System and Process for Corrosion Monitoring

The present invention is directed to system and process for corrosion monitoring. An embodiment of a system includes a conductor, an electrical connector, a sensor system, a transmitter, a network, and a computer having a database. The conductor is one or more current carrying conductors inline with and having a connector at each end such that there is electrical communication from connector to connector. The sensor system is configured for attachment to the conductor, and is operable to measure one or more of resistance, temperature, current flow, surrounding radio frequency and/or magnetic flux. The transmitter coupled the sensor system, operable to transmit data from the sensor system over a network to a processor for further processing. The computer includes a database for storage of sensor system in the form of instantaneous values, average values, a series of values, vectors representing values, or waveforms. In usage, threshold sensor system values are established and the electronic equipment having the current carrying conductors is deployed. Sensor systems are coupled to the current carrying conductors, which are monitored for one or more of resistance, temperature, current flow, surrounding radio frequency and/or magnetic flux. The sensor system data is compared to the baseline and when out of threshold, an alert is generated for further inspection.

BACKGROUND

FIELD OF THE INVENTION

The present invention relates to corrosion detection and, more particularly, to corrosion monitoring.

DESCRIPTION OF THE RELATED ART

Significant material and maintenance costs on military as well as commercial products are often attributed to the severity of the environment in which they operate. Ships and aircraft which operate in a maritime environment are particularly susceptible to corrosion. Corrosion damage of aircraft, piers, runways, underground conduits and other items within the military structure can be detrimental. The items themselves or the electronics therein suffer reduced lifecycles, degraded performance, increased failure rates.

Corrosion in wiring can lead to malfunctioning devices, short circuits, and even electrical fires. It is advantageous to detect corrosion issues before any particular issue becomes significant. Current corrosion inspections may not facilitate condition-based maintenance as current sensors may be of limited value, may not correlate well to actual corrosion conditions, and may not detect specific types of corrosion damage typical to the items' environments. Currently, the norm is to manually inspect the items. An inspector travels onsite to the location of the item and visually inspects it, or perhaps also uses a probe to aid in inspection. This leads to gaps in time in inspections and poor selection of items to target for inspection.

SUMMARY

The present invention is directed to system and process for corrosion monitoring. An embodiment of a system includes a conductor, an electrical connector, a sensor system, a transmitter, a network, and a computer having a database. The conductor is one or more current carrying conductor such as wire inline with and having a connector at each end such that there is electrical communication from connector to connector. The sensor system is configured for attachment to the conductor, and is operable to measure one or more of resistance, temperature, current flow, surrounding radio frequency and/or magnetic flux. The transmitter coupled the sensor system, operable to transmit data from the sensor system over a network to a processor for further processing. The computer includes a database for storage of sensor system in the form of instantaneous values, average values, a series of values, vectors representing values, or waveforms.

In usage, threshold sensor system values are established and the electronic equipment having the current carrying conductor is deployed. Sensor systems are coupled to the current carrying conductors, which are monitored for one or more of resistance, temperature, current flow, surrounding radio frequency and/or magnetic flux. The sensor system data is compared to the baseline and when out of threshold, an alert is generated for further inspection.

These and other features, aspects, and advantages of the invention will become better understood with reference to the following description, and accompanying drawings.

DETAILED DESCRIPTION

The present invention is directed to systems and processes for corrosion monitoring.FIG. 1illustrates an embodiment of a system according to the present invention as it may exist in operation. Depicted are a conductor14, an electrical connector12, a sensor system30, a network24, and a computer42having a database44.

The illustrated conductor14is an electrical wire14composed of conductive material, such as copper. The wire14is an electrical conductor used in power generation, power transmission, power distribution, telecommunications, electronics circuitry, and electrical equipment. Copper and its alloys are commonly used to make electrical contacts. When current is carried by the wire14, it has a certain resistance, current flow, surrounding radio frequency and magnetic flux16, and other properties. The values can be constant, periodic, aperiodic, simple or complex.

Certain embodiments of the invention include one or connectors12.FIGS. 2A and 2Billustrates representative connectors. The electrical connector12is a device for electrically, communicatively coupling. The electrical connector12includes a body having one or more inlets on a face defining a connector region, a cable outlet, a void interior region,. One or more electrical wires14extend from a side of the electrical connector12. Electrical wires14may include positive, negative, ground, signal, and other wires. Cable may house the wires and enter the body through a cable inlet. The connector face may take a variety of cross-sectional profiles, pinouts, and other configurations. The connector12may have seals, fingers for locking and unlocking, ridges for better interconnection, and other configurations.

Certain configurations of the connector12use MIL-DTL D38999 (FIG. 2A) and other military cylindrical connectors to inter-connect power, signal, RF, and grounding between systems. The D38999 conductors14are in close proximity to one another. Military cylindrical connectors feature a rear rubber gourmet that supports electrical contacts inserted into the rear of the connector. These electrical contacts (M39029) come is various diameters according to their current carrying capability. For example, a size 20 contact is rated for 5 Amps, whereas a size 16 contact is rated for 10 amps. The connector show below is a D38999/26 style plug and includes accommodation for one 16 AWG contact and fourteen 20 AWG contacts.

