The present paper reports the outcomes of activities concerning a real-time SHM system for debonding flaw detection based on ground testing of an aircraft structural component as a basis for condition-based maintenance. In this application, a damage detection method unrelated to structural or load models is investigated. In the reported application, the system is applied for real-time detection of two flaws, kissing bond type, artificially deployed over a full-scale composite spar under the action of external bending loads. The proposed algorithm, local high-edge onset (LHEO), detects damage as an edge onset in both the space and time domains, correlating current strain levels to next strain levels within a sliding inner product proportional to the sensor step and the acquisition time interval, respectively. Real-time implementation can run on a consumer-grade computer. The SHM algorithm was written in Matlab and compiled as a Python module, then called from a multiprocess wrapper code with separate operations for data reception and data elaboration. The proposed SHM system is made of FBG arrays, an interrogator, an in-house SHM code, an original decoding software (SW) for real-time implementation of multiple SHM algorithms and a continuous interface with an external operator.

The final objective of the study herein reported is the preliminary evaluation of the capability of an original, real-time SHM system applied to a full-scale wing-box section as a significant aircraft component, during an experimental campaign carried out at the Piaggio Lab in Villanova D’Albenga, Italy. In previous works, the authors have shown that such a system could be applied to composite beams, to reveal damage along the bonding line between a longitudinal stiffening element and the cap. Utilizing a suitable scaling process, such work has then been exported to more complex components, in order to confirm the outcomes that were already achieved, and, possibly, expanding the considerations that should drive the project towards an actual implementation of the proposed architecture. Relevant topics dealt with in this publication concern the application of the structural health monitoring system to different temperature ranges, by taking advantage of a climatic room operating at the Piaggio sites, and the contemporary use of several algorithms for real-time elaborations. Besides the real-time characteristics already introduced and discussed previously, such further steps are essential for applying the proposed architecture on board an aircraft, and to increase reliability aspects by accessing the possibility of comparing different information derived from different sources. The activities herein reported have been carried out within the Italian segment of the RESUME project, a joint co-operation between the Ministry of Defense of Israel and the Ministry of Defense of Italy.

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