Optimized MFC Sensor Placement for Shape Sensing of Gradient Metamaterial Leading Edges

Optimized MFC Sensor Placement for Shape Sensing of Gradient Metamaterial Leading Edges

Stať ve sborníku v databázi WoS či Scopus

Next-generation aerospace morphing structures require robust, real-time 3D shape-sensing. This study presents a physics-enhanced digital twin based on the inverse Finite Element Method (iFEM), tailored for a mechanical metamaterial flexible leading-edge skin. To preserve structural compliance, a highly sparse array of eight Macro Fiber Composite (MFC) sensors was embedded using compression pockets. Sensor placement was optimized via a Non-dominated Sorting Genetic Algorithm 2 (NSGA-II) multi-objective algorithm and Gray Relational Analysis (GRA) to maximize kinematic observability. To mitigate frictional micro-slip and signal degradation inherent to pocket embedding, a novel regularized contact-coupling calibration framework was introduced. Full-field 3D kinematics were successfully reconstructed using a Static-Augmented Hybrid Modal Basis with Tikhonov-regularized inversion. Experimental validation via quasi-static tensile tests demonstrated exceptional accuracy, yielding an aggregate Mean Absolute Percentage Error (MAPE) of 2.72%, an RMSPE of 3.25%. This framework confirms the viability of combining iFEM and optimal sensor placement for monitoring highly compliant aerospace metamaterials.

Next-generation aerospace morphing structures require robust, real-time 3D shape-sensing. This study presents a physics-enhanced digital twin based on the inverse Finite Element Method (iFEM), tailored for a mechanical metamaterial flexible leading-edge skin. To preserve structural compliance, a highly sparse array of eight Macro Fiber Composite (MFC) sensors was embedded using compression pockets. Sensor placement was optimized via a Non-dominated Sorting Genetic Algorithm 2 (NSGA-II) multi-objective algorithm and Gray Relational Analysis (GRA) to maximize kinematic observability. To mitigate frictional micro-slip and signal degradation inherent to pocket embedding, a novel regularized contact-coupling calibration framework was introduced. Full-field 3D kinematics were successfully reconstructed using a Static-Augmented Hybrid Modal Basis with Tikhonov-regularized inversion. Experimental validation via quasi-static tensile tests demonstrated exceptional accuracy, yielding an aggregate Mean Absolute Percentage Error (MAPE) of 2.72%, an RMSPE of 3.25%. This framework confirms the viability of combining iFEM and optimal sensor placement for monitoring highly compliant aerospace metamaterials.

Inverse finite element method, Shape sensing, Mechanical metamaterials, Optimal sensor placement, Macro fibre composite sensors

Inverse finite element method, Shape sensing, Mechanical metamaterials, Optimal sensor placement, Macro fibre composite sensors

Vojtěch Slabý, Jan Bajer, Zdeněk Hadaš

18.08.2026

Institute of Electrical and Electronics Engineers Inc.

Madrid

9798331551254

Conference Proceedings - 2026 IEEE 13th International Workshop on Metrology for AeroSpace, MetroAeroSpace 2026

689

694

5

https://ieeexplore.ieee.org/document/11646717

http://hdl.handle.net/11012/528140