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Abstract Electronic components that undergo shock and vibration are susceptible to failure caused by damage in the base printed circuit board that makes up the substrate of these systems. In certain applications, it may become paramount to know in real-time if the electronic components are damaged to enable a next-generation active system to take immediate responses. Broad examples of such systems include blast mitigation systems or safety systems in car accidents. These systems on classified under the term “high-rate” as they experience high shock levels on short time scales. This work proposes a long short-term memory neural network to enable real-time damage detection and assessment of electronic assemblies subjected to shock. The long short-term memory neural network is able to infer the state of the structure in approximately 4 milliseconds following the impact. The model obtains perfect classification results at 4 milliseconds for the data used in this work. This work is supported by experimentation that indicates damage to electronic packages can be quantified through the in situ monitoring of the impedance of electrical connections. Changes in impedance correlate to alterations in the physical properties of electronic components which indicate the occurrence of damage. On this basis, a comprehensive dataset is created to monitor the impedance changes of a daisy-chained connection through repeated high-energy shocks. Meanwhile, the shock response of the electronic components is captured using an accelerometer, enabling a detailed analysis of the effects of high-rate shock on the components’ performance. A dataset is developed to encompass 30 repeated impacts experiencing 10,000 gn during impact with an average half-sine time of 322 microseconds. The paper outlines the proposed real-time machine learning framework while performance metrics are presented and discussed in detail. 

Abstract To enable real-time control of next-generation active structures during shock events, there is a need to identify the start of a shock event within microseconds of its initiation. The delayed classification of a shock event may cause damage to the system that could have been prevented with assumed next-generation active control mechanisms. Addressing the challenge of ultra-low latency shock event classification requires utilizing prior information on normal behaviors (i.e., the system under vibrational loading) to identify abnormalities that can be classified as features of a shock event. The purpose of changepoint shock classification is to automatically recognize when a structure of interest behaves differently than expected in some measurable way. In this work, we analyze two different methods for shock classification using changepoint methodologies. We study the use of adaptive cumulative summation and expectation maximization algorithms in this work. Each method presents advantages and disadvantages for different scenarios. This study aims to derive features (streams of time series data) for the changepoint algorithms and revise the changepoint models to be used in real-time robust shock event detection. In this work, a printed circuit board under continuous vibrations before, during, and after a shock event is used to investigate the proposed methodologies. The printed circuit board is monitored with an accelerometer that is used to monitor both the vibrational and shock state of the system. The vibrational response of the system consists of accelerations up to 20 m/s2, while the shock event consists of loadings up to 2,000 m/s2. This work showed that the CUSUM algorithm is fairly effective at identifying the shock state in data but generates many false positives during normal behavior times, with no false positives post-shock, indicating accurate shock state detection despite early errors. In contrast, the Expectation Maximization (EM) algorithm shows improved performance by correctly predicting no shock in the initial phase and accurately identifying the onset of the shock state. It occasionally misclassifies shocked points as normal due to its change point identification process. Compared to CUSUM, EM has fewer false positives before the shock and similar performance during and after the shock event. Future research efforts will focus on developing online versions of these algorithms, which can identify system states with a minimum number of errors. The limitations of the system and its robustness to noise are discussed. 

Abstract Structures operating in high-rate dynamic environments, such as hypersonic vehicles, orbital space infrastructure, and blast mitigation systems, require microsecond (μs) decision-making. Advances in real-time sensing, edge-computing, and high-bandwidth computer memory are enabling emerging technologies such as High-rate structural health monitoring (HR-SHM) to become more feasible. Due to the time restrictions such systems operate under, a target of 1 millisecond (ms) from event detection to decision-making is set at the goal to enable HR-SHM. With minimizing latency in mind, a data-driven method that relies on time-series measurements processed in real-time to infer the state of the structure is investigated in this preliminary work. A methodology for deploying LSTM-based state estimators for structures using subsampled time-series vibration data is presented. The proposed estimator is deployed to an embedded real-time device and the achieved accuracy along with system timing are discussed. The proposed approach has shown potential for high-rate state estimation as it provides sufficient accuracy for the considered structure while a time-step of 2.5 ms is achieved. The Contributions of this work are twofold: 1) a framework for deploying LSTM models in real-time for high-rate state estimation, 2) an experimental validation of LSTMs running on a real-time computing system. 

