presented by g. la [email protected]

19-20 May 2005, Eindhoven

Presented by G. La Rocca [email protected]

Development of Design and Engineering Engines to Support

Multidisciplinary Design and Analysis of Aircraft


The challenges for the next 20 years of aviationAccording to ACARE and NASA the aircraft of the future will have to be: • Faster• with higher payload capacity• Safer• Cleaner• Quieter• …..different?• AFFORDABLE!How to achieve that in the current situation?• Less economic and intellectual resources available• Engineers have less experience from past programs• Increased mobility of knowledge workers• Globalization of the market • Projects run by teams scattered over the globe…..


• Reduce the time wasted in repetitive and routine activities• Give more space to creative design• Focus on methodologies to capture and efficiently reuse designers’ knowledge

Development of improved methodologies to allow thoroughly and efficient exploration of the design space


Definition of Design and Engineering Engine (DEE)

A DEE is an advanced design system to support and accelerate the design process of complex products through the automation of non-creative and repetitive design activities. A DEE consists of a multi-disciplinary collection of design and analysis tools, which are able to automatically interface each other and exchange data and information generated by their internal processes.

MULTI-MODEL GENERATOR (MMG)

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Calculation of product model

parameter values

Check of analysisresults on:1) convergence2) compliance with

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Paradigm of a Design and Engineering Engine (DEE)

The Multi Model

Generator(MMG)


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The product model


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The extent of achievable automation for the repetitive design activities mainly depends on:

- Capability of the DEE components to interface each other and exchange data and information (development required at framework level)- Quality and level of maturity of data and information generated by the DEE components (development required at tools level)

Development of a Design and Engineering Engine (DEE)


Knowledge Based Engineering (KBE): a technological implementation of the Knowledge Management vision for the engineering business

KBE technology integrates Artificial Intelligence and Computer Aided Design to produce computerized applications able to capture and re-use efficiently and effectively the engineering design knowledge of the organization

Eval ? first sparY

N

Rib = ‘FD ? spar nY

Point at root

N

Eval ? first sparY

N


Point at root

N

A.I.

CAD

Knowledge Based

Engineering

Functional requirements

INPUTSSize, material, positioning ….

GENERATIVE MODELProduct StructureDesign StandardsMaterial CharacteristicManufacturing ConstrainEngineering Analysis……..

OUTPUTSDrawings, 3-D Models, 2-D Models, Bills of material, Tool Design ….

Engineered design




GENERATIVE MODELProduct StructureDesign StandardsMaterial CharacteristicManufacturing ConstraintsEngineering Analysis……..


CAD

Knowledge Based

EngineeringEval ? first spar

Y

N


Point at root

N

Eval ? first sparY

N


Point at root

N

A.I.Eval ? first spar

Y

N


Point at root

N

Eval ? first sparY

N


Point at root

N

Eval ? first sparY

N


Point at root

N

Eval ? first sparY

N


Point at root

N

A.I.

CAD

Knowledge Based

Engineering




GENERATIVE MODELProduct StructureDesign StandardsMaterial CharacteristicManufacturing ConstrainEngineering Analysis……..


Engineered design

Engineered design




GENERATIVE MODELProduct StructureDesign StandardsMaterial CharacteristicManufacturing ConstraintsEngineering Analysis……..



Definition of the High Level Primitives (HLPs)

Wing-Trunk parameters set- Type of airfoil (from a library)- Amount of airfoils- Positioning of airfoils- Thickness of airfoils- Reference axis- Chords’ length- Span- Dihedral angle- Sweep angle- Twist angle- ……

Connection element

Wing-Trunk

Fuselage-Trunk

Engine part


The building block approach

Connection element

Wing-Trunk

Fuselage-Trunk

Engine part


Connection element

Wing-Trunk

Fuselage-Trunk

Engine part

Generation of many aircraft configurations


Connection element

Wing-Trunk

Fuselage-Trunk

Engine part

Generation of variants of one configuration


Generation of variants of one configuration

Connection element

Wing-Trunk

Fuselage-Trunk

Engine part


Development of the structural modelsThe MMG automatically generates the geometry of the structural elements inside each primitive.

