Transcript
INTEGRATED DESIGN FOR DESIGN HELICOPTER ROTOR INTEGRATED FOR HELICOPTER ROTOR
Forum For um 1 – Warw Warwick ick - Sept Septemb ember er 20-21 20-21,, 2005 2005
Patrice GODIOT VIVACE VIVACE FORUM FORUM 1 - Warwick Warwick © 2005 VIVACE Consortium Members. Members. Joris CEZARD All rights reserved
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Hugo FALGARONE Benoit FRICERO September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR GLOBAL USE CASE : ROTOR DESIGN ROTOR ROT OR SYSTEM SYSTEM : A COMPLEX COMPLEX SUBSY SUBSYSTE STEM M
- Expensi Expensive ve parts parts (materia (materials, ls, manufac manufacturi turing ng process processes) es) => Cost => Cost management is management is imperative
- Primary Primary functio functions ns => Safety => Safety requirements = requirements = important design important design constraints
- A complex complex assembly assembly with a complex complex behaviour, behaviour, specific specific to to helicopters industry
VIVACE VIVACE FORUM FORUM 1 - Warwick Warwick
© 2005 VIVACE Consortium Members. Members. All rights reserved
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR GLOBAL USE CASE : ROTOR DESIGN ROTOR ROT OR SYSTEM SYSTEM : A COMPLEX COMPLEX SUBSY SUBSYSTE STEM M
- Expensi Expensive ve parts parts (materia (materials, ls, manufac manufacturi turing ng process processes) es) => Cost => Cost management is management is imperative
- Primary Primary functio functions ns => Safety => Safety requirements = requirements = important design important design constraints
- A complex complex assembly assembly with a complex complex behaviour, behaviour, specific specific to to helicopters industry
VIVACE VIVACE FORUM FORUM 1 - Warwick Warwick
© 2005 VIVACE Consortium Members. Members. All rights reserved
Page: 2
September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR GLOBAL USE CASE : ROTOR DESIGN ROTOR ROT OR SYSTEM SYSTEM : A COMPLEX COMPLEX SUBSY SUBSYSTE STEM M - Dynamics Dynamics and aerodynamics aerodynamics behaviour behaviour prediction prediction requires requires complex simulations simulations
VIVACE VIVACE FORUM FORUM 1 - Warwick Warwick
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR GLOBAL USE CASE : ROTOR DESIGN ROTOR SYSTEM : A COMPLEX SUBSYSTEM - Complex relative motions between numerous parts (flapping masses, control system, …) => kinematics validations are mandatory
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR GLOBAL USE CASE : ROTOR DESIGN PROCESS PRE PROJECT Architecture & Technologies selection – Kinematics – Pre sizing
Scope of VIVACE activities DEVELOPMENT
Detailed design – Drawings – Tolerancing – Stress
INDUSTRIALISATION SUPPORT
IN SERVICE SUPPORT
VIVACE FORUM 1 - Warwick
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIOS PRE PROJECT Architecture definition & technologies selection Maintainability
Pre sizing
=>
Scenario 1.1
Kinematics
=>
Scenario 1.2
Design to Market & Multidisciplinary database
DEVELOPMENT => Scenario 2
Detailed design
N/A within VIVACE
Drawings
N/A within VIVACE
Stress
N/A within VIVACE
Tolerancing
VIVACE FORUM 1 - Warwick
=>
© 2005 VIVACE Consortium Members. All rights reserved
=> Scenario 3
Scenario 4
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.1 UPPER HUB PRE SIZING Scope Present rotor architecture : Spheriflex concept => Spherical bearing SB main functions: - to allow and withstand the flapping mass deflections range, - to transmit aero. loads and power.
Flapping mass VIVACE FORUM 1 - Warwick
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.1 UPPER HUB PRE SIZING Scope
Outer fitting fitting Outer
Elastomeric part part Elastomeric
Inner fitting fitting Inner
Bushing
Elastomeric part = succession of metal and rubber layers VIVACE FORUM 1 - Warwick
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.1 UPPER HUB PRE SIZING Scope Spherical Bearing pre sizing & blade motions spectrum => rotor eccentricity => the flight and control loads, => the rotor head architecture, including the control system, => the hub weight …
The reliability of the SB pre sizing is then very important in order : - to improve the SB specification and reduce the design loops with the supplier , - to freeze the hub architecture early, and then to optimise the Rotor head design and simulations process . VIVACE FORUM 1 - Warwick
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.1 UPPER HUB PRE SIZING AS IS description The rotor eccentricity lies on: > Spherical Bearing Pre sizing - realised on the basis of experience and available data concerning existing Spherical Bearings and later confirmed by first stress analysis. - results are not reliable enough, and behaviour characteristics (stiffness) are not available.
