Harness 3D routing is one of the most challenging steps in the design of aircraft Electrical Wiring Interconnection System (EWIS). This is due not only to the intrinsic complexity of the EWIS, but also to the increasing number of applying design constraints and its dependency on any change in the design of the airframe and installed systems. The current routing process employed by EWISdesign is largely based on the manual work of expert engineers, partially supported by conventional CAD systems. As a result, the routing process is quite inefficient, error prone and unable to deliver optimal solutions. Although many harness components are selected from catalogues and the design process is largely repetitive and rule based, it has been found that none or very limited automation solutions, which can significantly decrease the workload of engineers and increase their efficiency, are currently available. In this paper, an innovative approach is proposed to solve the 3D routing automation as an optimization problem. Knowledge Based Engineering (KBE) and optimization methods are proposed to achieve minimum cost routing solutions that satisfy all relevant design rules and constraints. The proposed solution is scalable in terms of constraints, can be deployed on any type of routing environment, and, thanks to the achieved level of automation, able to reduce the process lead time drastically. The basic idea is to achieve optimal EWIS routing solutions by optimizing the position of the harnesses clamping points, which are used as way-points to route the harnesses inside the aircraft digital mock-up. The challenge to solve this optimization problem is that the number and initial value of design variables, namely the number and position of clamping points, are not known a priori. To handle this challenge, a two-step, hybrid optimization strategy has been devised. The first step, called Initialization, uses a road map based path finding method to generate a preliminary harness definition, including the required number and preliminary position of its clamping points. The second step, called Refinement, uses a conventional optimization method to move the position of the clamps and refine the preliminary harness definition aiming for the minimum cost and the satisfaction of all the design constraints. This approach has been implemented into a KBE application connected with a commercial optimization package and tested on several routing cases. The results demonstrate that the proposed method is capable of handling cases of representative geometric complexity and design constraints and delivering proper 3D harness models in full automation.

Variable stiffness composites, where fibre angles are spatially varied by steering the tows in curvilinear paths to optimise the structural response, have been a subject of intensive study. In this paper, experimental validation of the variable stiffness composite technology is carried out for a panel representing a wing lower-skin with a large access hole designed against material failure. An idealised flat panel with a large cut-out under tension or combined tension and shear is modeled using finite elements. In addition to a quasi-isotropic laminate, constant stiffness and variable stiffness laminates are designed to maximise the failure load using a multi-step optimisation framework. Three panels, one for each type of laminate, are built from thermoset prepreg material using automated fibre placement. All three panels are tested in pure tension. The failure loads, failure modes and weights of the tested panels are compared. The results indicate that the variable stiffness laminate is capable of sustaining significantly larger loads, before failure, than the constant stiffness and quasi-isotropic laminates of equal weight.

A new parametrization method for aircraft shapes is presented to enhance shape optimization for aircraft design. This parametrization method was implemented in a tool that creates feasible initial solutions for multidisciplinary design optimization problems. The tool combines all aspects of the aerodynamic design process: parametrization, aerodynamic analysis and optimization. The novel parametrization method presented in this paper makes use of the Class-Shape-Refinement-Transformation (CSRT) method. This method employs a combination of Bernstein polynomials and B-splines to allow for both global and local control of the shape. Additionally, the use of B-splines makes it possible to efficiently handle volume constraints, which are very common in aircraft design. The parametrization method was coupled to two different aerodynamic analysis tools. The commercial panel method code VSAERO was used for the low-speed regime and an inhouse Euler code was used for transonic and supersonic flight conditions. Various different optimization schemes were investigated and compared. A number of test cases were performed. For the first set of test cases, a three-dimensional geometry was optimized for subsonic conditions, using VSAERO and various optimization algorithms. For the second set of test cases, an airfoil was optimized for transonic and supersonic conditions, using the in-house Euler solver and a gradient-based optimizer. From this work it can be concluded that a combination of stochastic and gradient-based optimization algorithms works best together with the CSRT method. Additionally, refining the shape using B-splines proved to be an efficient way of increasing the design freedom, while the design space remained smooth enough to employ gradient-based optimization.