The structure is:• parametrically defined • tailored to the outer surface

Upper wing-box panel

Lower wing-box panel

Front spar

Rear spar

Trailing edge

Leading edge

Ribs

if the aircraft outer shape changes….


Development of the structural modelsThe MMG automatically generates the geometry of the structural elements inside each primitive.

The structure is:• parametrically defined • tailored to the outer surface

Upper wing-box panel

Lower wing-box panel

Front spar

Rear spar

Trailing edge

Leading edge

Ribs

… the internal structure has to follow!


MMG links with the analysis tools:

How different experts look at the same product


Models generation for aerodynamics tools (HF/LF)ICAD environment

Aero analysis environment


Non Structural Items masses: Weight & C.G. location tableitem Mass_(kg) X_cg Y_cg Z_cg

GROUP_FUSELAGE_(left_half)TED_1_(half) 107.4 44973.1 -1250.3 1250.1……..ANTI-ICING-SYSTEM 240.0 12755.8 -6368.1 490.0OPERATIONAL_ITEMS_(half) 157.5 3000.0 0.0 0.0CABIN_ARRANGEMENTS_(half) 40.0 3000.0 0.0 0.0FLUIDS_(half) 3.0 3000.0 0.0 0.0

GROUP_WING_(left_half)TED_4_(iw_ins) 309.1 43256.9 -15067.4 2543.5TED_5_(iw_out) 292.0 41879.3 -20362.6 2256.1…….ANTI-ICING-SYSTEM_(ow) 402.0 40304.5 -31062.3 1671.6

GROUP_WINGLET_(left_half) RUDDER 174.5 49785.9 -39394.7 4990.1ANTI-ICING-SYSTEM_(wl) 80.0 47962.0 -39490.0 5531.1

GROUP_PROPULSION_(left_half)CENTER_ENGINE_(half) 3751.2 43758.0 0.0 4142.9CENT_ENG_.. 980.7 43758.0 0.0 2185.7LEFT_ENGINE 7502.3 39750.0 -7501.0 5410.5LEFT_ENG_STRUC….. 1961.3 39750.0 -7501.0 3453.2

GROUP_LANDING_GEARS_(left_half)NOSE_LANDING_RETRACTED_(half) 594.0 3500.0 0.0 -1298.6INNER_LANDING_RETRACTED 3415.7 33984.0 -3991.0 -87.1OUTER_LANDING_RETRACTED 3415.7 33984.0 -7501.0 381.5

Lumped mass representation


The MMG automatically detects the NSM-items to be attached to the various mainframe parts.

Non-Structural Masses connectivity

TED 5TED 6

TED 7 TED 8

Rear spar segmentsRibs Closure spar segments

TED’s control system CG’s

RBE

TED 5TED 6

TED 7 TED 8

Rear spar segmentsRibs Closure spar segments

TED’s control system CG’s

RBE

De-icing systems attached to the LE ribletsDe-icing systems attached to the LE riblets

Trapped fuel attached to the first bottom skin patches.

Wing fuel system attached to all the spar patches of the Inner wing

Trapped fuel attached to the first bottom skin patches.

Wing fuel system attached to all the spar patches of the Inner wing

This connectivity information is stored as an attribute of the given structure part.


The MMG automatically performs the fragmentation of the aircraft surfaces to ease preprocessing activities required for the FEM analysis. Skins, spars and ribs are automatically cut along their intersection lines in order to produce ALWAYS a set of ready-to-meshed surface patches.

Automatic surfaces fragmentation in meshable elements

LE fragments

TE fragmentsSkin fragments

Spars fragments Ribs fragments

Segmentation procedure based on FEM-experts best practice.

Automatic detection of non-meshable surfaces and selection of best extra cutting-procedure.


