Embedded Structural Health Monitoring for Intelligent Propellers

Rotating composite propeller blades of complex toroidal geometry sustain significant centrifugal forces, aerodynamic loads, temperature variations, and fatigue cycles during operation. Traditional inspection methods require grounding aircraft and cannot monitor and capture events during actual operation. In the TorPropel project, Brunel University London - Brunel Composites Centre (BCC), is developing an embedded sensor network integrated directly into the toroidal propeller's composite structure during manufacturing:

• Miniaturized strain gauges are installed on the composite laminate, providing continuous data on structural behaviour without compromising aerodynamic performance.

• Wireless interrogation systems enable monitoring during operation, creating a live representation of the propeller's condition.

• By analysing strain patterns and detecting anomalies early, maintenance can shift from scheduled intervals to condition-based decisions, thereby improving aviation safety 

This approach transforms the propeller into an intelligent structure, providing the sensor data that facilitate the development of a "digital twin" of the propeller's health throughout its operational life.