Tag Archives: design

Joining the dots

Six months ago, I wrote about ‘Finding DIMES’ as we kicked off a new EU-funded project to develop an integrated measurement system for identifying and tracking damage in aircraft structures.  We are already a quarter of the way through the project and we have a concept design for a modular measurement system based on commercial off-the-shelf components.  We started from the position of wanting our system to provide answers to four of the five questions that Farrar & Worden [1] posed for structural health monitoring systems in 2007; and, in addition to provide information to answer the fifth question.  The five questions are: Is there damage? Where is the damage? What kind of damage is present? How severe is the damage?  And, how much useful life remains?

During the last six months our problem definition has evolved through discussions with our EU Topic Manager, Airbus, to four objectives, namely: to quantify applied loads; to provide condition-led/predictive maintenance; to find indications of damage in composites of 6mm diameter or greater and in metal to detect cracks longer than 1mm; and to provide a digital solution.  At first glance there may not appear to be much connection between the initial problem definition and the current version; but actually, they are not very far apart although the current version is more specific.  This evolution from the idealised vision to the practical goal is normal in engineering projects.

We plan to use point sensors, such as resistance strain gauges or fibre Bragg gratings, to quantify applied loads and track usage history; while imaging sensors will allow us to measure strain fields that will provide information about the changing condition of the structure using the image decomposition techniques developed in previous EU-funded projects: ADVISE, VANESSA (see ‘Setting standards‘ on January 29th, 2014) and INSTRUCTIVE.  We will use these techniques to identify and track cracks in metals [2]; while for composites, we will apply a technique developed through an EPSRC iCASE award from 2012-16 on ‘Full-field strain-based methods for NDT & structural integrity measurement’ [3].

I gave a short briefing on DIMES to a group of Airbus engineers last month and it was good see some excitement in the room about the direction of the project.  And, it felt good to be highlighting how we are building on earlier investments in research by joining the dots to create a deployable measurement system and delivering the complete picture in terms of information about the condition of the structure.

Image: Infra red photograph of DIMES meeting in Ulm.

References

  1. Farrar & Worden, An introduction to structural health monitoring, Phil. Trans. R Soc A, 365:303-315, 2007
  2. Middleton, C.A., Gaio, A., Greene, R.J. & Patterson, E.A., Towards automated tracking of initiation and propagation of cracks in aluminium alloy coupons using thermoelastic stress analysis, Nondestructive Evaluation, 38:18, 2019.
  3. Christian, W.J.R., DiazDelaO, F.A. & Patterson, E.A., Strain-based damage assessment of accurate residual strength prediction of impacted composite laminates, Composites Structures, 184:1215-1223, 2018.

The INSTRUCTIVE and DIMES projects have received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreements No. 685777 and No. 820951 respectively.

The opinions expressed in this blog post reflect only the author’s view and the Clean Sky 2 Joint Undertaking is not responsible for any use that may be made of the information it contains.

Digital twins and seeking consensus

A couple of weeks ago I wrote about our work on a proof-of-concept for a digital twin of a fission nuclear reactor and its extension to fusion energy [‘Digitally-enabled regulatory environment for fusion power plants‘ on March 20th, 2019].  In parallel with this work and together with a colleague in the Dalton Nuclear Institute, I am supervising a PhD student who is studying the potential role of virtual reality and social network analysis in delivering nuclear infrastructure projects.  In a new PhD project, we are aiming to extend this research to consider the potential provided by an integrated nuclear digital environment [1] in planning the disposal of nuclear waste.  We plan to look at how provision of clear, evidence-based information and in the broader adoption of digital twins to enhance public confidence through better engagement and understanding.  This is timely because the UK’s Radioactive Waste Management (RWM) have launched their new consent-based process for siting a Geological Disposal Facility (GDF). The adoption of a digital environment to facilitate a consent-based process represents a new and unprecedented approach to the GDF or any other nuclear project in the UK. So this will be an challenging and exciting research project requiring an innovative and multi-disciplinary approach involving both engineering and social sciences.

The PhD project is fully-funded for UK and EU citizens as part of a Centre for Doctoral Training and will involve a year of specialist training followed by three years of research.  For more information following this link.

Reference:

[1] Patterson EA, Taylor RJ & Bankhead M, A framework for an integrated nuclear digital environment, Progress in Nuclear Energy, 87:97-103, 2016.