- iterations with the supplier may be numerous. > Flapping mass motions envelop - the selection of the critical flight cases for the analysis is performed on the basis of experience , - the motions of the flapping masses are then drawn manually. VIVACE FORUM 1 - Warwick
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.1 UPPER HUB PRE SIZING TO BE description Intput data file
Output data file
Loads Fc, Δθ, Δβ, Δδ, Temp
Stiffnesses Kr, Kθ, Kβ,
Geometry Ri, Re, α, ne, nm, ee, em,
Stresses & strains
Materials
To develop methods and tools allowing to realise with more effectiveness and reliability: - Pre sizing of the SB (elastomeric & metal parts) - Pre sizing of the SB links - Automatic generation of the SB 3D model - Automatic generation of the flapping mass motions envelope => Efficient eccentricity determination VIVACE FORUM 1 - Warwick
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.1 UPPER HUB PRE SIZING Status at M21
Functional description - environments, - inputs, outputs, formats, - performances …
About to be issued
Elastomeric part pre sizing tool
Planned from M22 to M36
Metal parts pre sizing tool
Planned from M25 to M42
Motions envelop generation
Planned from M25 to M42
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.2 KINEMATICS Scope Kinematics is a primary concern within the framework of a rotor design in order to validate the motions of the parts: range, no collisions. Design and aerodynamics studies progressing, Kinematics validations are realised several times during a development.
AS IS description Kinematics model is built manually (wire model, joints, commands). The selection of the critical flight cases for the analysis is performed on the basis of experience . Deflections and collisions analysis are realised manually , step by step. Very boring tasks to run several times VIVACE FORUM 1 - Warwick
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Relevance of the automation Page: 13
September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.2 KINEMATICS TO BE description Geometrical data file Rotor type Blade number Eccentricity Pitch horn length … Blade motions spectrum Case 1 2 3 …
θ0 3.5 2.4 1.9
θ1c 0.2 0.3 0.5
θ1s β0 β1c β1s δ0 δ1c δ1s
0.1 4.5 0.5 -0.3 1.1 0.3 0.4 -0.1 3.3 0.3 0.2 0.7 0.1 0.1 0.2 2.6 0.1 0.2 0.4 -0.1 0.1
To develop ergonomic functions within CATIA V5 allowing to make the kinematics analysis more reliable and easy: - Automatic generation of the kinematics model - Automatic deflection analysis (on the whole flight spectrum) - Automatic collision analysis (on the whole flight spectrum) VIVACE FORUM 1 - Warwick
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.2 KINEMATICS Status at M21 Functional description - environments, - inputs, outputs, formats, - performances, …
About to be issued
Automatic model generation
About to be issued
Automatic deflections analysis
Forecasted from M22 to M30
Automatic collisions analysis
Forecasted from M22 to M30
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 2 MAINTAINABILITY TOOLBOX Scope To improve maintainability studies efficiency within the framework of collaborative design
Maint. specialists
?
Designers
Objectives
Guidelines
Maintenance tools
Expected benefits: To take into account maintainability constraints at the right time in the project To make easier decision making for maintainability performance VIVACE FORUM 1 - Warwick
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 2 MAINTAINABILITY TOOLBOX AS IS Discontinuous maintainability optimisation : Maintainability analysis/assessments and maintenance tools studies are most often done during development phase
i t y l i a b g e n i t a l e d n i w M a k n o
Guidelines and norms
Maintainability assessment
Maintenance tools
ns to a e m No up for make ives object
l a c n i h c n T e e s i g d
Pre-design Concept choices Sub-assembly drawings Feasibility
VIVACE FORUM 1 - Warwick
Maintainability Objectives and constraints
Pre-development
Frozen drawing files Development
© 2005 VIVACE Consortium Members. All rights reserved
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 2 MAINTAINABILITY TOOLBOX TO BE
i t y l i b e a n i e d g a t i n o w l a M k n Define maintainability objectives
Capitalise maintainability knowledge for next projects Guidelines and norms
Maintenance assessments
Maintenance tools
Maintainability Objectives and constraints
Perform maintainability analysis
a l c i h n n c T e e s i g d VIVACE FORUM 1 - Warwick
Concept choices Feasibility
Pre-design Sub-assembly drawings Pre-development
© 2005 VIVACE Consortium Members. All rights reserved
n for t y g i s e D abili n i a t Main Frozen drawing files Development
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 2 MAINTAINABILITY TOOLBOX Status at M21
Functional specification
About to be issued
Detailed specification: - user interfaces - data links model - access rights - treatment
Planned from M21 to M24
Demonstrator development
VIVACE FORUM 1 - Warwick
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Planned for M30
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 3 DESIGN TO MARKET Scope Scope :
to deploy Design to Market methodology in terms of data management, traceability and project steering and reporting
Means :
1/ Define Design to Market methods and organisation 2/ Build a design to market tool
Programs and chief eng.
