Towards Interpretable Damage Detection based on Aerodynamic Pressure Measurements
Authors: Philip Franz, Max von Danwitz, Gregory Duthé, Alexander Popp, Eleni Chatzi
Abstract
The increasing flexibility of modern large wind turbine blades necessitates cost-efficient and reliable structural monitoring solutions. For this purpose, we propose to use aerodynamic pressure measurements obtained via Aerosense, a novel, non-intrusive and economical sensing system. In former work [Franz et al., 2025], we investigated the potential of aerodynamic pressure measurements for structural damage detection on elastic and aerodynamically loaded structures. An experimental campaign was conducted on a NACA 633418 airfoil mounted on a vertically vibrating cantilever beam within an open wind tunnel. Structural damage was introduced progressively through controlled saw cuts near the beam support. Aerodynamic pressure distributions were recorded under varying inflow conditions and structural states. Based on this data set, we developed a convolutional neural network to detect structural damage and classify its severity using only aerodynamic pressure signals. The results demonstrate that pressure measurements can effectively enable real-time detection and quantification of damage in elastic, beam-like structures subjected to mildly turbulent flow and varying operational conditions. Recognizing the limitations of pure black-box classification, in this study, we further incorporate physics-based insights and explainable machine learning methods to interpret how structural damage influences both the dynamic response and the aerodynamic pressure field. This leads to an enhanced damage detection pipeline, aiming to improve transparency, robustness, and physical consistency in data-driven monitoring of elastic, aerodynamically loaded structures.
Accurate modeling of aerodynamic loads is essential for understanding and predicting the responses of complex structural systems. However, these models often rely on simplifications of the true physical forces, introducing assumptions that can limit their accuracy. Validating such models becomes particularly challenging in the presence of noisy or incomplete data. To address this, we introduce a probabilistic physics-informed machine learning approach designed to reconstruct the underlying aerodynamic loads from noisy measurements of structural dynamic responses. The model avoids overfitting, eliminates the need for regularization schemes, and allows for the use of heterogeneous and multi-fidelity data during the training process. The efficacy of the approach is demonstrated through the reconstruction of aerodynamic loads on the Great Belt East Bridge, simulated under a linear unsteady assumption. Results show a strong agreement between true and predicted loads, particularly related to root mean squared errors, magnitude, phase angle and peak values of the signals. The method for load reconstructing holds broad applicability, such as modeling validation, future load estimation, and structural damage prognosis.
Gledson Rodrigo Tondo, Igor Kavrakov, Guido Morgenthal
Reliable structural health monitoring (SHM) of offshore wind turbine (OWT) support structures requires fast state estimation from sparse measurements. Repeated high fidelity finite element or aeroelastic analyses are difficult to use directly in online monitoring loops, while purely data-driven surrogates can require large training sets. This paper presents Digi Turbine, a synthetic reliability-aware Physics Informed Neural Network (PINN) benchmark for OWT monopile support structure monitoring. The workflow embeds a simplified Euler Bernoulli beam equation with Winkler soil foundation in the training objective, couples it with Bayesian-prior-informed inverse identification, and adds First Order Reliability Method (FORM) screening. All validation uses synthetic configurations with analytical or finite-difference ground truth motivated by the NREL 5MW reference turbine context.
Monitoring high-dimensional engineering structures in extreme environments is limited by non-stationary excitation, nonlinear structural kinematics, and stochastic forcing. Traditional model-based and black-box data-driven methods often struggle to resolve these dynamics in real time, particularly under sensor failure or partial observability. This paper introduces a rank-optimized digital twin framework based on Koopman operator theory, Hankel-matrix embeddings, and dynamic mode decomposition. By lifting operational data into a linear invariant subspace, the method enables autonomous, input-blind reconstruction of structural states without requiring a priori mass or stiffness matrices. The framework is validated on an NREL 5MW spar-buoy floating offshore wind turbine, representing a challenging coupled aero-hydro-servo-elastic system. Results show that the rank-optimized Koopman-Hankel manifold separates structural resonances from deterministic 3P rotor harmonics under colored noise, where standard subspace identification can be unreliable. A rolling-horizon virtual sensing strategy achieves high-fidelity reconstruction at critical structural hotspots, with coefficient of determination greater than 0.95 at 1 Hz data assimilation and accuracy exceeding 0.99 at higher sampling rates. By estimating a physical Lyapunov time of approximately 1.0 s, the study defines the predictability horizon associated with the system information barrier. The proposed framework provides a computationally efficient and resilient digital twin approach for real-time identification and virtual sensing of complex structural dynamics.
Mohammad Mahdi Abaei, Ahmad BahooToroody, Arttu Polojärvi +4