Image: Artist’s impression of geological disposal facility from https://www.gov.uk/government/news/geological-disposal-understanding-our-work

 

Digitally-enabled regulatory environment for fusion powerplants

Digital twins are a combination of computational models and real-world data describing the form, function and condition of a system [see ‘Can you trust your digital twin?‘ on November 23rd 2016]. They are beginning to transform design processes for complex systems in a number of industries.  We have been working on a proof-of-concept study for a digital reactor in fission energy based on the Integrated Nuclear Digital Environment (INDE) [1].  The research has been conducted by the Virtual Engineering Centre (VEC) at the University of Liverpool together with partners from industry and national laboratories with funding from the UK Government for nuclear innovation.  In parallel, I having been working with a colleague at the University of Manchester and partners at the Culham Centre for Fusion Energy on the form of a digital environment for fusion energy taking account of the higher order of complexity, the scale of resources, the integration of novel technologies, and the likely diversity and distribution of organisations involved in designing, building and operating a fusion powerplant.  We have had positive interactions with the regulatory authorities during the digital fission reactor project and the culture of enabling-regulation [2] offers an opportunity for a new paradigm in the regulation of fusion powerplants.  Hence, we propose in a new PhD project to investigate the potential provided by the integration of digital twins with the regulatory environment to enable innovation in the design of fusion powerplants.

The PhD project is fully-funded for UK and EU citizens as part of a Centre for Doctoral Training and will involve a year of specialist training followed by three years of research.  For more information following this link.

References:

[1] Patterson EA, Taylor RJ & Bankhead M, A framework for an integrated nuclear digital environment, Progress in Nuclear Energy, 87:97-103, 2016.

[2] http://www.onr.org.uk/documents/2018/guide-to-enabling-regulation-in-practice.pdf

Image: https://www.pexels.com/photo/diagram-drawing-electromagnetic-energy-326394/

Finding DIMES

A couple of weeks ago I wrote about the ‘INSTRUCTIVE final reckoning’ (see post on January 9th).  INSTRUCTIVE was an EU project, which ended on December 31st, 2018  in which we demonstrated that infra-red cameras could be used to monitor the initiation and propagation of cracks in aircraft structures (see Middleton et al, 2019).  Now, we have seamlessly moved on to a new EU project, called DIMES (Development of Integrated MEasurement Systems), which started on January 1st, 2019.  To quote our EU documentation, the overall aim of DIMES is ‘to develop and demonstrate an automated measurement system that integrates a range of measurement approaches to enable damage and cracks to be detected and monitored as they originate at multi-material interfaces in an aircraft assembly’.  In simpler terms, we are going to take the results from the INSTRUCTIVE project, integrate them with other existing technologies for monitoring the structural health of an aircraft, and produce a system that can be installed in an aircraft fuselage and will provide early warning on the formation of cracks.  We have two years to achieve this target and demonstrate the system in a ground-based test on a real fuselage at an Airbus facility.  This was a scary prospect until we had our kick-off meeting and a follow-up brainstorming session a couple of weeks ago.  Now, it’s a little less scary.  If I have scared you with the prospect of cracks in aircraft, then do not be alarmed; we have been flying aircraft with cracks in them for years.  It is impossible to build an aircraft without cracks appearing, possibly during manufacturing and certainly in service – perfection (i.e. cracklessness) is unattainable and instead the stresses are maintained low enough to ensure undetected cracks will not grow (see ‘Alan Arnold Griffith’ on April 26th, 2017) and that detected ones are repaired before they propagate significantly (see ‘Aircraft inspection’ on October 10th, 2018).

I should explain that the ‘we’ above is the University of Liverpool and Strain Solutions Limited, who were the partners in INSTRUCTIVE, plus EMPA, the Swiss National Materials Laboratory, and Dantec Dynamics GmbH, a producer of scientific instruments in Ulm, Germany.  I am already working with these latter two organisations in the EU project MOTIVATE; so, we are a close-knit team who know and trust each other  – that’s one of the keys to successful collaborations tackling ambitious challenges with game-changing outcomes.

So how might the outcomes of DIMES be game-changing?  Well, at the moment, aircraft are designed using computer models that are comprehensively validated using measurement data from a large number of expensive experiments.  The MOTIVATE project is about reducing the number of experiments and increasing the quality and quantity of information gained from each experiment, i.e. ‘Getting Smarter’ (see post on June 21st 2017).  However, if the measurement system developed in DIMES allowed us to monitor in-flight strain fields in critical locations on-board an aircraft, then we would have high quality data to support future design work, which would allow further reductions in the campaign of experiments required to support new designs; and we would have continuous comprehensive monitoring of the structural integrity of every aircraft in the fleet, which would allow more efficient planning of maintenance as well as increased safety margins, or reductions in structural weight while maintaining safety margins.  This would be a significant step towards digital twins of aircraft (see ‘Fourth industrial revolution’ on July 4th, 2018 and ‘Can you trust your digital twin?’ on November 23rd, 2016).

The INSTRUCTIVE, MOTIVATE and DIMES projects have received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreements No. 685777, No. 754660 and No. 820951 respectively.

The opinions expressed in this blog post reflect only the author’s view and the Clean Sky 2 Joint Undertaking is not responsible for any use that may be made of the information it contains.

Sources:

Middleton CA, Gaio A, Greene RJ & Patterson EA, Towards automated tracking of initiation and propagation of cracks in Aluminium alloy coupons using thermoelastic stress analysis, J. Non-destructive Testing, 38:18, 2019