Wire arc additively manufactured parts can take a significant amount of time to fabricate from several hours to days. During this process, the part is exposed to a steady localized heating at the build zone, and rapid cooling away from the arc contact point. The heated zone is constantly moving across the part geometry during the build resulting in spatially localized heating and cooling throughout the part geometry. In this investigation, we utilize the broadband emission signal from the wire arc to measure the acoustic response of the part build. Experimental results are obtained using contact emission transducers mounted such that they are isolated from the direct heat to avoid damage. Transient acoustic signals are recorded throughout the entire build process and evaluated using Fourier analysis. Acoustic spectra are utilized to capture modal data which slowly track the parts construction. In a second effort the modal response of the part is modeled as a function of each build layer and the two modal structures are compared. The emphasis is to understand and track the modal response of the structure of the part as it is fabricated and develop a real time process monitoring capability.

future capabilities that must be achieved in order to satisfy the critical demands created by the AM process. In its basic foundations, signal processing is essentially the “extraction of critical information (signals) from noisy, uncertain data.” Clearly, in a perfect world the best signal processing is none---just make a reliable, noise-free, uncertainty-free, measurement. Unfortunately, even the best of systems is still straddled within the confines and limitations of physical instrumentation. With this in mind, we discuss the development of signal processing techniques to extract the desired UT information from noisy measurement data. We start with a discussion of a simple homogeneous representation of a “part” under investigation and its insonification by an ultrasonic excitation from a physics-based perspective. Once developed, we briefly discuss the various choices of excitation signals and their tradeoffs. Next we discuss a simulation approach employing simple models from the signal processing perspective and then move on to the development of the basic signal processing approach to ultrasonic signal processing all based on estimating the pulse arrival estimation. Starting with simple peak detection techniques, progressing to the processing workhorse so-called “matched-filter” and finally to the more sophisticated “model-based matched filter.” The underlying pre- and post-processing of noisy measurement data along with the application of these techniques are subsequently demonstrated on experimental ultrasonic data. Finally, we discuss some open problems in UT and suggest a much more sophisticated model-based approach expanding these revolutionary ideas and encompassing more realistic signal models that incorporate noise, jitter and other pertinent uncertainties into the processor.

Self-powering sensors and networks are a reality. The ability to extract ambient energy from the surroundings to power electronic devices has a profound impact on the realization of smart adaptable sensor networks. In this study, a magnetically coupled dual spring and magnet design has been investigated to improve the efficiency and performance bandwidth of vibration energy harvesting (VEH) sensors. Using numerical models based on traditional systems of coupled ordinary differential equations (ODE), an optimized design was developed and compared to experimental measurements. Numerical and empirical results show good agreement. Results show improvement in the bandwidth over an equivalent linear system and corresponding improvement in output power conversion efficiency. The increased bandwidth allows improved conversion sensitivity and enhanced power harvesting capabilities. This operational bandwidth coincides with the expected input spectrum for in situ applications.

the structurally unknown device along with its subsystems that capture these salient features. One approach is to recognize that unique modal frequencies (sinusoidal lines) appear in the estimated power spectrum that are solely characteristic of the device under investigation. Therefore, the objective of this effort is based on constructing a black box model of the device that captures these physical features that can be exploited to “diagnose” whether or not the particular device subsystem (track/detect/classify) is operating normally from noisy vibrational data. Here we discuss the application of a modern system identification approach based on stochastic subspace realization techniques capable of both (1) identifying the underlying black-box structure thereby enabling the extraction of structural modes that can be used for analysis and modal tracking as well as (2) indicators of condition and possible changes from normal operation.

Deconvolution of noisy measurements, especially when they are multichannel, has always been a challenging problem. The processing techniques developed range from simple Fourier methods to more sophisticated model-based parametric methodologies based on the underlying acoustics of the problem at hand. Methods relying on multichannel mean-squared error processors (Wiener filters) have evolved over long periods from the seminal efforts in seismic processing. However, when more is known about the acoustics, then model-based state-space techniques incorporating the underlying process physics can improve the processing significantly. The problems of interest are the vibrational response of tightly coupled acoustic test objects excited by an out-of-the-ordinary transient, potentially impairing their operational performance. Employing a multiple input/multiple output structural model of the test objects under investigation enables the development of an inverse filter by applying subspace identification techniques during initial calibration measurements. Feasibility applications based on a mass transport experiment and test object calibration test demonstrate the ability of the processor to extract the excitations successfully.

