The optimal design of fibre composite structures with embedded sensor systems is investigated to address the interaction between the fibre composite structure and sensor design disciplines for Multidisciplinary Design Optimisation (MDO). Optimisation within the composite structure discipline involves changes in the geometry and ply orientations to achieve a design meeting strength and weight constraints. Other design decisions involve choices of materials, material forms and manufacturing processes, and these affect the valid design space for such variables as minimum thicknesses or curvatures, and strength properties. Within the sensor discipline, optimisation involves changes in sensor locations to achieve a design meeting the requirements for sensor functionality (e.g. detecting damage of a particular size), robustness, cost, and structural integrity. Design decisions such as choice of sensor type influence allowable locations for embedment, the degree of strength reduction in the fibre composite structure, compatible methods of component manufacture, and coverage area for each sensor. The nature of the disciplinary design spaces differ significantly leading to varied approaches to optimisation and the requirement to bring together a range of commercial and customised analysis programs and optimisation algorithms into a cohesive MDO environment.
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