Programmable Diagnostic System PDS-10

Transcription

1 Programmable Diagnostic System PDS-10 ORDER OUR DIAGNOSTIC SYSTEM, IF YOU ARE NOT SATISFIED WITH ULTRASONIC, X-RAY AND OTHER CONVENTIONAL METHODS OF NONDESTRUCTIVE TESTING TIMELY DAMAGE DETECTION IN AIRCRAFT IS THE WAY TO PREVENT FATAL ACCIDENT AND SAVE PRESTIGE OF ENTERPRISE, COMPANY, COUNTRY

2 2 CONTENTS 1. MAIN PURPOSE PDS-10 COMPOSITION INFORMATION ABOUT USING DETECTION SENSITIVITY TIME FOR TESTING ADVANTAGES OF THE SYSTEM OFFERED OTHER APPLICATION FIELDS 9 8. BUSINESS REALIZATION FORMS PDS-10 SALES ORDER REFERENCES.10

3 3 Fatigue cracks hidden under the skin are the most dangerous defects. Their well timed detection is the way to prevent material losses and save human lives, as well as a possibility for aircraft's overhaul-period renewal, gaining significant economical profit. 1. MAIN PURPOSE Programmable diagnostics system PDS -10 is designed for fatigue cracks searching in reinforced units (stringers, ribs, fixing brackets, temperature compensators) of thin-walled construction (for instance: fuselages and lifting surfaces of aircrafts, helicopters and various class rockets, ship hulls on air-cushion and hydrofoil; bodies of vans, buses, cars, etc.). It also can be used for evaluation of repair quality of rivetted joints. Each of the conventional methods of nondestructive testing (ultrasonic, X-ray, luminescent, acoustic-emission, etc.) has their own limitations. PDS-10 gives good results beyond the limits of these methods. 2. PDS-10 COMPOSITION Block diagram of PDS-10 is presented in Fig. 1, and Fig. 2 shows it in prefabricated view. PDS-10 consists of working head with sensors and changeable tips (Fig. 3), vibroexciter synchronization and control block (Fig. 4), hammer striker s synchronization block (Fig.5), amplifier and filter block (Fig. 6), personal computer and interconnection cables. Mobile trolley (Fig. 7) is used for work on upper wing surfaces and prefabricated tube trapezium - on lower ones. Packing version is shown in Fig. 8 (electronic blocks along with working head in briefcase, trapezium in case, computer in boxes). Working head is suspended on the special ropes when diagnostics of aircraft's fuselage is conducted.

4 4 Fig. 1. Block diagram of PDS-10 Fig. 2. PDS-10 in prefabricated view Fig. 3. Working head with sensors and changeable tips

5 5 Fig. 4. Vibroexciter synchronization and control block Fig. 5. Hammer striker s synchronization block Fig. 6. Amplifier and filter block Fig. 7. Mobile trolley

6 6 To search damages, head is being transferred along the reinforced member (stringer, frame, spar, rib). Signals received by sensors are forwarded towards the computer and processed by special program. As a result, three problems are simultaneously solved without a preliminary construction s calibration (the presence or absence of defects in testing object is found out, and their location and sizes are determined, too). Vibrating table (Fig. 9) can be produced upon customer request. Fig. 8. PDS -10 packing version Fig. 9. Vibrating table 3. INFORMATION ABOUT USING The earlier PDS -10 analogues were successfully used in the Scientific and Production Association "Molniya" (Russia) during the designing of "Buran" space shuttle, in CAGI (Central State Aviation Institute, Russia) for flaw detection in reinforced members of aircraft IL-86, in Siberian Aviation Research Institute, in Tupolev Design Bureau, in Riga branch of

7 7 State Research Institute of Civil Aviation for inspection for likely defects the airframe of aircraft TU 134. Device was rewarded with silver medal at the Achievements Exhibition of the USSR in Moscow and with Honorary Diploma at the International Exhibition in Plovdiv (Bulgaria). Small series of device was produced for Scientific and Production Association "Molniya". Main design of the device is protected by four USSR inventions. 4. DETECTION SENSITIVITY PDS - 10 allows to detect wear and destruction of rivets, cracks in such aircraft s members as stringers, spars, temperature compensators, ribs, aileron suspension bracket units, etc. The size of detected crack is about % of the undamaged element s cross section area. 5. TIME FOR TESTING Time for testing of part of stringer, spar, etc. with the length of cm is as follows: triple point testing - about 1 min; multiple point testing (20-30 points) - about 8-10 min. 6. ADVANTAGES OF THE SYSTEM OFFERED In some cases there is no need for calibration of elastic and dissipative parameters of new aircrafts. Reduction of working hours on preliminary aircraft preparation for testing (defueling, etc.) Conduction of diagnostic procedures allows to get the more deep information concerning defects presence in testing object on the base of solution of all three diagnostic problems (answers on questions: is there defect or not, where it is located and what is its size). Defects along whole wing s length are detected with the same efficiency. The most elements of fuselage, ailerons, flaps, fixing brackets may be tested, too.