Knowledge of the internal structure of an object or device under investigation proceeds from the basic idea of constructing its dynamic behavioral relations governed by a set of differential/algebraic equations that characterize its response. These equations can be partial differential equations leading to finite element or finite difference relations requiring a complex numerical solution on a super computer or ordinary differential equations requiring sophisticated numerical integration techniques to obtain the desired solution. Discrete dynamic systems evolving from digitized data acquisition are typically captured by sampled-data (continuous-to-discrete) representations characterized by a set of difference equations specifying the underlying system dynamics. In any case, with a mathematical description in hand, Grey-Box modeling techniques have evolved, concerned with the estimation of model parameters embedded in a prescribed set of equations (the system) governing its behavior, while capturing the underlying physical phenomenology of the problem at hand.

Critical acoustical systems operating in complex environments contaminated with disturbances and noise offer an extreme challenge when excited by out-of-the-ordinary, impulsive, transient events that can be undetected and seriously affect their overall performance. Transient impulse excitations must be detected, extracted, and evaluated to determine any potential system damage that could have been imposed; therefore, the problem of recovering the excitation in an uncertain measurement environment becomes one of multichannel deconvolution. Recovering a transient and its initial energy has not been solved satisfactorily, especially when the measurement has been truncated and only a small segment of response data is available. The development of multichannel deconvolution techniques for both complete and incomplete excitation data is discussed, employing a model-based approach based on the state-space representation of an identified acoustical system coupled to a forward modeling solution and a Kalman-type processor for enhancement and extraction. Synthesized data are utilized to assess the feasibility of the various approaches, demonstrating that reasonable performance can be achieved even in noisy environments.

Vibrational energy harvesting (VEH) is a method of capturing incidental mechanical vi brational energy and converting it to electrical energy. This is enabled by two technologies: Electromagnetic induction via a cantilever or piezoelectric devices. When designing a VEH system, a fast forward model is desired for response determination and optimal parameter es timation. An ordinary different equation (ODE) system model is developed for the cantilever system based upon the derivations of [1] and [2], and compared with a full electromechanical COMSOL model.

Acoustic resonance tracking is investigated for a wire arc additive manufacturing process as a possible real time in situ diagnostic during the build. A small 40kHz acoustic emission sensor was attached to one end of a 5 × 1.5 in. cylindrical 316 SS rod. A series of layers (weld beads) were programmed into the control software of the robot to build a thin bar upward off the end of the cylinder. A high-speed long-duration digitizer-recorder was used to capture the transient acoustic signals (100 Hz–70 kHz) during the build process. Typical build durations were on the order of 1–2 h. The transient data were analyzed using short time window FFTs, as a function of build parameters. The model and experiment share similar features, however there are some notable differences. In particular, the number of actual modes recorded in the experiment is less than predicted due to the sensors low in-plane sensitivity. The current results indicate that the evolving spectral response of a part during the build process has the potential to provide real time process monitoring information. The time-frequency analysis of the diffuse sound field in the part, reveals a unique spatial and temporal perspective of temperature, stress and geometric features.

When uncertain acoustic processes can no longer be characterized by Gaussian or for that matter unimodal (single peak) distributions along with the fact that the underlying phenomenology is nonstationary (time-varying) and nonlinear, then more general Bayesian processors must be applied to solve the underlying signal enhancement/extraction problem. A particle filter provides a solution to this multimodal (multiple peaks) posterior distribution estimation problem in noisy acoustic environments. A particle filter is a sequential Markov chain Monte Carlo processor capable of providing reasonable performance for data evolving from a multimodal distribution by estimating a nonparametric representation of the posterior distribution from which a multitude of meaningful statistics can be retrieved. However, the question of evaluating its performance can be challenging even for the simplest of processes. For instance, it is well-known that Kalman filter optimality can be obtained only when the resulting error residuals (innovations) are zero-mean and white. It is not that simple for the particle filter. Once characterized, the performance of the particle filter must be analyzed for it to be of practical value. Here a set of design and analysis criteria is discussed and applied to demonstrate their ability to quantify particle filtering performance.

Ultrasonic testing (UT) for nondestructive evaluation (NDE) is a critical entity necessary to resolve both the quality and precision questions of complex parts evolving from the innovative additive manufacturing (AM) process. This modality provides the essential quantitative information for acceptance and potential flaw detection of the part under investigation. A primary ingredient in UT besides the required precision robotic hardware for the acquisition of high quality measurement data is the underlying signal processing. It is here that much of the system performance capability resides. In this report, we discuss the basic steps in UT signal processing along with current and future capabilities that must be achieved in order to satisfy the critical demands created by the AM process. In its basic foundations, signal processing is essentially the “extraction of critical information (signals) from noisy, uncertain data.” Clearly, in a perfect world the best signal processing is none---just make a reliable, noise-free, uncertainty-free, measurement. Unfortunately, even the best of systems is still straddled within the confines and limitations of physical instrumentation. With this in mind, we discuss the development of signal processing techniques to extract the desired UT information from noisy measurement data. We start with a discussion of a simple homogeneous representation of a “part” under investigation and its insonification by an ultrasonic excitation from a physics-based perspective. Once developed, we briefly discuss the various choices of excitation signals and their tradeoffs. Next we discuss a simulation approach employing simple models from the signal processing perspective and then move on to the development of the basic signal processing approach to ultrasonic signal processing all based on estimating the pulse arrival estimation. Starting with simple peak detection techniques, progressing to the processing workhorse so-called “matched-filter” and finally to the more sophisticated “model-based matched filter.” The underlying pre- and post-processing of noisy measurement data along with the application of these techniques are subsequently demonstrated on experimental ultrasonic data. Finally, we discuss some open problems in UT and suggest a much more sophisticated model-based approach expanding these revolutionary ideas and encompassing more realistic signal models that incorporate noise, jitter and other pertinent uncertainties into the processor.

