helicopter design roadmap

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Page: 1 2004 VIVACE Consortium Members.

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HELICOPTER

PRE-DESIGN PROCESS IMPROVEMENT

Warwick UK, 20 &21 September 2005VIVACE Forum-1

HELICOPTER

PRE-DESIGN PROCESS

IMPROVEMENT

M. GREILLER (Eurocopter)

VIVACE Forum 1, Warwick UK, 20-21 September 2005


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Table of contents

HELICOPTER INDUSTRY PARTICULARITIESMultiple customers and missionsMarket characteristicsHeavy development

DEVELOPMENT PROCESS DESCRIPTIONGeneral development processPre-Design process

USE CASE DESCRIPTIONAS-IS pre-design processTO-BE pre-design processBenefits

SCENARIOSMastering uncertaintyGeneral architectureLife Cycle CostVisualisation & selection

ROADMAP

WhyVIVA

CE

forhelicop

ter

VIVACE

Actions

Photos EUROCOPTER


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HELICOPTER INDUSTRY PARTICULARITIES

Commercial companies offering regularflights (Off-shore, commuters)

Customers :

Charter or private owners

Military or public customers

Multiple customers and missions

Search and Rescue

Missions :

Off-shore or commuter

Military missions

Photos EUROCOPTER


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Very small seriesMany versions for the same type of helicopter

Low self financing capacityDue to the small series, the recurrent costs and the sale prices cant bereduced.

Fewer major national programsDecrease of great National contracts

(usually military ones)

Market characteristics


Photos EUROCOPTER


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Complex air wake generated by themain rotor

Behavior simulation difficulties

Numerous modifications during thedevelopment phase due to:

- Vibrations

- Flight qualities

- Icing

- Wake interactions

Parts generally reworked :

- Position of the horizontal stabiliser

- Anti-vibration devices

- Air intakes

- Upper cowlings

Heavy development


Photos EUROCOPTER


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DEVELOPMENT PROCESS

General development process

Feasibility

Pre-Development Development

Industrialisation

Service life support

Pre-Design process

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Feasibility (Managed by Pre-project team)Actors:- Pre-project team,

- Strategy,

- Marketing and sales,

- Finance.

Results:- Top level requirements,

- Technical feasibility document,

- Business case.

PRE-DESIGN PROCESS

Pre-Development (Managed by Program team)Actors (those above and):

-Project management

-Technical specialists

-Purchasers

-Production

Results:

-Global aircraft and major sub-

systems specification frozen.

-Major interfaces frozen,

-Major subcontractors chosen,

-Risk management Plan,

-Business case (complete)


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AS-IS Pre-design process

USE CASE DESCRIPTION

TO-BE Pre-design process

Main risks andopportunities:

Identification

and assessmentwith a new

process

General architecture definition:

- Customers requirements fulfillment

- Simplification of the helicopter

integration

Costs evaluation :

Assessment andoptimization for a

large panelofcustomers and/or

mission

Main risks andopportunities:

Coming from

experience of somespecialists

Costs evaluation :

For eachcustomer and/or

mission

General architecture definition:

- New products derived from existing

products.

- Not complete pre-design phase, with

high level of risks.


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USE CASE DESCRIPTION

BENEFIT

Spend more time and money during this first phase, in order to avoid a re-

design later.

HOW

By using the 4 following scenarios

1. Mastering the uncertainty

2. General architecture

3. Life Cycle Cost

4. Visualisation and selection


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SCENARIO 1. Mastering uncertainty

Scope :

AS-IS Process

TO-BE Process

Data provided without assessment of their uncertainty.All values could be very lower or higher than the good data.

Its mandatory to identify, categorise and quantify themain risks or opportunities before sending data

Provide common methodology to express andassess the uncertainty of numerical data.


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- 1 - Identifyand categorise

all the types ofrisks

- 2 - Map thoseRisks and trace their

interdependencies.

- 3 - Evaluate theexisting probabilistic

tool and make aselection.

- 4 - Builda technicalexample

- 5 - Performsensitivity analysisof the example

- 6 - Conclude withthe benefit and thelimits of the method

Scenario description :



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Today referenceArithmetical sum of the elementary margins to

ensure usual level of confidence for sub-parts

Objective

Save 20-30% of the standard margins

Criteria - Metrics

Identify and quantify

R-O*Categorise R-O* and trace

their interdependencies

Aggregate elementary

R-O*

Service functions

CriteriaMargin to ensure usual level of confidence

(90%)

Perform sensitivity

analysis Link back-up solutions

* R-O = Risks orOpportunities



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This scenario is linked with WP3.3 through the

following activities

(Design to Decision Objectives)

Analyse the state

of art and propose

adapted solutions

Help to identify,

categorise and map the

generic risks and

opportunities

Evaluate the existing

probabilistic tool and

propose a selection

Contributions

Help for sensitivity

analysis



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Scope

To

formalise

To

make

explicit

The purpose

of this

scenario is

The steps of the elaboration process fora global aircraft architecture

and

SCENARIO 2. General Architecture

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TO-BE process :