FEM environment

Meshable surfaces

surface_ID_number 2000023Isoparametric? Tmembership INNER-WING-INSIDEtype QUAD-SEGMENTdesign_variable_group 2010203material AL_ZI_PLATEthickness_(mm) 6.0Attach_non_struc_mass DE-ICE_SYSTEMOther information …………. number_of_nodes 4node_ID X Y Z 92 49542.0 -39936.5 8381.3 93 49454.4 -39895.0 8173.1 94 49871.0 -39859.8 8061.9 95 49962.0 -39926.1 8383.2

FEM-Tables

Integration of the ICAD MMG with the FE toolsKBE

environment


Sub-models generation for Multi-Level analysis

Analysis of details should reflect all the changes in the global model

Details generation should not affect the complexity of the global model


Generation of components models for manufacturing feasibility study, tooling design

and cost analysis

Examples of movable surfaces moulds models and tooling


Role of the MMG in the MOB project Multi disciplinary design and Optimisation of Blended wing body aircraft

TU Delft

NLR, Cranfield University

DLR

NLR, EADS, BAe System Siegen

University

SAAB, NLR

NLR, BAe System


The Design and Engineering Engine (DEE) Framework MULTI-MODEL GENERATOR (MMG)

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• Design and Engineering Engine Framework– DEE can be seen as a Integrated Product

Team (IPT) or Design Built Team (DBT).• Analogue to human group co-operation• Detached capabilities combined through in-

direct co-operation.

SOFTWARE FRAMEWORK FOR DEEs


Four actors:Specialist (Disciplinary Tools)Integrator (Helper Agent, DEEF development)Operator (Operation of DEE)Maintainer (Operation of DEEF)


Four Functions:Resource ManagementResource InterfacingProcess Execution SupportInformation Flow Control

Management functions

Facilitating functions


Actors• Tool development by

Specialist. – Offline testing– Batch operation

• Agent/DEEF development by Integrator

• Operation of DEE by an Operator

• Maintenance of the DEEF by Maintainer

SOFTWARE FRAMEWORK FOR DEEsCollection of Agents wrapped disciplinary tools form a DEE

• Tool process viewed strictly as capacity• Agent & Tool can take part in group process


Messaging System• Communicating (Speech

Act)• All agents capable of

performing the 4 DEEF functions (management/facility) due to same code base

• Most senior agent performs the master functions.

• Fall back when master agent unavailable to next most senior.

Collection of Agents wrapped disciplinary tools form a DEE



EXAMPLE of A DESIGN SCENARIO


STEP 1: Before any client can participate in the DEE environment it must register itself by a dedicated DEE Server. Typical registration data: hostname, IP address, identifier. The DEE server returns a list of all available DEE clients and the services they provide.

Example of a design scenario : Structural analysis of a wingDisciplines/tools involved : Multi model generator (MMG), Aerodynamics, FEM

DEE SERVERDEE Client:Structure

List of registered DEE clients and provided services

register

THE DEE IN ACTION: an example


STEP 2: Once the registration has finished, clients are allowed to have peer-to-peer connections with other clients. In our scenario the structures client first connects to the multi-model generator. Typical messages are requests for structural topology and requests for meta-data.



register

MMG

URL for TOPOLOGY and META-DATA

Request for TOPOLOGY and META-DATA



STEP 3: The structure client will also send a request for aerodynamic pressure to the aerodynamics client. However, the aerodynamics client itself needs topology data from the MMG.



register

DEE Client: MMG

URL for AERODYNAMIC PRESSURE


DEE Client: AerodynamicsRequest for AERODYNAMIC

PRESSURE




STEP 4 (IMPLICIT): The aerodynamics client will make an implicit request for aerodynamic topology to the MMG. If every request is satisfied the structures client can start the numerical analysis.



register

DEE Client: MMG

URL for AERODYNAMIC PRESSURE


DEE Client: Aerodynamics


URL for AERODYNAMIC TOPOLOGY

Request for

AER

OD

YNA

MIC

TO

POLO

GY

Request for AERODYNAMIC PRESSURE



SOME RESULTS

Generation of a unique Multi-Model Generator to supply data and consistent models for all the discipline tools implemented in the DEE.

Flexible integration of many design and analysis tools through a smart and reconfigurable software framework.

Generation of a flexible design tool able to support the conceptual and preliminary design of different aircraft configurations and configurations variants.

Supported creative design, via automation of repetitive, time consuming activities.

Use of KBE and agent based technology to mimic the actual behaviour of designers and design teams.


…QUESTIONS ?

presented by g. la [email protected]

Documents

tool design

engineering design knowledge

multidisciplinary design

repetitive design activities

creative design focus

computer aided design

advanced design system

d models