Sensor Skin for Fiber-Reinforced Plastic Damage Detection
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Solution Overview
Problem
Current methods for detecting damage in fiber-reinforced plastic components, such as those in aircraft and spacecraft, are costly and limited to maintenance intervals, and existing thermal sensor approaches render components unusable during operation or require additional test setups.
Innovation Solution
A measurement arrangement using a flexible substrate with integrated temperature sensors and heating elements that form a 'sensor skin' to monitor temperature changes and detect damage by analyzing thermal conductivity and distribution, allowing for continuous, cost-effective monitoring during production and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal sensors are introduced into the matrix of the plastic material during maintenance/inspection, then damage detection capability is improved, but the component becomes unusable and additional test setups are required
Solution Approach 1:
Temperature sensors are integrated into the component during the production phase rather than during maintenance/inspection. The sensors are embedded in the plastic material before the component is put into service, allowing continuous monitoring during operation without requiring additional test setups or rendering the component unusable
Solution Approach 2:
A flexible substrate serves as an intermediary carrier that holds multiple temperature sensors and allows them to be integrated into the component during production. This substrate enables the sensors to be positioned optimally within the component structure while maintaining component functionality
2Measurement precision
If known damage detection methods are used for aircraft and spacecraft, then damage assessment capability is improved, but costs become substantial and monitoring is limited to maintenance intervals
Solution Approach 1:
The temperature sensors enable continuous monitoring of the component during operation rather than periodic monitoring only during maintenance intervals. By continuously recording temperature data and analyzing thermal behavior, the system provides ongoing damage detection capability throughout the component's service life
Solution Approach 2:
The component becomes self-monitoring through integrated temperature sensors that continuously track its own thermal behavior. The component's own operational temperature data is used to detect damage, eliminating the need for separate, costly external testing equipment and procedures
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 cost-effective monitoring of structural integrity and damage detection in fiber-reinforced plastic components, both internally and externally, without rendering the components unusable, and provides real-time data during operation and production.
Implementation Method 1
detect delaminations and damage to the structure by means of a change in the thermal properties of the material, and specifically, as will be shown hereinafter, in particular, a change in the thermal conductivity thereof or the temperature distribution in the component
Implementation Method 2
A measurement arrangement using a flexible substrate with integrated temperature sensors and heating elements
Data Source
AI summary
A measurement arrangement for detecting damage to components that are made of at least one fiber-reinforced plastic material, has a plurality of temperature sensors that are arrangeable or arranged on a component at a spacing from one another. In order to provide a measurement arrangement, by means of which temperature data can be cost-effectively obtained during the production and operation of a component and for it to thus be possible for damage to the component to be recorded and monitored, the plurality of temperature sensors on the component form a sensor array and a change in the thermal material properties of the component is detected by means of the sensor array.