Design of Experiments Approach for Structural Optimization of Urban Air Mobility Vehicles

The current global context demands the development of new solutions that prioritize energy efficiency, time optimization, safety, and sustainability. Urban transportation is one of the sectors undergoing significant transformation. Pursuing new urban transportation solutions has become increasingly intense, involving research institutions and companies. Considering this context, this study focused on the optimization procedures for designing a new vehicle capable of vertical take-off for urban air mobility applications. This paper reports on the optimization process of a thruster deployment mechanism using statistical techniques. In particular, the authors tested the use of Design of Experiments (DOE) techniques for the optimal design of a structural component of a new vehicle for urban mobility purposes under development at the Applied Mechanics laboratory of the Department of Industrial Engineering of the University of Salerno. For this reason, it was decided that a parametric multibody model would be developed in the Simscape Multibody environment for structural optimization using designed experiment plans to “guide” the designer in the analysis phase and search for an optimal configuration using a minimum number of configurations. Finally, employing FEM analysis, the chosen configuration was validated. This study allowed us to test the use of DOE techniques to design new systems. It allowed us to evaluate different configurations, the static and dynamic behavior, the constraining reactions present in the joints, and the active forces and torques of the actuators, highlighting the correlation between factors that can guide the designer in identifying optimal solutions.