Corrosion at the connector12or wire14sometimes occurs. Corrosion is a process which chemically converts a refined metal conductor to a different form, such as its oxide. It is the gradual destruction of materials by chemical and/or electrochemical reactions with their environment. Commonly, this means electrochemical oxidation of metal in reaction with an oxidant in the air such as oxygen.

Many compositions corrode from exposure to moisture in air, but the process can be strongly affected by exposure to certain substances such as salt (NaCl) water or salt fog. Corrosion can be pervasive on electronics on ships, aircraft, and other equipment used in sea water maritime service. Atmospheric corrosion of metals exposed on or near coastlines, and hot salt corrosion in engines operating at sea or taking in salt-laden air are problematical.

Sometimes, mechanical action can cause or exacerbate the corrosion. It can occur at electrical terminals, result from the improper tightening of the lugs or screws fastening the conductive wire14or connectors12.

Corrosion normally begins on directly exposed surfaces. Corrosion is the unwanted breakdown and weakening of the material. Corrosion degradation can be concentrated locally to form a pit or crack (see surface ofFIG. 3C), or it can extend across a wide area more or less uniformly corroding the exposed surface (see surface ofFIG. 3D).

As mentioned, when current is carried by the wire14, it has a certain resistance, temperature, current flow, surrounding radio frequency and magnetic flux16, and other properties. The values can be constant, periodic, aperiodic, simple or complex. Corrosion can cause voltage and current flow degradation. As mentioned, corrosion can alter the resistance, temperature, voltage, current flow, surrounding radio frequency and magnetic flux16, and/or other properties. Corrosion can alter resistance (leading to heat generation), arcing and sparking (leading to current or voltage spikes).

Certain embodiments of the invention includes sensor system30attached to the conductor14, operable to measure one or more of resistance, temperature, current flow, surrounding radio frequency and magnetic flux16, and other properties of the conductor14to which it is attached. The measurements can be instantaneous, periodic, or ongoing. The sensor system30outputs a value or values for determining the target property. A fastener may be included in the sensor system30in order to secure it to the conductor14and maintain its position relative to the conductor14.

In certain configurations, the employed sensor system30is a Rogowski coil system (FIG. 3A), which measures alternating current or high speed current pulses. It consists of a helical coil of wire with the lead from one end returning through the center of the coil to the other end, so that both terminals are at the same end of the coil. The whole assembly is then wrapped around the straight conductor whose current is to be measured. The winding density, the diameter of the coil and the rigidity of the winding is configured to optimize immunity to external fields and positioned for optimum sensitivity of the measured conductor14. The output of the Rogowski coil is usually connected to a signal processors to provide an output signal that is proportional to the current. Additionally disclosure for Rogowski coil systems is included in the appendix.

In certain configurations, the employed sensor system30is a Hall effect sensor system (FIG. 3B, 3C)., which measures magnetic flux16. A Hall effect sensor is a transducer that varies its output voltage in response to a magnetic field. The Hall sensor includes semiconductor material, such as gallium arsenide or indium arsenide. A current is passed through the semiconductor material which, when placed in a magnetic field has a “Hall effect” voltage developed across it. The Hall effect is seen when a conductor is passed through a uniform magnetic field. The result is seen as a charge separation, with a buildup of either positive or negative charges on the bottom or on the top of the plate, providing a measured output. Again, the Hall sensor system may include signal processors to provide driving current to the sensors, amplify/pre-process the output signal, coefficient corrections, error adjustment and the like. In exemplary usage, the Hall effect sensor system is secured so that the magnetic field lines are passing at right angles through the sensor of the probe, in order to get optimum magnetic flux density values. Additionally disclosure for Hall effect and other sensor systems is included in the appendix.

Other sensor systems30can be employed to determine the target property. For example, fluxgate magnetometers sensors, magnetoresistance-based sensors, or other sensors may be employed. Further, the above sensor systems30may be used individually or in combination.

In certain configurations, the system10includes a transmitter32, operable to transmit data from the sensor system30, wired or wirelessly. for further processing. In certain configurations, a wired and wireless combination is employed, with a wire a certain distance from the subject, measured conductor14to the wireless transmitter in order to minimize interference. Wireless transmission may can use those known in the art such as AM, FM, analog, digital, or other known transmission formats. Additionally, the transmitter32may employ spectrum and/or communication protocols such as Bluetooth, Zigbee, Low-Power Wide-Area Network, WiFi, and others known in the art.

