Smart Monitoring of a Full-scale Composite Hydrofoil Manufactured using Automated Fibre Placement under High Cycle Fatigue

Abstract Fibre reinforced composites materials offer a pathway to produce passive shape adaptive smart marine propellers, which have improved performance characteristics over traditional metallic alloys. Automated Fibre Placement (AFP) technology can provide a leap forward in Cyber-Physical automated manufacturing, which is essential for the implementation and operation of smart factories in the marine propeller industry towards Industry 4.0 readiness. In this paper, a comprehensive structural health monitoring (SHM) routine was performed on an AFP full-scale composite hydrofoil to gain confidence in its dynamic and structural performances through a number of active and passive sensors. The hydrofoil was subjected to constant amplitude flexural fatigue loading in a purpose-built test rig for 105 cycles. The hydrofoil was embedded with distributed optical fibre sensors (DOFS), traditional electrical strain gauges and linear variable displacement transducers (LVDTs). Both microelectromechanical system (MEMS) and piezoelectric (PZT) accelerometers were used to conduct experimental modal analyses (EMA) to observe changes in the modal response of the hydrofoil at regular intervals throughout the fatigue program. The hydrofoils modal response, as well as the stiffness measured using both displacements and strains, remained unchanged over the fatigue loading regime demonstrating the structural integrity of the hydrofoil. The optical fibre sensors endured the fatigue test cycles showing their robustness under fatigue loads. Furthermore, the sensing systems demonstrated the potential of being utilised as a useful maintenance tool combining their adaptability with automated manufacturing during manufacturing through integration within the hydrofoil, a structural test framework for performance measurement, data acquisition and analytics for visualization, and the prospect of decision making for maintenance requirement during any onset in structural performance.

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Optical fibre sensors for assessing food quality in full scale production ovens — a principal component analysis and artificial neural network based approach

Nonlinear Analysis Hybrid Systems ◽

10.1016/j.nahs.2006.05.008 ◽

2008 ◽

Vol 2 (1) ◽

pp. 51-57 ◽

Cited By ~ 5

Author(s):

E. Lewis ◽

C. Sheridan ◽

M. O’Farrell ◽

C. Flanagan ◽

J.F. Kerry ◽

...

Keyword(s):

Neural Network ◽

Principal Component Analysis ◽

Artificial Neural Network ◽

Optical Fibre ◽

Food Quality ◽

Principal Component ◽

Component Analysis ◽

Full Scale ◽

Scale Production ◽

Optical Fibre Sensors

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On the feasibility of optical fibre sensors for strain monitoring in thermoplastic composites under fatigue loading conditions

Optics and Lasers in Engineering ◽

10.1016/j.optlaseng.2008.01.001 ◽

2009 ◽

Vol 47 (3-4) ◽

pp. 403-411 ◽

Cited By ~ 32

Author(s):

I. De Baere ◽

G. Luyckx ◽

E. Voet ◽

W. Van Paepegem ◽

J. Degrieck

Keyword(s):

Optical Fibre ◽

Fatigue Loading ◽

Thermoplastic Composites ◽

Loading Conditions ◽

Optical Fibre Sensors ◽

Strain Monitoring

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Optical-fibre sensors using micromachined silicon resonant elements

IEE Proceedings D Control Theory and Applications ◽

10.1049/ip-d.1988.0053 ◽

1988 ◽

Vol 135 (5) ◽

pp. 353 ◽

Cited By ~ 10

Author(s):

R.E. Jones ◽

J.M. Naden ◽

R.C. Neat

Keyword(s):

Optical Fibre ◽

Optical Fibre Sensors

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Mode I Crack Propagation Experimental Analysis of Adhesive Bonded Joints Comprising Glass Fibre Composite Material under Impact and Constant Amplitude Fatigue Loading

Materials ◽

10.3390/ma14164380 ◽

2021 ◽

Vol 14 (16) ◽

pp. 4380

Author(s):

Alirio Andres Bautista Villamil ◽

Juan Pablo Casas Rodriguez ◽

Alicia Porras Holguin ◽

Maribel Silva Barrera

Keyword(s):

