Selecting right positions for composite-integrated sensors for monitoring cure during manufacturing and loads during product use presents challenges for engineering design. Since an optimal sensor placement (OSP) methodology for both phases is not emphasised enough in literature, a new methodology is proposed. This methodology is based on a Genetic Algorithm and strain gauges, temperature sensors and interdigitated electrode sensors for cure monitoring and physics-informed neural network-based load detection. Additionally, it includes sensor node positions optimization in a sensor network.

The use of sensor networks (SNs) on the surface or the inside of large-scale components allows the continuous acquisition of data on the applied loads and their structural integrity. A lot of publications on SN's system reliability deal with this topic from a hardware- or a data- and energy-oriented viewpoint. To give an overview on the state of the art in the field of reliability-oriented concept-optimization of SNs, a Systematic Literature Review is conducted. The found literature is used to investigate how different models combine the different viewpoints to analyse the system reliability. By analysing the results regarding the used reliability indicators and methods to assess the system reliability from the different viewpoints, it can be observed that most publications deal with the accuracy, loss and delay of data as well as the energy consumption in SNs. Few publications use common modelling methods like reliability block diagrams or Markov chains with a focus on the hardware reliability. Furthermore, none of the found publications combines the data, hardware and energy perspective and uses them to optimize a SN regarding its reliability from all three viewpoints.

Data of operational conditions of structural components, acquired, e.g., in structural health monitoring (SHM), is of great interest to optimise products from one generation to the next, for example, by adapting them to occurring operational loads. To acquire data for this purpose in the desired quality, an optimal sensor placement for so-called shape and load sensing is required. In the case of large-scale structural components, wireless sensor networks (WSN) could be used to process and transmit the acquired data for real-time monitoring, which furthermore requires an optimisation of sensor node positions. Since most publications focus only on the optimal sensor placement or the optimisation of sensor node positions, a methodology for both is implemented in a Python tool, and an optimised WSN is realised on a demonstration part, loaded at a test bench. For this purpose, the modal method is applied for shape sensing as well as a physics-informed neural network for solving inverse problems in shape sensing (iPINN). The WSN is realised with strain gauges, HX711 analogue-digital (A/D) converters, and Arduino Nano 33 IoT microprocessors for data submission to a server, which allows real-time visualisation and data processing on a Python Flask server. The results demonstrate the applicability of the presented methodology and its implementation in the Python tool for achieving high-accuracy shape sensing with WSNs.

Wireless sensor networks (WSNs) are attracting increasing research interest due to their ability to monitor large areas independently. Their reliability is a crucial issue, as it is influenced by hardware, data, and energy-related factors such as loading conditions, signal attenuation, and battery lifetime. Proper selection of sensor node positions is essential to maximise system reliability during the development of products equipped with WSNs. For this purpose, this paper presents an approach to estimate WSN system reliability during the development phase based on the analysis of measurements, using strain measurements in finite element (FE) models as an example. The approach involves dividing the part under consideration into regions with similar strains using a region growing algorithm (RGA). The WSN configuration is then analysed for reliability based on data paths and measurement redundancy resulting from the sensor positions in the identified measuring regions. This methodology was tested on an exemplary WSN configuration at an aircraft wing box under bending load and found to effectively estimate the hardware perspective on system reliability. Therefore, the methodology and algorithm show potential for optimising sensor node positions to achieve better reliability results.

Wireless Sensor networks (WSNs) are gaining more and more research interest due to their ability to monitor large areas more or less independent. However, their reliability is an important issue, since their system reliability is influenced from a hardware, a data and an energetic point of view due to different factors like loading conditions, signal attenuation and battery lifetime. Regarding these issues, the positions of sensor nodes have to be chosen correctly to maximize the system reliability, which has to be considered during the development of new products equipped with WSNs. In this paper, an approach to estimate a WSNs system reliability during the development phase based on the analysis of the measurements on the example of strain measurements in finite elements (FE) models is presented. For that, the part under consideration is divided into regions with similar strains by the use of a Region Growing Algorithm (RGA). Afterwards, the WSN’s configuration is analyzed regarding its reliability in accordance to the data paths and measurement redundancy due to the sensor positions in the found measuring regions. This methodology is tested on an exemplary WSN configuration at an aircraft wing box under bending load and was found to work very well regarding the estimation of the hardware perspective on the system reliability. Therefore, the methodology and the developed algorithm show potentials for optimizations in sensor node positions for better reliability results.