 -80 -2 10 -1 10 0 10 Frequency [Hz] Nd 1 10 2 10 36 Model Synthesis Methods Example: Linear Least Squares Polynomial form: bn −1s n −1 + ... + bo B( jω ,θ ) G ( s) = n = n −1 s + an −1s + ... + ao A ( jω ,θ ) We want to obtain an estimate of the polynomial coefficient of G(s) θ T = [ ao a1 ... an −1 bo Define a cost function: 1 J= N ... bn −1 ] B( jω k ,θ ) 1 ˆ ∑ k =1 2 G( jω k ) − A( jω ,θ ) k 2 N J is quadratic in θ: can apply a gradient search technique to minimize cost J Search for: ∂J = 0 → θ optim ∂θ Simple method but two major problems •Sensitive to order n •Matches poles well but not zeros Other Methods: ARX, logarithmic NLLS, FORSE 16.810 37 State Space Measurement Models Wheel -> ENC 0 -50 2 10 0 -50 -2 10 -20 0 10 2 10 Wheel -> DPL Gimbal -> DPL 0 10 -40 -60 -80 -2 10 50 0 -50 -100 -2 10 50 Wheel -> Gyro -100 -2 10 50 Gimbal -> Gyro Gimbal -> ENC Measurement models obtained for MIT ORIGINS testbed (30 state model) 0 10 2 10 0 10 2 10 0 -50 -2 10 0 0 10 2 10 -50 data fit -100 -2 10 0 10 2 10 Software used: DynaMod by Midé Technology Corp. 16.810 38 Summary Upfront work before actual testing / data acquisition is considerable: • What am I trying to measure and why ? • Sensor selection and placement decisions need to be made • Which bandwidth am I interested in ? • How do I excite the system (caution for non-linearity) ? The topic of signal conditioning is crucial and affects results : • Do I need to amplify the native sensor signal ? • What are the estimates for noise levels ? • What is my sampling rate ∆T and sample length T (Nyquist, Leakage) ? • Need to consider Leakage, Aliasing and Averaging Data processing techniques are powerful and diverse: • FFT and DFT most important (try to have 2^N points for speed) • Noise considerations (how good is my measurement ? -> coherence) 16.810 39