Crack Propagation ◽

Structural Integrity ◽

Crack Propagation Rate ◽

Fatigue Loading ◽

Propagation Rate ◽

Operating Conditions ◽

Impact Testing ◽

Mode I ◽

Mode I Crack ◽

Constant Amplitude

The T-90 Calima is a low-wing monoplane aircraft. Its structure is mainly composed of different components of composite materials, which are mainly bonded by using adhesive joints of different thicknesses. The T-90 Calima is a trainer aircraft; thus, adverse operating conditions such as hard landings, which cause impact loads, may affect the structural integrity of aircrafts. As a result, in this study, the mode I crack propagation rate of a typical adhesive joint of the aircraft is estimated under impact and constant amplitude fatigue loading. To this end, effects of adhesive thickness on the mechanical performance of the joint under quasistatic loading conditions, impact and constant amplitude fatigue in double cantilever beam (DCB) specimens are experimentally investigated. Cyclic impact is induced using a drop-weight impact testing machine to obtain the crack propagation rate (da/dN) as a function of the maximum strain energy release rate (GImax) diagram; likewise, this diagram is also obtained under constant amplitude fatigue, and both diagrams are compared to determine the effect of each type of loading on the structural integrity of the joint. Results reveal that the crack propagation rate under impact fatigue is three orders of magnitude greater than that under constant amplitude fatigue.

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Optical Fibre Sensors 18 (OFS-18)

Measurement Science and Technology ◽

10.1088/0957-0233/18/10/e01 ◽

2007 ◽

Vol 18 (10) ◽

Author(s):

Julian D C Jones ◽

Ralph P Tatam

Keyword(s):

Optical Fibre ◽

Optical Fibre Sensors

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Prediction of an actual RPM and engine power of an LNGC based on full-scale measurement data

Ocean Engineering ◽

10.1016/j.oceaneng.2017.10.054 ◽

2018 ◽

Vol 147 ◽

pp. 496-516 ◽

Cited By ~ 5

Author(s):

Youngjun You ◽

Jaehan Kim ◽

Min-Guk Seo

Keyword(s):

Measurement Data ◽

Full Scale ◽

Engine Power

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France’s State of the Art Distributed Optical Fibre Sensors Qualified for the Monitoring of the French Underground Repository for High Level and Intermediate Level Long Lived Radioactive Wastes

Sensors ◽

10.3390/s17061377 ◽

2017 ◽

Vol 17 (6) ◽

pp. 1377 ◽

Cited By ~ 17

Author(s):

Sylvie Delepine-Lesoille ◽

Sylvain Girard ◽

Marcel Landolt ◽

Johan Bertrand ◽

Isabelle Planes ◽

...

Keyword(s):

Optical Fibre ◽

State Of The Art ◽

Radioactive Wastes ◽

Intermediate Level ◽

Optical Fibre Sensors ◽

High Level

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Distributed optical fibre sensors

Optics & Laser Technology ◽

10.1016/0030-3992(92)90128-o ◽

1992 ◽

Vol 24 (3) ◽

pp. 160

Author(s):

Fumio Wada

Keyword(s):

Optical Fibre ◽

Optical Fibre Sensors

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A Frequency-Domain Filtering Technique for Triple Decomposition of Unsteady Turbulent Flow

Journal of Fluids Engineering ◽

10.1115/1.2909998 ◽

1992 ◽

Vol 114 (1) ◽

pp. 45-51 ◽

Cited By ~ 13

Author(s):

G. J. Brereton ◽

A. Kodal

Keyword(s):

Time Series ◽

Turbulent Flow ◽

Frequency Domain ◽

Measurement Data ◽

Averaging Technique ◽

Phase Averaging ◽

Spectral Estimates ◽

Improved Performance ◽

A New Technique ◽

Flow Variables

A new technique is presented for decomposing unsteady turbulent flow variables into their organized unsteady and turbulent components, which appears to offer some significant advantages over existing ones. The technique uses power-spectral estimates of data to deduce the optimal frequency-domain filter for determining the organized and turbulent components of a time series of data. When contrasted with the phase-averaging technique, this method can be thought of as replacing the assumption that the organized motion is identically reproduced in successive cycles of known periodicity by a more general condition: the cross-correlation of the organized and turbulent components is minimized for a time series of measurement data, given the expected shape of the turbulence power spectrum. The method is significantly more general than the phase average in its applicability and makes more efficient use of available data. Performance evaluations for time series of unsteady turbulent velocity measurements attest to the accuracy of the technique and illustrate the improved performance of this method over the phase-averaging technique when cycle-to-cycle variations in organized motion are present.

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