Aircraft Repair Patch With Integrated Strain Sensor
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Solution Overview
Problem
Current methods for repairing aircraft structural components, particularly the outer skin, lack effective monitoring and quality assurance for adhesive bonding methods, which are less invasive but risk structural integrity issues due to uncertainty in connection strength.
Innovation Solution
A system comprising a repair patch adhesively bonded to the structural component with integrated sensors to measure strains and stresses, and an evaluating device to assess connection quality, allowing for real-time monitoring and early detection of weakening, using a bridge element and negative pressure to simulate operational loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive bonding methods are used to repair the structural component, then the ease of manufacture is improved, but the reliability of the connection is worsened due to uncertainty in connection strength
Solution Approach 1:
The patent implements continuous monitoring of the adhesive bonding connection using sensors that measure strains and stresses in the repair patch. The evaluating device processes this data to provide feedback on connection quality, enabling detection of bonding deficiencies and strengthening trends over time. This feedback mechanism transforms the unreliable adhesive bonding process into a monitored and controllable connection method.
2Measurement precision
If sensors are integrated into the repair patch to monitor connection quality, then the measurement precision is improved, but the device complexity is worsened
Solution Approach 1:
The patent combines multiple functions into the evaluating device: it processes sensor data from the repair patch, stores measurement results, generates acoustic signals for quality assessment, and monitors strengthening trends over time. By merging sensing, processing, storage, and evaluation functions into a single integrated device, the system achieves high measurement precision while minimizing the increase in overall device complexity.
3Reliability
If traditional riveting methods are used to repair the structural component, then the reliability of the connection is improved, but the ease of manufacture is worsened
Solution Approach 1:
The patent replaces the mechanical riveting system with an adhesive bonding system. Instead of using mechanical fasteners (rivets) to join the repair patch to the structural component, the invention uses chemical adhesion through bonding agents. This substitution eliminates the complexity of mechanical fastening operations while providing sufficient connection reliability, especially when combined with the monitoring system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable and simple monitoring of repair quality, reducing the risk of structural integrity issues by providing immediate feedback on connection strength and early detection of potential failures, facilitating the adoption of adhesive bonding methods over traditional riveting.
Implementation Method 1
The sensor is adapted to detect strains and/or stresses occurring in the repair patch
Implementation Method 2
using a bridge element and negative pressure to simulate operational loads
Data Source
AI summary
A system for repairing a structural component, in particular an aircraft structural component, includes a repair patch which is connected to the structural component in such a manner that it covers an opening in the structural component resulting from removing a damaged region of the structural component. A sensor is fastened to the repair patch in a region of the repair patch covering the opening in the structural component and is designed to detect strains and/or stresses occurring in the repair patch. An evaluating device is adapted to evaluate the strain values and/or stress values detected by the sensor and, in dependence on the result of this evaluation, output a signal which is characteristic of the quality state of the connection between the structural component and the repair patch.