Abstract Real-time model updating of active structures subject to unmodeled high-rate dynamic events require structural model updates on the timescale of 2 ms or less. Examples of active structures subjected to unmodeled high-rate dynamic events include hypersonic vehicles, active blast mitigation, and orbital infrastructure. Due to the unmodeled nature of the events of interest, the real-time model updating algorithm should circumvent any model pre-calculations. In this work, we present a methodology that updates the finite element analysis (FEA) model of a structure experiencing varying dynamics through online measurements. The algorithm is demonstrated for a testbed, comprised of a cantilever beam and a roller that serves as movable support. The structure’s state is updated (i.e. the position of the moving roller) by continuously updating the associated FEA model through an online adaptive meshing and search algorithm. The structure’s state is continuously estimated by comparing the measured signals with FEA models. New FEA models are built based on the enhanced estimate of the structure’s state through adaptive meshing for modal analysis and adaptive search space for the FEA model selection. The proposed methodology is verified experimentally in real-time using the testbed. It is demonstrated that the adaptive features can achieve accurate state estimations within the required 2 ms timescale. 

Abstract Many structures are subjected to varying forces, moving boundaries, and other dynamic conditions. Whether part of a vehicle, building, or active energy mitigation device, data on such changes can represent useful knowledge, but also presents challenges in its collection and analysis. In systems where changes occur rapidly, assessment of the system’s state within a useful time span is required to enable an appropriate response before the system’s state changes further. Rapid state estimation is especially important but poses unique difficulties. In determining the state of a structural system subjected to high-rate dynamic changes, measuring the frequency response is one method that can be used to draw inferences, provided the system is adequately understood and defined. The work presented here is the result of an investigation into methods to determine the frequency response, and thus state, of a structure subjected to high-rate boundary changes in real-time. In order to facilitate development, the Air Force Research Laboratory created the DROPBEAR, a testbed with an oscillating beam subjected to a continuously variable boundary condition. One end of the beam is held by a stationary fixed support, while a pinned support is able to move along the beam’s length. The free end of the beam structure is instrumented with acceleration, velocity, and position sensors measuring the beam’s vertical axis. Direct position measurement of the pin location is also taken to provide a reference for comparison with numerical models. This work presents a numerical investigation into methods for extracting the frequency response of a structure in real-time. An FFT based method with a rolling window is used to track the frequency of a data set generated to represent the range of the DROPBEAR, and is run with multiple window lengths. The frequency precision and latency of the FFT method is analyzed in each configuration. A specialized frequency extraction technique, Delayed Comparison Error Minimization, is implemented with parameters optimized for the frequency range of interest. The performance metrics of latency and precision are analyzed and compared to the baseline rolling FFT method results, and applicability is discussed. 

Modeling dry friction is a challenging task. Accurate models must incorporate hysteretic rise of force across displacement and non-linearity from the Stribeck effect. Though sufficiently accurate models have been proposed for simple friction systems where these two effects dominate, certain rotational friction systems introduce self-energizing and accompanying backlash effects. These systems are termed self-energizing systems. In these systems, the friction force is amplified by a mechanical advantage which is charged through motion and released during reversing the direction of travel. This produces energized and backlash regimes within which the friction device follows different dynamic behaviors. This paper examines self-energizing rotational friction, and proposes a combined physics and machine learning approach to produce a unified model for energized and backlash regimes. In this multi-process information fusion methodology, a classical LuGre friction model is augmented to allow state-dependent parameterization provided by a machine learning model. The method for training the model from experimental data is given, and demonstrated with a 20 kN banded rotary friction device used for structural control. Source code replicating the methodology is provided. Results demonstrate that the combined model is capable of reproducing the backlash effect and reduces error compared to the standard LuGre model by a cumulative 32.8%; in terms modeling the tested banded rotary friction device. In these experimental tests, realistic pre-defined displacements inputs are used to validate the damper. The output of the machine learning model is analyzed and found to align with the physical understanding of the banded rotary friction device.