Multidisciplinary database
Procurements
Customer service VIVACE FORUM 1 - Warwick
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Design office
Industry Page: 20
September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 3 DESIGN TO MARKET Scope TO&BE AS IS 100%
SAP
High
Intensity of steering activities
Low
Configuration Mgt + Data Mgt prevailing
Functional need Support DtM methodology
VPM
SAP
VIVACE
As-is
No tools
To-be
VIVACE
Feasibility
VIVACE FORUM 1 - Warwick
VIVACE
Pre-Development
© 2005 VIVACE Consortium Members. All rights reserved
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VIVACE
Development
September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 3 DESIGN TO MARKET TO BE Design to market is applied from the beginning of the project (feasibility phase) with the help of the Multidisciplinary Database Breakdown Structure
Traceability
Main topics…
Communication with existing Eurocopter IS
Costing data reported
Configuration Management
Opportunities
Steering & Reporting
Multidisciplinary Database
Centralization
Communication of results & hypothesis
Accessibility to data
Capitalization Dashboard
Opportunities
VIVACE FORUM 1 - Warwick
Parameters assessment & hypothesis
Knowledge Management
© 2005 VIVACE Consortium Members. All rights reserved
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 3 DESIGN TO MARKET TO BE Design to market is applied from the beginning of the project (feasibility phase) with the help of the Multidisciplinary Database
Main topics… Breakdown Structure
…along a project process
Traceability Communication with existing Eurocopter SI
Costing data reported
Market objectives
Target cascading
Parameters assessments
Trade-off perfo-cost
Management By Objective (MBO)
DtC application for purchase
DtC know-how capitalisation
Configuration Management
Opportunities
Steering & Reporting
to n g i s De ke t Mar
Multidisciplinary Database
Capitalization
Centralization
Communicatio n of results & hypothesis
Accessibility to data
Dashboard
Opportunities
VIVACE FORUM 1 - Warwick
Parameters assessment & hypothesis
y t i l i b a s i a F v e d e r P
Knowledge Management
© 2005 VIVACE Consortium Members. All rights reserved
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v e D
September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 3 DESIGN TO MARKET Status at M21
Functional specification
About to be issued
Detailed specification: - user interfaces - data links model - access rights - treatment
Planned from M21 to M24
Demonstrator development
VIVACE FORUM 1 - Warwick
© 2005 VIVACE Consortium Members. All rights reserved
Planned for M30
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING Scope Tolerances analysis are essential in order : - to ensure the functional requirement, - to optimise the manufacturing, control and mounting processes.
AS IS description > CATIA V4 environment > 1D Tolerance analyses are realised manually. Real 3D analyses can't be treated this way. > Tolerances are defined in order to ensure assembling, but without any generic rules: Tolerancing depends on the designer expertise. > Important number of parts in an assembly, important number of tolerances on a part: Important duration of non-conformity analyses > No requirements / analysis storage file VIVACE FORUM 1 - Warwick
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING AS IS description t n e m p o l e v e D n o i t a s i l a i r t s u d n I
Toleranced drawings based on designers experience and knowledge
1 - Answer the requirements dossier 2 - Functional validation (interchangeability included)
1D tolerance analyses
3 - Discussions with Manufacturing and Quality offices
Validated toleranced drawings
4 - Definition of manufacturing and control processes
VIVACE FORUM 1 - Warwick
TO BE IMPROVED
5 - Manufacturing
6 - Control
© 2005 VIVACE Consortium Members. All rights reserved
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING TO BE description Tolerances analysis are based on new methodology and tools ensuring - the traceability from the functions to the specifications - the relevance and the traceability of the tolerances analyses - efficient 3D analyses (how to do? How to understand the results?) - efficient non conformity analyses (production support) Those objectives need : - a state of the art and the evaluation on use cases of CATIA V5 integrated tools for 3D tolerance analyses (CETOL 6 from SIGMETRIX, 3DCS from DCS and Anatole from EADS CRC) - an evaluation of present drawings conformity with regard to ISO standards (required to use this kind of tools) - the definition and validation of new methodologies for functional analyses and 3D tolerance analyses
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING TO BE description Functional analysis taking into account manufacturing and control constraints
1 - Answer the requirements dossier t n e m p o l e v e D
n o i t a s i l a i r t s u d n I
Drawings
2 - Parts design 3 - Tolerances breakdown on the basis of the functional analysis
Toleranced drawings
4 - Functional validation (interchangeability included)
Validated toleranced drawings thanks to 3D analyses
5 - Definition of manufacturing and control processes
VIVACE FORUM 1 - Warwick
6 - Manufacturing Non conformity analysis
7 - Control © 2005 VIVACE Consortium Members. All rights reserved
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING Status at M21 EC statement of work : tolerance management
Done
EC statement of work : respect of ISO standards
Done
3D tolerancing tools state of the art
Done
New methodology definition
In progress from M10 to M42
Tools selection / solution development
In progress from M13 to M42
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Page: 29
September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR CONCLUSION PRE PROJECT Pre sizing Kinematics
DEVELOPMENT
CATIA V5 Integration
Detailed design Drawings Stress Tolerancing
GAIA
IT ENVIRONMENTS AND TOOLS INTEGRATION VIVACE FORUM 1 - Warwick
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September 20-21, 2005
INTEGRATED DESIGN FOR HELICOPTER ROTOR CONCLUSION PRE PROJECT Maintainability
Design to Market & Multidisciplinary database
Pre sizing Kinematics
DEVELOPMENT Detailed design
N/A
Drawings
within
Stress
VIVACE
Tolerancing
SKILLS DEVELOPMENT & COMMUNICATION IMPROVEMENT VIVACE FORUM 1 - Warwick
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September 20-21, 2005
