I've been trying to work out some rudimentary dead-reckonings with an IMU chip, and most of the kinetics/kinematics and algorithms are borrowed from aviation related textbooks. I understand what the Euler angles are, how the rotation matrix originates from a dot product between frames, or how to convert my Euler angles to Quaternion to run the algorithm etc. But I just couldn't understand gimbal lock at all.
There are plenty of resources on the web (e.g. Matthew Brett's Gimbal Lock, J.Gallifent's Gimbal Lock, and most notably this YouTube video Euler (gimbal lock) Explained) and a good number of related if not identical questions on SE (most related if not practically identical questions Euler Angles - Gimbal lock, why non-orthogonal axes Gimbal lock confusion and Euler-angles-and-gimbal-lock). Even If I can follow the math derivation, I could not make any qualitative sense or visualization of the concept if the object is not mounted on a gimbal or rings (why would I ever want to mount a plane or an IMU on a gimbal anyway).
The basis of any frame $(\mathbf{i},\mathbf{j},\mathbf{k})$ is always orthogonal, and each of the three rotation matrices in $R_x(\phi)_2^3R_y(\theta)_1^2R_z(\psi)_0^1$ transform the basis all together, from one frame to another. In between or throughout the three rotation transformations, the basis stays orthogonal - the nose always points in the $+\mathbf{i}$ direction, the right wing to $+\mathbf{j}$ and belly of the plane faces the $+\mathbf{k}$ direction. No order of rotation and not one value of $\psi, \theta, \text{or } \phi$ can possibly align $\mathbf{i}$ to $\mathbf{j}$, or $\mathbf{j}$ to $\mathbf{k}$.
The only ways to align two axis to satisfy the condition needed for gimbal lock is to mechanically deform the object, such as bending the nose $90^{\circ}$ around the $y$-axis to align $\mathbf{i}$ and $\mathbf{k}$, or chopping off both wings and attaching them to the nose to align $\mathbf{i}$ and $\mathbf{j}$. But that's just non-sense.
I think I'm in need of a qualitative answer or an example of a plane gimbal locking itself to understand what gimbal lock is. Or correct me if I have an entirely erroneous concept of gimbal lock.
[EDIT]
Adding a quote from my textbook Small Unmanned Aircraft Theory and Practice by R. Beard (p.15-16):
The rotation sequence ψ-θ-φ is commonly used for aircraft and is just one of several Euler angle systems in use. The physical interpretation of Euler angles is clear and this contributes to their widespread use. Euler angle representations, however, have a mathematical singularity that can cause computational instabilities. For the ψ-θ-φ Euler angle sequence, there is a singularity when the pitch angle θ is ±90 deg, in which case the yaw angle is not defined. This singularity is commonly referred to as gimbal lock.