Aircraft condition monitoring system (Advanced Flying Laboratory)

Can fiber optic technologies effectively monitor aircraft structures, enabling predictive maintenance?

Using the FBG sensor technology, we developed a system for the aircraft condition monitoring, which made it possible to evaluate its structural health, even during its operation.

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ABOUT THE CLIENT

universities and private companies

CLIENT EXPECTATIONS

development of a new condition monitoring system featuring increased mobility, robustness, small dimensions, and minimal power consumption

new FBG based aircraft sensors designed for embedding directly into the composite aircraft structures and joints

INITIAL STATE

many aircraft’s spaces and parameters are not being measured
the monitoring deflection of all controlled surfaces is missing

available aircraft health monitoring systems too big or lacking the functionality

WHAT did the client turn to us with

The project’s goal was the development of an aircraft condition monitoring system enabling the assessment of the aircraft’s structural condition, especially after a harsh landing or flight through heavy turbulence. Another project’s challenge was the development of new FBG strain sensors for embedding directly into the composite aircraft structure and joints in order to monitor the entire process of aircraft construction, and its health during its operation, thus enabling predictive aircraft maintenance.

Benefits of the solution compared to conventional methods

I. COMPLEX STRUCTURE HEALTH OVERVIEW

The system receives information from over 100 stress sensors built directly into the aircraft composite structures. Thus, it is possible to evaluate the state of the aircraft structure, health and safety after a hard landing or passage through strong turbulences.

II. Functional multiparametrical measurement platform

The aircraft monitoring system was built into the U-15 and its functionality was verified by measuring up to 16 flight parameters in test flights.

III. Does not affect the rigidity and load-bearing capacity of the aircraft structure

Verified by manufacturing and destructive testing of samples with built-in optical aircraft sensors and samples without sensors and subsequent comparison of measured results.

How did we approach the solution?

We have developed the Advanced Flying Laboratory Phoenix Air U-15 AFL, based on an all-composite S-LSA motor glider, which had a number of parts equipped with FBG aircraft sensors for monitoring strain, deformation and temperature. Those measured 16 flight parameters (flight speed and altitude, engine speed, load multiples, control surface deflections, etc.) and provided the customer with valuable real time information on the actual state of the aircraft’s technical life, health and safety. In addition, we have verified that the deployment of optical fiber sensors does not significantly affect static strength and durability of tested aircraft structures.

Products used

Video from realized project

Why work with us?

Our company was invited to the project thanks to its rich experience of using fiber optic aircraft sensors in composite materials for predictive maintenance in aviation. Our specialty is the development of aircraft monitoring systems and fiber optic sensors to suit the client’s needs.

FBG technology is the most suitable solution where conventional procedures fail or are not viable because of routine operation.

Our aircraft structural health monitoring systems monitor continuously and in real time, so you will receive error notifications immediately without unnecessary delays.

High durability and reliability are the characteristics of fiber optic technology.

Industry

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