Helicopter

INTEGRATED DESIGN FOR HELICOPTER ROTOR INTEGRATED DESIGN FOR HELICOPTER ROTORForum 1 – Warwick - September 20-21, 2005 Patrice GODIOT © 2005 VIVACE Consortium Members. VIVACE FORUM 1 - Warwick Joris CEZARD reserved All rights Page: 1 Hugo FALGARONE Benoit FRICERO September 20-21, 2005 INTEGRATED DESIGN FOR HELICOPTER ROTOR GLOBAL USE CASE : ROTOR DESIGN ROTOR SYSTEM : A COMPLEX SUBSYSTEM - Expensive parts (materials, manufacturing processes) => Cost management is imperative - Primary functions => Safety requirements = important design constraints - A complex assembly with a complex behaviour, specific to helicopters industry VIVACE FORUM 1 - Warwick © 2005 VIVACE Consortium Members. All rights reserved Page: 2 September 20-21, 2005 INTEGRATED DESIGN FOR HELICOPTER ROTOR GLOBAL USE CASE : ROTOR DESIGN ROTOR SYSTEM : A COMPLEX SUBSYSTEM - Dynamics and aerodynamics behaviour prediction requires complex simulations VIVACE FORUM 1 - Warwick © 2005 VIVACE Consortium Members. All rights reserved Page: 3 September 20-21, 2005 All rights reserved Page: 4 September 20-21. …) => kinematics validations are mandatory VIVACE FORUM 1 .Complex relative motions between numerous parts (flapping masses. control system.Warwick © 2005 VIVACE Consortium Members.INTEGRATED DESIGN FOR HELICOPTER ROTOR GLOBAL USE CASE : ROTOR DESIGN ROTOR SYSTEM : A COMPLEX SUBSYSTEM . 2005 . Warwick © 2005 VIVACE Consortium Members. 2005 .INTEGRATED DESIGN FOR HELICOPTER ROTOR GLOBAL USE CASE : ROTOR DESIGN PROCESS PRE PROJECT Scope of VIVACE activities DEVELOPMENT Detailed design – Drawings – Tolerancing – Stress Architecture & Technologies selection – Kinematics – Pre sizing INDUSTRIALISATION SUPPORT IN SERVICE SUPPORT VIVACE FORUM 1 . All rights reserved Page: 5 September 20-21. All rights reserved Page: 6 September 20-21.2 DEVELOPMENT => Scenario 2 Detailed design Drawings Stress Tolerancing => N/A within VIVACE N/A within VIVACE N/A within VIVACE Scenario 4 => Scenario 3 VIVACE FORUM 1 . 2005 .1 Scenario 1.Warwick © 2005 VIVACE Consortium Members.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIOS PRE PROJECT Architecture definition & technologies selection Maintainability Design to Market & Multidisciplinary database Pre sizing Kinematics => => Scenario 1. . loads and power.to allow and withstand the flapping mass deflections range.1 UPPER HUB PRE SIZING Scope Present rotor architecture : Spheriflex concept => Spherical bearing SB main functions: . 2005 . All rights reserved Page: 7 September 20-21.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.Warwick © 2005 VIVACE Consortium Members.to transmit aero. Flapping mass VIVACE FORUM 1 . 1 UPPER HUB PRE SIZING Scope Outer fitting Outer fitting Elastomeric part Elastomeric part Inner fitting Inner fitting Bushing Elastomeric part = succession of metal and rubber layers VIVACE FORUM 1 . 2005 . All rights reserved Page: 8 September 20-21.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.Warwick © 2005 VIVACE Consortium Members. . => the hub weight … The reliability of the SB pre sizing is then very important in order : . => the rotor head architecture.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.to improve the SB specification and reduce the design loops with the supplier. All rights reserved Page: 9 September 20-21. and then to optimise the Rotor head design and simulations process.1 UPPER HUB PRE SIZING Scope Spherical Bearing pre sizing & blade motions spectrum => rotor eccentricity => the flight and control loads.to freeze the hub architecture early. VIVACE FORUM 1 . including the control system.Warwick © 2005 VIVACE Consortium Members. 2005 . realised on the basis of experience and available data concerning existing Spherical Bearings and later confirmed by first stress analysis. .Warwick © 2005 VIVACE Consortium Members. .1 UPPER HUB PRE SIZING AS IS description The rotor eccentricity lies on: > Spherical Bearing Pre sizing .iterations with the supplier may be numerous. and behaviour characteristics (stiffness) are not available. .the selection of the critical flight cases for the analysis is performed on the basis of experience. 2005 .the motions of the flapping masses are then drawn manually. VIVACE FORUM 1 . > Flapping mass motions envelop .INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.results are not reliable enough. All rights reserved Page: 10 September 20-21. Pre sizing of the SB links .Automatic generation of the flapping mass motions envelope => Efficient eccentricity determination VIVACE FORUM 1 .Pre sizing of the SB (elastomeric & metal parts) . 