In certain communications, communication of the transmitted sensor system30data is further facilitated by a network24. Network24may also include one or more wide area networks (WANs), local area networks (LANs), personal area networks (PANs), mesh networks, all or a portion of the Internet, and/or any other communication system or systems at one or more locations. Further, all or a portion of network24may comprise either a wireline or wireless link. In other words, network24encompasses any internal or external network, networks, sub-network, or combination thereof operable to facilitate communications between various computing components inside and outside the illustrated environment. The network24may communicate, for example, Bluetooth, Zigbee, Internet Protocol (IP) packets, Frame Relay frames, Asynchronous Transfer Mode (ATM) cells, voice, video, data, and other suitable information between network addresses.

In certain configurations, a computer42receives the sensor system30data for further processing. A computer or server, generally refers to a system which includes a processor, memory, a screen, a network interface, storage, and input/output (I/O) components connected by way of a data bus. The I/O components may include for example, a mouse, keyboard, buttons, or a touchscreen. A server contains various server software programs and preferably contains application server software. Those skilled in the art will appreciate that the computer or servers can take a variety of configurations, including personal computers, hand-held devices, multi-processor systems, microprocessor-based electronics, network PCs, minicomputers, mainframe computers, and the like. Additionally, the computer may be part of a distributed computer environment where tasks are performed by local and remote processing devices that are communicatively linked. One skilled in the art can understand that the structure of and functionality associated with the aforementioned elements can be optionally partially or completely incorporated within one or the other, such as within one or more processors.

Certain configurations of the system include specialized storage in the form of a database44configured to store sensor system30and other data. In exemplary configuration, sensor system30data is received for storage and processing. The sensor system30data may be instantaneous values, average values, a series of values, vectors representing values, waveforms, or other types known in the art. One skilled in the art would appreciated that the data may reside in one or more databases, tables, or computers. Representative suitable database systems include text, Excel, SQL, noSQL, or other formats known in the art.

Having describe major elements of an embodiment of a system, a process of use is described. At step110, baseline values are established. At step120, electronic equipment is deployed. At step130, sensor systems are coupled to the conductors. At step140, the conductors are monitored. At step150, the sensor system data is compared to the baseline. More consideration will be given to each of the steps below.

At step110, threshold values are established. Threshold values for the target property are determined. For example, certain resistance, current flow, surrounding radio frequency and magnetic flux16, and/or other properties are determined. The threshold(s) can be single values (representing an instantaneous values), average value (weighted or otherwise), curve or vector, or a waveform.

Threshold values may be determination by reference, change over time, experimentation, learning, and/or other means known in the art. The values may be adjusted for the operating environment. To illustrate, the wire14may be expected to be deployed in a certain high voltage, high current alternating current environment. In determining threshold values, threshold flux value(s) might be adjusted by the voltage, current, wire length, wire orientation, wire gauge, and other operating parameters.

For example, in determination of a threshold by reference, if the wires14are of a common gauge, expected to operate at a common voltage and current, and is in a linear orientation, the expected flux value may be retrieved by reference and a threshold set proportional to that value.

For example, in determination of a threshold by historical changes, periodic readings of the subject measurement are taken. The threshold is set based on deviation from one or more of the historical readings.

the target if the wires14are of a common gauge, expected to operate at a common voltage and current, and is in a linear orientation, the expected flux value may be retrieved by reference and a threshold set proportional to that value.

For example, in determination of a threshold by experimentation, corroded wires14of a known gauge, are operated at a known voltage and current, and in a known orientation, the flux value is measured a threshold set based on that value.

For example, in determination by learning, machine learning may employed. One or more training datasets are created by measuring the properties of wires14in various states of corrosion and the target measured property, such as magnetic flux. In certain configurations, a sample dataset is employed for corroded wire14recognition by machine learning. In certain configurations, a sample dataset is employed for corrosion probability recognition.

In one approach, nearest neighbour classifiers such as the k-nearest neighbors algorithm are used to compare wire14transmission properties with stored features and a nearest threshold match is made. A reference classifier wire dataset is input to the system. In certain configurations, a wire properties dataset from the sensor systems30to be deployed in the environment is input into the system.

At step120, the electronic equipment is deployed to the target environment. A connector12is selected (FIGS. 2A and 2B). At step130, the sensor system30is securely coupled to the wire14at the set position (FIGS. 3A and 3D). Power is provided to the sensor system30and the transmitter32is activated. At step140, the wire14is monitored, with the sensor system30providing readings (FIG. 4A), which are transmitted32over the network24to a server for storage in the database44and processing (FIG. 1).

At step150, the received values are compared against the threshold values (FIG. 4B). The system compares the monitored values against the threshold values by raw value comparison, against averages (average, weighted, moving, or otherwise). Where the values are out of the threshold range, an alert is generated for further inspection.

Insofar as the description above and the accompanying drawing disclose any additional subject matter that is not within the scope of the single claim below, the inventions are not dedicated to the public and the right to file one or more applications to claim such additional inventions is reserved.