Operational Load Monitoring of a Composite Panel Using Artificial Neural Networks

Operational Load Monitoring consists of the real-time reading and recording of the number and level of strains and stresses during load cycles withstood by a structure in its normal operating environment, in order to make more reliable predictions about its remaining lifetime in service. This is particularly important in aeronautical and aerospace industries, where it is very relevant to extend the components useful life without compromising flight safety. Sensors, like strain gauges, should be mounted on points of the structure where highest strains or stresses are expected. However, if the structure in its normal operating environment is subjected to variable exciting forces acting in different points over time, the number of places where data will have be acquired largely increases. The main idea presented in this paper is that instead of mounting a high number of sensors, an artificial neural network can be trained on the base of finite element simulations in order to estimate the state of the structure in its most stressed points based on data acquired just by a few sensors. The model should also be validated using experimental data to confirm proper predictions of the artificial neural network. An example with an omega-stiffened composite structural panel (a typical part used in aerospace applications) is provided. Artificial neural network was trained using a high-accuracy finite element model of the structure to process data from six strain gauges and return information about the state of the panel during different load cases. The trained neural network was tested in an experimental stand and the measurements confirmed the usefulness of presented approach.