Open Competition 1 - Information Technology

Structural Health Integrated Electronic Life Determination (SHIELD) System

Sponsor: Caterpillar Inc.

• Project Performance Period: 11/1/2002 - 12/9/2006
• Total project (est.): $8,890,844.00
• Requested ATP funds: $4,417,479.00

Countless steel and aluminum equipment structures carry or bear heavy loads in construction, transportation, and other applications. The unknown variability of these loads during use pose significant risks, and as a result the structures tend to be over-designed, expensive, and wasteful of resources because of redundant maintenance schedules and unexpected downtime. To improve risk and failure management and structural efficiency, a joint venture led by Caterpillar plans a three-year project to develop and demonstrate prototype sensor and analysis technologies for determining in real time the condition and remaining functional life of large pieces of equipment and/or structures. The Structural Health Integrated Electronic Life Determination (SHIELD) system will consist of wireless sensors that could be attached to different parts of a structure to collect data continuously on actual use, fatigue damage, cracks and other parameters, and hardware and software to analyze the data. Low-cost, low-power sensors will be developed based on microelectromechanical systems. Hardware will be developed for high-speed damage calculations, and software will be written to accurately determine the loads of dynamic systems. Neural networks will be used to supplement real-time dynamic structural analysis. Other project participants are Motorola, Inc. (Schaumberg, Ill.) and Native American Technologies (Golden, Colo.). The University of Illinois at Urbana-Champaign (Urbana, Ill.) and Drexel University (Philadelphia, Pa.) will serve as consultants on damage analysis calculations and structural health monitoring, respectively. The ATP funding enables the multidisciplinary team to collaborate and will accelerate the implementation of continuous structural monitoring systems on mobile structures by five years. If successfully developed and deployed, the new technology will improve safety and reduce losses by predicting potential catastrophic failures, enhance productivity through optimized structural design and operation, and reduce maintenance and repair costs through monitoring of damage accumulation. In addition to the initial applications in mining and construction equipment, the SHIELD system could be used to monitor bridges, buildings, aircraft, railways, and ships.

For project information:

Carl M. Volz, (309) 675-5819
volz_carl_m@CAT.com

Active Project Participants

• MicroStrain, Inc. (Williston, VT)
  [New Member since original JV was formed]
  
• Motorola, Inc. (Plantation, FL)
  [Original, Active Member]
  
• Native American Technologies Company (Golden, CO)
  [Original, Active Member]
  

ATP Project Manager

Eric Samuelson, (301) 975-6393
eric.samuelson@nist.gov