Vehicle Subsystem Remaining Life Evaluation via Vibration Sensor

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Solution Overview

Problem

Current methods for evaluating the remaining life of vehicle electronics systems are labor-intensive, prone to human error, and require repeated testing when systems are moved or when actual flight profiles differ from predicted ones, leading to unreliable data.

Innovation Solution

A sensor assembly is secured to the operative sub-system, equipped with sensors to detect vibration and shock energy, and a processing unit that determines damage data to calculate the remaining life based on empirical or pre-set full life data, eliminating the need for continuous human intervention and retesting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual monitoring and tracking of electronics systems is performed, then remaining life data can be recorded, but labor and time costs increase and human error may produce inaccurate data

Engineering Contradiction:

Improveaccuracy of remaining life dataVSAvoidtime for monitoring and data entry

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The electronics system automatically monitors its own operational parameters and calculates remaining life without external intervention. The system self-updates databases and generates reports, eliminating the need for manual data collection and entry while ensuring accurate, consistent data recording.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual monitoring processes are replaced with automated electronic sensing and processing systems. Sensors continuously collect operational data, and computer algorithms automatically calculate remaining life based on accumulated damage models, replacing human analysts and manual data entry procedures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If repeated vibration testing is performed when systems are moved or flight profiles change, then accurate vibration profiles can be obtained, but testing time and labor increase

Engineering Contradiction:

Improveaccuracy of vibration profileVSAvoidspeed of obtaining remaining life data

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The system performs preliminary vibration qualification testing once during initial system certification, establishing baseline damage models and thresholds. These pre-established models are then reused for remaining life calculations across different locations and flight profiles, eliminating the need for repeated full-scale vibration testing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The remaining life calculation system is designed to be universally applicable across multiple electronics system locations and various flight profiles. A single automated monitoring system can serve different aircraft configurations and operational scenarios without requiring separate testing protocols for each case.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If manual tracking of electronics system movement and retesting is performed, then accurate remaining life data can be maintained, but the process becomes more complex and labor-intensive

Engineering Contradiction:

Improvereliability of remaining life informationVSAvoidcomplexity of monitoring process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system continuously monitors operational parameters and provides real-time feedback on accumulated damage and remaining life status. This automated feedback loop eliminates the need for complex manual tracking procedures, as the system self-adjusts and self-reporting ensures data reliability without increasing process complexity.

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system provides accurate and reliable remaining life data autonomously, reducing labor and time costs, and allowing for continuous monitoring without modifying the sub-system, even when systems are moved or flight profiles change.

Implementation Method 1

The sensor assembly may include a piezo ceramic sensor that is configured to generate an electrical signal in response to the vibration or shock energy

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS9683913B2System and method for evaluating remaining life of an operative sub-system of a vehicle

Publication Date: 2017.06.20 THE BOEING CO

AI summary

A vehicle may include an operative sub-system positioned within a body of the vehicle, and a sensor assembly secured to the operative sub-system. The sensor assembly may include at least one sensor configured to detect vibration or shock energy, directed into the operative sub-system; and a processing unit configured to determine damage to the operative sub-system as damage data that is based on one or both of a magnitude and duration of the vibration or shock energy detected by the sensor(s). The sensor assembly may be self-powered.