Fault detection system and method

A fault detection system for detecting a structural failure in real time of a fastener connecting a first component of a machine with a second component of the machine, comprising:

• an ultrasonic sensor disposed at one end of the fastener, the ultrasonic sensor being integrated with the fastener;
• an ultrasonic emitter integrated with the ultrasonic sensor and capable of emitting an ultrasonic signal that travels through a length of the fastener;
• an ultrasonic receiver integrated with the ultrasonic sensor and capable of receiving a returning ultrasonic signal;
• an ultrasonic reflector disposed at another end of the fastener, the ultrasonic reflector adapted to reflect the ultrasonic signal and send the returning ultrasonic signal to the ultrasonic receiver;
• a processor receiving signals from the ultrasonic emitter and the ultrasonic receiver that are indicative of a travel time between an emission of the ultrasonic signal and a receipt of the returning ultrasonic signal;
• the processor being disposed to:
• calculate an actual length of the fastener based on the travel time;
• compare the actual length with the length of the fastener, which is predetermined;
• and
• emit a wireless signal to an electronic controller of the machine that is indicative of a structural state of the fastener in real time.

A method for diagnosing in real time a structural condition of a fastener disposed in a machine during operation, the method comprising:

• emitting an ultrasonic signal from an ultrasonic sensor operably associated with the fastener and disposed at one end thereof;
• reflecting the ultrasonic signal with an ultrasonic reflector operably associated with the fastener and disposed at another end thereof;
• receiving the ultrasonic signal in the ultrasonic sensor;
• calculating an actual length of the fastener based on a time between the emission and receipt of the ultrasonic signal;
• providing a wireless signal from the ultrasonic sensor to an electronic controller of the machine that is indicative of a structural state of the fastener;
• and
• determining whether a fault condition has occurred in the electronic controller based on the wireless signal in real time.