CD Laboratory for Structural Strength Control of Lightweight Constructions

Lightweight constructions, e.g. in aeroplanes or modern motor vehicles, are exposed to high loads. The research topic of the CD Laboratory is the automated strength control of such optimised structures during operation.

The aim of lightweight construction is to maximise weight savings. The result is often thin-walled components that are also made of high-performance materials such as carbon fibre-reinforced plastic. In order to guarantee the load-bearing capacity and safety of such optimised construction methods, the lightweight construction sector develops refined calculation models and special computer programs and carries out complex load tests. However, the long-term load-bearing capacity of a lightweight construction must also be ensured during its continued operation, which is generally achieved through regular inspections and detailed maintenance programmes.

This is where the interdisciplinary research work of the CD Laboratory for Structural Strength Control of Lightweight Structures comes in. The aim is to develop mechatronic systems that use sensors to monitor and ensure (i.e. control) the load-bearing capacity (i.e. strength) of lightweight components during operation, in real time and over the entire service life of the component. Classic structural health monitoring (SHM) is an essential element of this, albeit only one part of the overall process. The research work of the CD Laboratory goes beyond this pure observation of the structural condition. The systems developed are also intended to directly assess any damage that may occur (e.g. cracks in metallic materials or delamination in fibre-reinforced plastics), predict their further influence on component strength and ultimately suggest repair measures.

The development of such systems requires interdisciplinary research into corresponding calculation models and calculation methods for strength analysis, sensors, their optimal arrangement and the processing of sensor signals, structural-mechanical processes during damage initiation and further damage propagation, as well as repair measures that are optimised in terms of remaining service life and updated operating requirements. The technical realisation is achieved by supporting modern systems engineering methods, for example by setting up an extended, integrated structural database that stores, processes and passes on all relevant information and data on the component and the control system. Tests are carried out on the structure and component test bench to validate the research results in practice.