Specific Modeling Issues on an Adaptive Winglet Skeleton

Morphing aeronautical systems may be used for a number of aims, ranging from improving performance in specific flight conditions, to keeping the optimal efficiency over a certain parameters domain instead of confining it to a single point, extending the flight envelope, and so on. An almost trivial statement is that traditional skeleton architectures cannot be held as a structure modified from being rigid to deformable. That passage is not simple, as a structure that is able to be modified shall be designed and constructed to face those new requirements. What is not marginal, is that the new configurations can lead to some peculiar problems for both the morphing and the standard, supporting, elements. In their own nature, in fact, adaptive systems are designed to contain all the parts within the original geometry, without any "external adjoint", such as nacelles or others. Stress and strain distribution may vary a lot with respect to usual structures and some particular modifications are required. Sometimes, it happens that the structural behavior does not match with the common experience and some specific adjustment shall be done to overcome the problem. What is reported in this paper is a study concerning the adaptation of the structural architecture, used to host a winglet morphing system, to make it accomplish the original requirements, i.e., allow the deformation values to be under the safety threshold. When facing that problem, an uncommon behavior of the finite element (FE) solver has been met: the safety factors appear to be tremendously dependent on the mesh size, so as to raise serious questions about the actual expected value, relevant for the most severe load conditions. On the other side, such singularities are more and more confined into single points (or single lines), as the mesh refines, so to evidence somehow the numerical effect behind those results. On the other side, standard engineering local methods to reduce the abovementioned strain peaks seem to work very well in re-distributing the stress and strain excesses to the whole system domain. The work does not intend to give an answer to the presented problem, being instead focused on describing its possible causes and its evident effects. Further work is necessary to detect the original source of such inconsistencies, and propose and test operative solutions. That will be the subject of the next steps of the ongoing research

VST project: mechanical design optimization

The VLT Survey Telescope (VST) is a cooperative program between the European Southern Observatory (ESO) and the INAF Capodimonte Astronomical Observatory (OAC), Naples, for the study, design, and realization of a 2.6-m wide-field optical imaging telescope to be operated at the Paranal Observatory, Chile. The VST has been specifically designed to carry out stand-alone observations in the UV to I spectral range and to supply target databases for the ESO Very Large Telescope (VLT). The telescope design, manufacturing and integration are responsibility of TWG and have been carried out on the base of a model of optimized design not only for mechanics but for all telescope subsystems. The paper is an overview on the telescope mechanical design and optimization

SMA-Based System for Environmental Sensors Released from an Unmanned Aerial Vehicle

In the work at hand, a shape memory alloy (SMA)-based system is presented. The system, conceived for releasing environmental sensors from ground or small unmanned aerial vehicles, UAV (often named UAS, unmanned aerial system), is made of a door, integrated into the bottom of the fuselage, a device distributor, operated by a couple of antagonistic SMA springs, and a kinematic chain, to synchronize the deployment operation with the system movement. On the basis of the specifications (weight, available space, energy supply, sensors size, etc.), the system design was addressed. After having identified the main system characteristics, a representative mock-up was manufactured, featuring the bottom part of the reference fuselage. Functionality tests were performed to prove the system capability to release the sensors; a detailed characterization was finally carried out, mainly finalized at correlating the kinematic chain displacement with the SMA spring temperature and the supplied electrical power. A comparison between theoretical predictions and experimental outcomes showed good agreement

SMA-Based System for Environmental Sensors Released from an Unmanned Aerial Vehicle

In the work at hand, a shape memory alloy (SMA)-based system is presented. The system, conceived for releasing environmental sensors from ground or small unmanned aerial vehicles, UAV (often named UAS, unmanned aerial system), is made of a door, integrated into the bottom of the fuselage, a device distributor, operated by a couple of antagonistic SMA springs, and a kinematic chain, to synchronize the deployment operation with the system movement. On the basis of the specifications (weight, available space, energy supply, sensors size, etc.), the system design was addressed. After having identified the main system characteristics, a representative mock-up was manufactured, featuring the bottom part of the reference fuselage. Functionality tests were performed to prove the system capability to release the sensors; a detailed characterization was finally carried out, mainly finalized at correlating the kinematic chain displacement with the SMA spring temperature and the supplied electrical power. A comparison between theoretical predictions and experimental outcomes showed good agreement

A Shape Memory Alloy Application for Compact Unmanned Aerial Vehicles

Shape memory alloys materials, SMA, offer several advantages that designers can rely on such as the possibility of transmitting large forces and deformations, compactness, and the intrinsic capability to absorb loads. Their use as monolithic actuators, moreover, can lead to potential simplifications of the system, through a reduction of number of parts and the removal of many free play gaps among mechanics. For these reasons, technological aerospace research is focusing on this kind of technology more and more, even though fatigue life, performance degradation, and other issues are still open. In the work at hand, landing gear for unmanned aerial vehicles, UAV, is presented, integrated with shape memory alloys springs as actuation devices. A conceptual prototype has been realized to verify the system ability in satisfying specs, in terms of deployment and retraction capability. Starting from the proposed device working principle and the main design parameters identification, the design phase is faced, setting those parameters to meet weight, deployment angle, energy consumption, and available room requirements. Then, system modeling and performance prediction is performed and finally a correlation between numerical and experimental results is presented

