Stiffening Component with Integrated Pneumatic Sensor for Adhesive Monitoring
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Solution Overview
Problem
Current methods for monitoring the functionality of structural adhesive layers in CFRP components during manufacturing and operation are inadequate due to cost considerations and the inability to integrate complex sensor arrays, leading to potential weight increases and manufacturing delays.
Innovation Solution
A stiffening component with integrated air and vacuum openings and channels, along with a sensor block, allows for continuous monitoring of adhesive bonds using a pneumatic SHM sensor array, enabling detection of failures during manufacturing and operation without significant production delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors for nondestructive monitoring are integrated into CFRP assemblies, then the functionality of adhesive bonds can be monitored continuously, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent merges the sensor block with the stiffening component into a single integrated unit. The sensor block containing air and vacuum channels is permanently bonded to the stiffening component, creating a unified structure that eliminates separate sensor installation steps and reduces overall system complexity while maintaining continuous monitoring capability
Solution Approach 2:
The stiffening component serves multiple functions: it provides structural stiffening, houses the sensor block for adhesive bond monitoring, and integrates air and vacuum channels for pneumatic testing. This multi-functionality eliminates the need for separate monitoring devices and reduces device complexity
2Reliability
If a complex array of sensors is integrated during manufacturing, then continuous monitoring is achieved, but the production time increases due to narrow curing tolerances
Solution Approach 1:
The sensor block is pre-integrated with the stiffening component before the final assembly operation. By preparing the monitoring system in advance and bonding it to the stiffening component prior to adhesive application, the patent eliminates post-assembly sensor installation steps that would consume valuable production time within narrow curing windows
Solution Approach 2:
The stiffening component itself serves as the housing and mounting structure for the sensor block. The stiffening component's structure is utilized to hold and position the sensor block, eliminating the need for separate mounting hardware and installation procedures that would extend manufacturing time
3Strength
If material thickness is increased or adhesive bonds are reinforced to offset calculation uncertainties, then mechanical safety is improved, but the weight of the CFRP component increases
Solution Approach 1:
The integrated sensor block provides real-time feedback on the functionality and integrity of adhesive bonds through pneumatic pressure monitoring. This continuous monitoring enables early detection of bonding defects, allowing for corrective actions that maintain mechanical safety without requiring excessive material thickness or adhesive reinforcement, thereby preventing weight increase
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
The solution provides robust, continuous monitoring of structural adhesive layers, reducing the need for manual inspections, minimizing weight increases, and allowing for the use of CFRP components in critical applications like aircraft construction, while maintaining existing production processes.
Implementation Method 1
The evaluator unit (38) exhibits at least one vacuum pump, so as to lower an air pressure in the vacuum channel (34) to a value below the ambient air pressure
Implementation Method 2
Any change, no matter how slight, in the measured difference in pressure between the air channel and vacuum channel in the event of an error is evaluated and displayed by means of an evaluator unit
Data Source
AI summary
An arrangement for monitoring the functionality of a structural adhesive layer to be fabricated between a first surface of a stiffening element and another component. A sensor block is bonded to a second surface of the stiffening component opposite to the first surface. The area of the structural adhesive layer incorporates a plurality of air openings and vacuum openings that vertically extend through the stiffening component and structural adhesive layer and the sensor block. The air openings are interconnected among each other by at least one air channel, and the vacuum openings by at least one vacuum channel. At least one of the channels is connected to an evaluator unit to detect a failure of the structural adhesive layer.