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Design of a Modularized IoT Multi-Functional Sensing System and Data Pipeline for Digital Twin-Oriented Real-Time
Shengkai Guo1, Andrew West2, Jan Papuga3
1Department of Aeronautical and Automotive Engineering, Loughborough University, Loughborough LE11 3TU, UK.
Sensors (Basel, Switzerland)
|November 13, 2025
Summary
This study introduces a modular, multi-functional sensing system for real-time aircraft structural monitoring. Flight tests confirm a 1000 Hz sampling rate is crucial for accurate fatigue life estimation and failure detection.
Area of Science:
- Aerospace Engineering
- Structural Health Monitoring
- Internet of Things (IoT)
Background:
- Continuous real-time monitoring of aircraft structural performance is essential for safety and maintenance.
- Existing systems may lack the multi-sensor, multi-location capabilities required for comprehensive analysis.
- The Internet of Things (IoT) paradigm offers a framework for developing advanced monitoring solutions.
Purpose of the Study:
- To design and evaluate a modular, multi-functional sensing (MMFS) system for continuous, real-time monitoring of aircraft structural performance during flight.
- To integrate various sensors for detecting potential in-flight failures and estimating remaining useful service life.
- To validate the system's performance through real flight tests and laboratory experiments.
Main Methods:
- Development of an MMFS system integrating a microcontroller with strain, acceleration, vibration, and temperature sensors.
- Implementation of resistance strain gauge networks, piezoelectric sensors, accelerometers, and thermistors.
- Conducting real flight tests on Evektor's Cobra VUT100i and SportStar RTC aircraft.
- Laboratory evaluation using an Instron Hydraulic 250 kN machine for stress/strain experiments.
Main Results:
- Real flight test data analysis indicated a necessary sampling rate of 1000 Hz for optimal data representation and fatigue life estimation.
- The MMFS system successfully acquired and processed data related to aircraft structural performance during flight.
- Laboratory tests validated the prototype's performance under representative stress/strain conditions.
Conclusions:
- The developed MMFS system provides a viable solution for continuous, real-time structural health monitoring of aircraft.
- A 1000 Hz sampling rate is recommended for balancing data fidelity and fatigue life analysis accuracy.
- The system demonstrates potential for enhancing aircraft safety by enabling early detection of failures and improved service life estimations.
