The strain gauge method and the digital image correlation (DIC) method are commonly employed for measuring strain in tested objects, including material specimens and structural elements. The optical method enables the assessment of 3D strain fields across the entire area of interest, achieved through cameras and advanced software. The study investigates both quasi-static strength tests and more advanced research of structures. It explores full-scale construction testing, featuring highly stressed components of new wagon designs. The paper reviews the benefits and challenges of using the DIC method to measure large-scale elements. Conducting full-scale object testing is characterized by significant complexity, often involving interactions between elements, complex loading conditions, and the influence of friction. Numerous factors affect the measurements. Therefore, to compare both methods, an initially standard shear by tensile test of CFRP composite was analyzed. The analysis of strain maps provides valuable visualization of deformation patterns occurring during construction loading. The strain gauge method was crucial for verifying the quality of the DIC measurements. The results obtained provide a detailed understanding of how the components behave, highlighting the versatility of digital image correlation technology. For strain values of 0.3% and above, a good match was obtained between optical and strain gauge measurements. Below this value, the results have less accuracy. The results obtained provide a detailed understanding of how the components behave, highlighting the versatility of digital image correlation technology. The error comparison and discussion between different measurement scenarios were conducted. The paper presents a developed methodology for measuring strain and displacement state in complex and crucial structural elements. The method can be applied to measurements of heavily loaded components used in the transportation industry; for example, in railways.

This study explores the effectiveness of 3D Digital Image Correlation (DIC) for measuring displacement and strain of a propeller undergoing angular motion. Traditional methods, such as strain gauges, face limitations including physical interference, technical difficulties in sensor connections, and restricted measurement points, leading to inaccuracies in capturing true conditions. To overcome these challenges, this research utilizes non-contact 3D DIC technology, enabling measurement of surface displacements and deformations without interfering with the tested component. Experiments were conducted using the model aircraft propellers mounted on a custom-built test stand for partial angular motion. The 1 Mpx high-speed cameras captured strain and displacement data across the propeller blades during motion. The DIC strain measurements were then compared to strain gauge data to evaluate their accuracy and reliability. The results demonstrate that 3D DIC enables precise displacement measurements, while strain measurements are subject to certain limitations. Displacement measurements were achieved with a noise level of ±10 μm, while strain measurement noise ranged from 26 to 174 µm/m depending on direction. Strain gauge measurements were also performed for verification of the DIC measurements and calibration of the filtering procedure. Two types of non-metallic materials were used in the study: Nylon LGF60 PA6 for the propeller and 3D-printed PC ABS for the cantilever beam used in strain measurement validation. This study underscores the potential of DIC for monitoring rotating components, with a particular focus on measuring strains that are often overlooked in publications addressing similar topics. Additionally, it focuses on comparing DIC strain measurements with strain gauge data on rotating components, addressing a critical gap in existing literature, as strain measurement in rotating structures remains underexplored in current research.