New Structural Health Sensors Reach For The Skies
13 Jun 2005
A system of smart sensors that can automatically inspect structures for damage will soon be flying in a Hawk test aircraft.
The experimental ‘acoustic emission detection’ kit housed in a self-contained pod attached to the underside of the airframe, will be able to pinpoint cracks in specifically designed dummy structures during flight and download a diagnosis when the aircraft lands.
The trials are part of a newly launched European project led by BAE Systems and are an important step towards the eventual goal of self-inspecting aircraft.
Structural inspection is a significant factor in the cost of supporting fleets of both military and commercial aircraft. In-service lives of 40 years or more are now expected and, as the aircraft age, the servicing needed to maintain stringent air-worthiness standards becomes ever more costly.
The new system that has been devised by the BAE Systems Advanced Technology Centre (ATC) aims to avoid lengthy and expensive structural inspections that require the repeated dismantling of large sections of aircraft. Very often inspections are precautionary and no faults needing repairing are found.
If sensors fitted deep inside the aircraft structure can reliably detect the onset of damage, the need to dismantle sections of the airframe will be considerably reduced. The new detection process can be performed remotely; at the press of a button or even automatically on-line. It is estimated that this could save many millions of pounds over the lifetime of a fleet.
‘Engineers are just beginning to realise the potential value of this type of structural monitoring’ says Peter Foote, senior specialist at BAE Systems. ‘Aircraft are expensive assets and their owners are pushing to get the maximum possible use from them. Any technology that can help deliver more cost effective operations or increased availability is bound to be welcome.’
The ATC is concentrating on development of miniature sensor systems that listen for growing flaws in a structure. These sensors can pick out the sound and position of the smallest of cracks in metal or carbon fibre composites that make up the airframe. While the concept of acoustic emission detection has been known or some time it has rarely been tested in flight.
‘The great thing about this project is that we get to test the technology in a real environment: a modern, fully operational fast jet. There is only so much that you can demonstrate in a test laboratory. The real test is bringing all the components together and operating them under real conditions’ comments Foote.
In addition to the ATC other partners in the programme include Smart Fibres Ltd. (fibre optics), Qinetiq (ultrasonics) and EDS from Germany. Emmecon of Finland is supporting the onboard network in which all sensor systems are linked while NLR from the Netherlands is providing a central computer.
Flight tests of the system are expected to be completed in mid 2006.
About BAE SYSTEMS
BAE Systems is an international company engaged in the development, delivery and support of advanced defence and aerospace systems in the air, on land, at sea and in space. The company designs, manufactures and supports military aircraft, surface ships, submarines, fighting vehicles, radar, avionics, communications, electronics and guided weapon systems. It is a pioneer in technology with a heritage stretching back hundreds of years. It is at the forefront of innovation, working to develop the next generation of intelligent defence systems.
BAE Systems has major operations across five continents and customers in some 130 countries. The company has more than 90,000 people and generates annual sales of over 13 billion through its wholly-owned and joint venture operations.
For further information, please contact:
Ashleigh Mcclure BAE Systems
Tel: +44 (0) 1772 856311 Fax: +44 (0) 1772 856524
ashleigh.mcclure@baesystems.com
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