Pre-Projectteam

Experience

feed-backdata base

and tools

Elaboration of balanced architectures for new helicopters

40% 60%

Experience

of involvedpeople

The definition

Result of pre-project phase

The technical

specifications

Context HypothesisChoices

Forgotten parameters

AS-IS process



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- 1 -Collectingthe Know-Howof specialists

- 2 - Collectingmain justifications ofgeneral architecture

- 3 - Formalisingthese informationsfor a further re-use

- 4 -Developing ofa tool to link the

inter-connectedsubjects

- 6 - Defining and

formalising thecriteria to assess anarchitecture.

- 5 - Identifying themajor topics or

problematics,addressed by thegeneral architectureprocess

Scenario description


Photos EUROCOPTER


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Criteria

Time to elaborate a new architecture

Today reference

About 1 year for experienced people

Objective

About 9 months

Criteria - Metrics

Service functions of the developed tool

Identify and capitalise

the Know-How of

experienced people

Make this Know-How

usable for non-specialists

Propose a formal model

to elaborate an

architecture

Service functions



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This scenario is linked with WP3.3 through thefollowing activities

(Design to Decision Objectives)

Define an adequate

structure for the

Know-How data-base

Define the tools to

link the inter-

connected subjects

Formalise the

general architecture

process

Contributions



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Scope

Optimising the technical definition of a helicopter for :- Different customers -

- Different requirements -- Opposite profiles -

AS-IS &TO BE processes

Market analysis for many

customers, for only one definition

Cost estimation based on the

most critical mission

Economical impact estimation for

all the categories of customers

Market analysis for all

customers and all missionsAS-IS TO-BE

Technical choices

(which involve a cost aspect)

SCENARIO 3. Life Cycle Cost


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- 1 - Definethe categoriesof customer

- 2 - Adapt the sizingmodels of NLR and EC:find a common list oftechnical parameters

- 3 - Developthe cost model

- 4 - Perform sensitivityanalysis on a limitednumber of parameters

- 5 - Optimise helicopterdefinition for LCC of 1customer first.

- 6 - Define a criteriato combine LCC ofmultiple customers &

missions

- 7 - Optimisehelicopter definitionfor this composite

criteria

Scenario description



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CriteriaTime to perform combined technical & market analysis

Today reference1 2 weeks

(Models not complete or not connected)

Objective

1 Day

Criteria - Metrics


Estimate the LCC of any

technical definition for

any customers profile

Perform sensitivity

analysis

Optimise helicopter

definition for LCC of 1 or

multiple customers &missions

Service functions



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Adapt the sizing

tool for cost

calculations

Connect the

sizing tool with

the cost model

Define the multi-

criteria optimisation

method

Contributions

This scenario is linked with WP3.2 through thefollowing activities

(Multidisciplinary Design & Optimisation)

Perform the

sensitivity

analysis



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Scope :

Visualisation of complete helicopter geometric models with:- Short access time -

- Focusing only on interesting areas -- High precision -

AS-IS &TO BE processes :

The size of the models are too much

important for a complete helicopter

Models are too long to be visualised

with usual CAD tools

Capability to visualise any part of

an helicopter in its context.

Perform general architecture studiesAS-IS TO-BE

Only used for details studies, or with

rough models for complete helicoptersVisualisation of an entire digital

mock-up

SCENARIO 4. Visualisation and selection


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Scenario description:

- 1 - Evaluateexistingvisualisation

tools- 2 - Definemethodology to usethose models

- 3 - Select an existingtool or write an userspecification forfurther tools.


Photos EUROCOPTER


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CriteriaTime to visualise typical complete helicopter model

Today reference

About 1 hour

Objective

Few seconds

Criteria - Metrics


Visualise and animate

models of completehelicopters,

Refine selected

areas up to

elementary items

Service functions

Automatically

simplify native

models



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ROADMAP

First

prototype

release

Solutions

assessment &

selectionSEEMAGE software evaluation in

progress.

Requirements

and

specifications

report

DONE

4. Visualisation and selection

First

prototype

release

Solutions

assessment &

selection

A helicopter Life Cycle Cost model

was sent to NLR in order to integrate

it into the NLR sizing tool SPEAR

tool.

Requirements

and

specifications

report

DONE

3. Life Cycle Cost

First

prototyperelease

Solutions

assessment &selection

Assessment of a forecasted solut ion

using INGENIUM sof tware, in

progress

Requirements

and

specificationsreport

DONE

2. General arch itecture

First

prototype

release

Solutions

assessment &

selectionWP3.3 solutions assessment in

progress.

Requirements

and

specifications

report

DONE

1. Mastering the uncertainty

M30(Deliverable)

M24(Deliverable)

M21M12

(Deliverable)SCENARIO

helicopter design roadmap

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