Real-Time Structural Health Monitoring with Bayesian Neural Networks: Distinguishing Aleatoric and Epistemic Uncertainty for Digital Twin Frameworks

Reliable real-time analysis of sensor data is essential for structural health monitoring (SHM) of high-value assets, yet a major challenge is to obtain spatially resolved full-field aleatoric and epistemic uncertainties for trustworthy decision-making. We present an integrated SHM framework that combines principal component analysis (PCA), a Bayesian neural network (BNN), and Hamiltonian Monte Carlo (HMC) inference, mapping sparse strain gauge measurements onto leading PCA modes to reconstruct full-field strain distributions with uncertainty quantification. The framework was validated through cyclic four-point bending tests on carbon fiber reinforced polymer (CFRP) specimens with varying crack lengths, achieving accurate strain field reconstruction (R squared value > 0.9) while simultaneously producing real-time uncertainty fields. A key contribution is that the BNN yields robust full-field strain reconstructions from noisy experimental data with crack-induced strain singularities, while also providing explicit representations of two complementary uncertainty fields. Considered jointly in full-field form, the aleatoric and epistemic uncertainty fields make it possible to diagnose at a local level, whether low-confidence regions are driven by data-inherent issues or by model-related limitations, thereby supporting reliable decision-making. Collectively, the results demonstrate that the proposed framework advances SHM toward trustworthy digital twin deployment and risk-aware structural diagnostics.