Structural integrated sensor and actuator systems for active flow control

An adaptive flow separation control system is designed and implemented as an essential part of a novel high-lift device for future aircraft. The system consists of MEMS pressure sensors to determine the flow conditions and adaptive lips to regulate the mass flow and the velocity of a wall near stream over the internally blown Coanda flap. By the oscillating lip the mass flow in the blowing slot changes dynamically, consequently the momentum exchange of the boundary layer over a high lift flap required mass flow can be reduced. These new compact and highly integrated systems provide a realtime monitoring and manipulation of the flow conditions. In this context the integration of pressure sensors into flow sensing airfoils of composite material is investigated. Mechanical and electrical properties of the integrated sensors are investigated under mechanical loads during tensile tests. The sensors contain a reference pressure chamber isolated to the ambient by a deformable membrane with integrated piezoresistors connected as a Wheatstone bridge, which outputs voltage signals depending on the ambient pressure. The composite material in which the sensors are embedded consists of 22 individual layers of unidirectional glass fiber reinforced plastic (GFRP) prepreg. The results of the experiments are used for adapting the design of the sensors and the layout of the laminate to ensure an optimized flux of force in highly loaded structures primarily for future aeronautical applications. It can be shown that the pressure sensor withstands the embedding process into fiber composites with full functional capability and predictable behavior under stress