Design of a sensor network for structural health monitoring of a full-scale composite horizontal tail

The detection capability of a given structural health monitoring (SHM) system strongly depends on its sensor network placement. In order to minimize the number of sensors while maximizing the detection capability, optimal design of the PZT sensor network placement is necessary for structural health monitoring (SHM) of a full-scale composite horizontal tail. In this study, the sensor network optimization was simplified as a problem of determining the sensor array placement between stiffeners to achieve the desired the coverage rate. First, an analysis of the structural layout and load distribution of a composite horizontal tail was performed. The constraint conditions of the optimal design were presented. Then, the SHM algorithm of the composite horizontal tail under static load was proposed. Based on the given SHM algorithm, a sensor network was designed for the full-scale composite horizontal tail structure. Effective profiles of cross-stiffener paths (CRPs) and uncross-stiffener paths (URPs) were estimated by a Lamb wave propagation experiment in a multi-stiffener composite specimen. Based on the coverage rate and the redundancy requirements, a seven-sensor array-network was chosen as the optimal sensor network for each airfoil. Finally, a preliminary SHM experiment was performed on a typical composite aircraft structure component. The reliability of the SHM result for a composite horizontal tail structure under static load was validated. In the result, the red zone represented the delamination damage. The detection capability of the optimized sensor network was verified by SHM of a full-scale composite horizontal tail; all the diagnosis results were obtained in two minutes. The result showed that all the damage in the monitoring region was covered by the sensor network.