Specific Modeling Issues on an Adaptive Winglet Skeleton

Morphing aeronautical systems may be used for a number of aims, ranging from improving performance in specific flight conditions, to keeping the optimal efficiency over a certain parameters domain instead of confining it to a single point, extending the flight envelope, and so on. An almost trivial statement is that traditional skeleton architectures cannot be held as a structure modified from being rigid to deformable. That passage is not simple, as a structure that is able to be modified shall be designed and constructed to face those new requirements. What is not marginal, is that the new configurations can lead to some peculiar problems for both the morphing and the standard, supporting, elements. In their own nature, in fact, adaptive systems are designed to contain all the parts within the original geometry, without any “external adjoint”, such as nacelles or others. Stress and strain distribution may vary a lot with respect to usual structures and some particular modifications are required. Sometimes, it happens that the structural behavior does not match with the common experience and some specific adjustment shall be done to overcome the problem. What is reported in this paper is a study concerning the adaptation of the structural architecture, used to host a winglet morphing system, to make it accomplish the original requirements, i.e., allow the deformation values to be under the safety threshold. When facing that problem, an uncommon behavior of the finite element (FE) solver has been met: the safety factors appear to be tremendously dependent on the mesh size, so as to raise serious questions about the actual expected value, relevant for the most severe load conditions. On the other side, such singularities are more and more confined into single points (or single lines), as the mesh refines, so to evidence somehow the numerical effect behind those results. On the other side, standard engineering local methods to reduce the abovementioned strain peaks seem to work very well in re-distributing the stress and strain excesses to the whole system domain. The work does not intend to give an answer to the presented problem, being instead focused on describing its possible causes and its evident effects. Further work is necessary to detect the original source of such inconsistencies, and propose and test operative solutions. That will be the subject of the next steps of the ongoing research

Numerical Analysis Results of Debonding Damage Effects for an SHM System Application on a Typical Composite Beam

In the aeronautical field, the damage that occurs to a carbon-fibre-reinforced polymer (CFRP) structure analysis is a crucial point for further improving its capability and performance. In the current the state of the art, in fact, many issues are linked to the certification process more than to technological aspects. For the sake of clarity, it should be added that regulations call for technological solutions that are invasive (in terms of weight and manufacturing costs) or exploit technologies that are not fully mature. Thus, the truth is in between the above statements. One of the possible solutions to bypass this issue is the assessment of a structural health monitoring system (SHM) that is sufficiently reliable to provide a full-state representation of the structure, automatically, perhaps in real-time, with a minimum intervention of specialized technicians, and that can raise an alert for safe maintenance whenever necessary. Among the different systems that have been proposed in the scientific and technological literature, SHM systems based on strain acquisitions seem very promising: they deduce the presence of flaws by analysing the variations of the intimate response of the structure. In this context, the SHM using fibre optics, supported by a dedicated algorithm, seems to be able to translate the effects of the damage reading the strain field. This means that is necessary to have a full comprehension of the flaws’ effects in terms of strain variation to better formulate a strategy aimed at highlighting these distortions. It should be remarked that each type of damage is distinct; imperfections of the bonding line are herein targeted since the quality of the latter is of paramount importance for ensuring the correct behaviour of the referred structure. This presents paper focuses on a deep investigation on the strain field peculiarities that arise after the imposition of irregularities in the adhesive region. The aim is to explore the damage dimension versus its effect on the strain map, especially when bonding connects different parts of a complex composite beam. By means of finite element method applied on a typical aeronautical beam, a parametric numerical simulation was performed in order to establish the influence of a debonding dimension on a reference strain map. This work provides evidence that these effects on strain flaw decrease the distancing itself of the damage. The knowledge of these effects can be highly helpful during the design of a preliminary phase of an SHM system in order to choose the most suitable sensor in terms of reading sensitivity error, the number to be used, and their location

De-Bonding Numerical Characterization and Detection in Aeronautic Multi-Element Spars

Structural health monitoring has multifold aims. Concerning composite structures, the main objectives are perhaps reducing costs by shifting from scheduled to on-demand maintenance and reducing weight by removing redundant precautions as the insertion of chicken fasteners to for ensuring joint safety in cases of bonding layer fail. Adhesion defects may be classified along different types, for instance distinguishing between glue deficiency or de-bonding. This paper deals with a preliminary numerical characterization of adhesive layer imperfections on a representative aircraft component. The multipart composite spar is made of two plates and two corresponding C-beams, bonded together to form an almost squared boxed section beam. A numerical test campaign was devoted to extract relevant information from different defect layouts and to try to assess some parameters that could describe their peculiarities. A focus was then given to macroscopic evidence of fault effects behavior, as localization, reciprocal interference, impact on structural response, and so on. A proprietary code was finally used to retrieve the presence and size of the imperfections, correlating numerical outcomes with estimations. Activities were performed along OPTICOMS, a European project funded within the Clean Sky 2 Joint Technology Initiative (JTI)

Preliminary Results of a Structural Health Monitoring System Application for Real-Time Debonding Detection on a Full-Scale Composite Spar

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