Model Reference Adaptive Control (MRAC) is based on the fundamental concept that the process under investigation is to be controlled to follow or “track” a reference system (model) characterized by a state/input/output model employing an adaptive optimization algorithm to adjust the controller parameters in real-time. The generic structure of the MRAC is shown in Fig. 1 consisting of the following primary components: Reference model, Process (system) model, controller and the adaption algorithm. The basic structure of the controller is specified by a linear construct with the corresponding real-time adaption algorithms given by a gradient-type (so-called MIT rule) or based on stability theory (Lyapunov, hyperstability). This approach to adaptive control is termed “direct”, since the controller (parameters) are adjusted based on the component models/algorithm in contrast to the “indirect” approach that adjusts the process model parameters applying real-time system identification techniques.

This report details the development of DAIMU-2, a MEMS accelerometer-based Gyro-Free Inertial Measurement Unit (GF-IMU). Previously, a GF-IMU called the Distributed Accelerometer IMU (DAIMU) was developed at LLNL using traditional analog accelerometers. This project leverages the experience gained from DAIMU and recent advances in sensor and embedded systems technology to develop DAIMU-2. The report introduces the theory and mathematics of a GF-IMU, followed by the design of an Unscented Kalman Filter (UKF) and simulation results. Finally, the DAIMU-2 prototypes developed to date are presented. After approximately one year of development work, the project was suspended, to be resumed in the future. Because of this, some efforts were partially completed, and this report attempts to indicate areas where further work is needed. MATLAB files, drawings, and other design documents have been archived for future project resumption.

Dynamic testing of large flight vehicles (rockets) is not only complex, but also can be very costly. These flights are infrequent and can lead to disastrous effects if something were to fail during the flight. The development of sensors coupled to internal components offers a great challenge in reducing their size, yet still maintaining their precision. Sounding rockets provide both a viable and convenient alternative to the more costly vehicular flights. Some of the major objectives are to test various types of sensors for monitoring components of high interest as well as investigating real-time processing techniques. Signal processing presents an extreme challenge in this noisy multichannel environment. The estimation and tracking of modal frequencies from vibrating structures is an important set of features that can provide information about the components under test; therefore, high resolution multichannel spectral processing is required. The application of both single channel and multichannel techniques capable of producing reliable modal frequency estimates of a vibrating structure from uncertain accelerometer measurements is discussed.

Spectral estimation is a necessary methodology to analyze the frequency content of noisy data sets especially in acoustic applications. Many spectral techniques have evolved starting with the classical Fourier transform methods based on the well-known Wiener-Khintchine relationship relating the covariance-to-spectral density as a transform pair culminating with more elegant model-based parametric techniques that apply prior knowledge of the data to produce a high-resolution spectral estimate. Multichannel spectral representations are a class of both nonparametric, as well as parametric, estimators that provide improved spectral estimates. In any case, classical nonparametric multichannel techniques can provide reasonable estimates when coupled with peak-peaking methods as long as the signal levels are reasonably high. Parametric multichannel methods can perform quite well in low signal level environments even when applying simple peak-picking techniques. In this paper, the performance of both nonparametric (periodogram) and parametric (state-space) multichannel spectral estimation methods are investigated when applied to both synthesized noisy structural vibration data as well as data obtained from a sounding rocket flight. It is demonstrated that for the multichannel problem, state-space techniques provide improved performance, offering a parametric alternative compared to classical methods.

Spectral estimation is a necessary methodology to analyze the frequency content of noisy data sets especially in acoustic applications. In this paper, the performance of both nonparametric (periodogram) and parametric (state-space) multichannel spectral estimation methods are investigated when applied to synthesized noisy structural vibration data. It is demonstrated that for the multichannel problem state-space techniques provide improved performance.

Probability and Statistics Overview James V. Candy, James V. CandySearch for more papers by this author Book Author(s):James V. Candy, James V. CandySearch for more papers by this author First published: 22 July 2016 https://doi.org/10.1002/9781119125495.app1 AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onFacebookTwitterLinked InRedditWechat Bayesian Signal Processing: Classical, Modern, and Particle Filtering Methods, Second RelatedInformation