Composite patches bonded to defective aircraft structures are a recognized cost‐effective repair or reinforcement technique for many types of structural problems, such as metallic cracking, repairing corrosion damage, and reducing fatigue strain at structural hot spots. However, certification concerns limit the application of composite bonded repairs in critical components. For certification and management of repairs to critical structure, the
smart patch
approach may be a useful approach from the airworthiness perspective in facilitating certification. The
smart patch
consists of a number of
in situ
sensors used to monitor the structural condition (health or well‐being) of the patch system and the status of the remaining damage in the parent structure. In summary the
smart patch
is an
in situ
structural health monitoring (SHM) technology applied to a composite bonded repaired structure. The demonstration of the
smart patch
on an operational aircraft offers an excellent vehicle to demonstrate autonomous SHM technology in an operational environment.
This article describes the development, evaluation, and implementation of the self‐powered wireless
smart patch
system, including issues such as system design, functionality and certification testing, and installation. This system had no primary power source (i.e., battery) and was powered instead by energy harvested from the local strain environment. It was wirelessly interrogated using a magnetic transceiver and employed piezoelectric elements for both powering and health monitoring functions. The article gives a brief overview of the various available power‐harvesting techniques considered and discusses several key issues that arose when designing and developing the self‐powered
smart patch
system, namely, (i) demand—power requirements, (ii) supply—energy generation from vibration or strain‐based sources, and (iii) conversion—issues and efficiencies associated with energy conversion from mechanical to electrical energies. Flight data from the system and lessons learned during the program are also presented.