Sacrificial Sensor for Composite Damage Detection
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Solution Overview
Problem
Existing methods for detecting damage in laminated fibre reinforced polymer structural parts are either costly, time-consuming, or have adverse effects on the structural integrity of the parts.
Innovation Solution
A sacrificial sensor system that is coupled with the part, featuring an electrical property that changes as the sensor is damaged, providing an early indication of damage to the part without affecting its structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasound inspection is used to detect defects, then measurement precision is improved, but loss of time and device complexity increase
Solution Approach 1:
The sacrificial sensor is embedded within the composite part during manufacturing, performing preliminary preparation so that damage detection can occur passively without requiring active probing during inspection. The sensor is pre-positioned to detect damage as it occurs, eliminating the need for time-consuming active ultrasound scanning.
2Measurement precision
If strain gauges are applied within composite layers to measure strain, then measurement precision is improved, but the structural integrity of the part deteriorates
Solution Approach 1:
The sacrificial sensor is designed as a disposable element that is sacrificed when damage occurs to the composite part. It serves its detection function until it is damaged, at which point its degradation signals the damage event, eliminating the need for durable, structurally-invasive strain gauges.
3Strength
If mechanical fastening is used to join composite elements, then joint strength is improved, but the weight and structural integrity of the composite part deteriorate
Solution Approach 1:
The sacrificial sensor extracts the detection function from the structural components themselves, allowing the use of lighter bonding materials and designs without compromising detection capability. The sensor is a separate, dedicated element that does not need to contribute to structural strength.
4Device complexity
If adhesive bonding is used to join composite elements, then the number of parts is reduced, but defect detection becomes more difficult
Solution Approach 1:
The sacrificial sensor merges the bonding function with the detection function by being embedded within the adhesive bond line itself. This integration allows the sensor to monitor the health of the bonded joint directly, solving both the simplification and detection difficulty issues simultaneously.
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 early detection of damage, allowing for timely repairs and reducing the risk of structural failure, while being cost-effective and non-invasive to the part's structure.
Implementation Method 1
an electrical property of the sacrificial sensor is configured to change as the sacrificial sensor is damaged to indicate damage to the part
Data Source
AI summary
There is provided a sacrificial sensor configured to be coupled with a part and provide an indication of damage in the part, wherein an electrical property of the sacrificial sensor is configured to change as the sacrificial sensor is damaged to indicate damage to the part.