8 8 The proposed method of nondestructive testing has the more high detection sensitivity in comparison with integral methods. Vibrodiagnostic problem can be solved in the more short time and with the less material expenditures. To serve PDS top skill of staff is not required. Junior aviation specialists can make flaw detection. Time for specialist s training is not more than 1 (one) month. The use of PDS allows transferring diagnostics from repair bases and factories to the fixed field aerodromes. Using four - five such devices the team consisting of 4-5 people can inspect airframe during 1-2 weeks ensuring a high reliability of flaw detection (at the initial stage of its appearance). PDS may be used not only for overhaul-period renewal, but also for nondestructive testing of aircraft on aerodromes during service life. Defects are detected through general background of airframe stiffness reduction. However stiffness general reduction does not affect on efficiency of flaw detection by the methods proposed. Moreover, the use of PDS gives the possibility to study ageing of various aircraft parts and to correlate the process of ageing with the appearance of fatigue cracks. Diagnostic procedure may be carried out directly on the place of flying accident. All types of wings (with single or double beam spar, monoblock, triangle) may be tested. The possibility to acquire PDS (due to its low prices) even by small Research Institutes will facilitate the rise of testing reliability of different aviation units. The proposed vibrodiagnostic method may be easily converted for use with other types of structures (railway vans, building construction, ships on air-cushion, etc.)

9 9 7. OTHER APPLICATION FIELDS Customer taking additional equipment (vibration-testing machine, loading devices, etc.) can use computer part of PDS for realization of new effective nonlinear diagnostic algorithms, listed below: algorithms for detection of fatigue cracks in flexible rotors based on the analysis of interaction between forced and parametric oscillations as well as on the utilization of specific arising in rotor of longitudinal elastic waves; algorithms for quality evaluation of adhesive joints in high-temperature insulation of space apparatus and soldered joints in honeycomb sandwich; algorithms for determination of dielectric constant and some related mechanical characteristics of materials (moisture absorption, ageing, reduction of elasticity modulus, etc.) on the base of excitation and analysis of super- and subharmonic oscillations; algorithms for vibration testing of air pressure in automobile tires, balloons and other tanks; algorithms for determination of fluid viscosity as well as internal friction in flexible elements (chains, ropes, belts, etc.); vibration test method; algorithms for determination of dry friction force in such units as springs of vehicles, pneumatic hydraulic cylinders, couplings, cylinders of internal combustion engine, shockabsorbers, etc. 36 USSR copyrights on invention protect the algorithms listed above. 8. BUSINESS REALIZATION FORMS The lack of similar diagnostics means at competitors will allow the buyer to establish instantly a firm on device realization of the method proposed. Such firm might have the following business forms: Visiting aviation companies of different countries with mobile apparatus for concrete order fulfillment.

10 10 Diagnostic Centre setting up. Such centre could provide services to the aviation companies in own country and neighboring ones as well on more profitable conditions (in comparison with firms, proposing conventional approaches). It will allow conquering the market in this region. Industrial output and sales of the diagnostic system offered. 9. PDS-10 SALES ORDER PDS-10 is demonstrated in operation on testing of standard defects (without being acquainting the developer with production and service forms). Exclusive sales of all know-how and PDS - 10 to the single buyer with the right of production and sales. PDS - 10 sales with no right to produce and disclose know-how and with further buyer's personnel training during three days. This form is possible only after receiving of 100% payment. 10. REFERENCES From the test report of the vibrodiagnostic device executed in CAGI (Central State Aviation Institute, Russia) and approved by Institute Deputy Head, Mr. A. Selihov: " device can be used for failure testing of compensators in joint of airframe with fuselage skin of aircraft IL -86 (both in testing and in operation conditions)". From the test report of the vibrodiagnostic device executed in Riga branch of State Research Institute of Civil Aviation and approved by Institute Director Mr. A. Ivaniko: " device allows to determine cracks hidden by a skin and occupying 50% of the undamaged cross-section area of a stringer; allows to determine such defects as disturbance of force connection between longitudinal and cross reinforcing members. Device doesn't require object calibration and allows to make nondestructive testing of surface rotated through any corner towards the horizontal".

11 11 From the vibrodiagnostic device adoption report approved by Mr. A. Ivaniko, Director of the State Research Institute of Civil Aviation: " device had been introduced into the practice of bench test directed on inspection for likely defects in reinforcing members of TU-134 airframe in the State Research Institute of Civil Aviation. From the report of adoption of results of research and development works approved by Mr. A. Ivaniko, Head of Riga Experimental Centre of Institute of Civil Aviation: Riga Polytechnical Institute along with Riga Experimental Centre of Institute of Civil Aviation conducted works on the projects No. 2761, No. 3162, No As the result of project execution, methods and apparatus for nondestructive testing of aviation constructions had been developed. Project s results on subject indicated as well as other results have made it possible the renewal of overhaul-period of aircraft s TU -134, Mi- 8, Yak -40 that gave significant public-economy effect amount to 1,22 mil. roubles. From the test report No. 754 approved by Mr. Shirinyants V.A., head of the department of the V. Myasishchev plant (Zhukovsky town, Russia): Data received show the possibility to determine the change of construction stiffness on the stage of static and vibration testing. The vibrodiagnostic device is reflecting pattern of local destruction truthfully enough. Strength status of construction members is displayed well on different testing stages. In this sense this device has no analogues among the known measuring means and it can find the very widespread application in the purposes of aircraft diagnostics. From the test report of the Device Computer Diagnostic System PDS-10 approved by Mr. N. Chalanov, Director of the CL "AVIATEST": "Testing of the PDS-10 system was carried out in the CL "AVIATEST" from 15 October 2001 till February of During testing cracks were detected in such aviation elements as stringers and airframes of fuselage of aircraft YAK-40, stabilizer's spar of helicopter MI-8. The size of crack made up about 18-30% of the cross-section area of undamaged element.

12 12 Diagnostic System PDS-10 is convenient in services and may be used in repair factories, research institutes, design offices and other enterprises concerned with designing of aerospace objects."