2005 .Warwick © 2005 VIVACE Consortium Members. All rights reserved Page: 11 September 20-21. Kβ. Temp Geometry Ri. Δδ. Stresses & strains To develop methods and tools allowing to realise with more effectiveness and reliability: .1 UPPER HUB PRE SIZING TO BE description Intput data file Loads Fc. em. α. ee. Kθ. Materials Output data file Stiffnesses Kr. Δβ.Automatic generation of the SB 3D model . ne.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1. nm. Re. Δθ. formats.inputs. .1 UPPER HUB PRE SIZING Status at M21 Functional description .environments. All rights reserved Page: 12 September 20-21. outputs. .performances … Elastomeric part pre sizing tool Metal parts pre sizing tool Motions envelop generation About to be issued Planned from M22 to M36 Planned from M25 to M42 Planned from M25 to M42 VIVACE FORUM 1 .Warwick © 2005 VIVACE Consortium Members.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1. 2005 . no collisions. 2005 . Kinematics validations are realised several times during a development. Very boring tasks to run several times VIVACE FORUM 1 . All rights reserved Page: 13 Relevance of the automation September 20-21. step by step.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. Design and aerodynamics studies progressing. AS IS description Kinematics model is built manually (wire model. joints. Deflections and collisions analysis are realised manually.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1. commands).Warwick © 2005 VIVACE Consortium Members. The selection of the critical flight cases for the analysis is performed on the basis of experience. 2 δ0 δ1c 1. All rights reserved Page: 14 September 20-21.3 2.5 θ1s 0.7 0.4 0.1 To develop ergonomic functions within CATIA V5 allowing to make the kinematics analysis more reliable and easy: .1 0.5 0.2 0.1 β1s -0.5 2.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.4 1.5 3.Warwick © 2005 VIVACE Consortium Members.Automatic generation of the kinematics model .6 β1c 0.2 β0 4.1 δ1s 0.1 0.3 0.1 0.Automatic collision analysis (on the whole flight spectrum) VIVACE FORUM 1 . 2005 .3 0.1 0.3 0.1 -0.4 -0.3 0.Automatic deflection analysis (on the whole flight spectrum) .2 KINEMATICS TO BE description Geometrical data file Rotor type Blade number Eccentricity Pitch horn length … Blade motions spectrum Case 1 2 3 … θ0 3.9 θ1c 0.2 0. 2005 . All rights reserved Page: 15 September 20-21.environments.2 KINEMATICS Status at M21 Functional description . … Automatic model generation About to be issued About to be issued Automatic deflections analysis Forecasted from M22 to M30 Automatic collisions analysis Forecasted from M22 to M30 VIVACE FORUM 1 . .inputs. .INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.Warwick © 2005 VIVACE Consortium Members. formats. outputs.performances. 2005 . specialists Objectives ? Designers 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 . All rights reserved Page: 16 September 20-21.Warwick © 2005 VIVACE Consortium Members.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 2 MAINTAINABILITY TOOLBOX Scope To improve maintainability studies efficiency within the framework of collaborative design Maint. All rights reserved . 2005 Pre-design Concept choices Sub-assembly drawings Feasibility Pre-development VIVACE FORUM 1 .Warwick © 2005 VIVACE Consortium Members.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 ty ili b na dge Guidelines ai and norms nt wle i o a M kn Maintainability Objectives and constraints Maintainability assessment Maintenance tools l ca i hn n c Te sig de s to mean r No p fo ake u s m tive objec Frozen drawing files Development Page: 17 September 20-21. 2005 .INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 2 MAINTAINABILITY TOOLBOX TO BE ty ili b na dge i ta le n a i ow M kn Capitalise maintainability knowledge for next projects Guidelines and norms Maintenance assessments Maintenance tools Define maintainability objectives Perform maintainability analysis Maintainability Objectives and constraints l ca i hn n c Te sig de VIVACE FORUM 1 .Warwick Concept choices Feasibility Pre-design Sub-assembly drawings Pre-development or ign f lity Des abi in ainta M Frozen drawing files Development © 2005 VIVACE Consortium Members. All rights reserved Page: 18 September 20-21. All rights reserved Page: 19 September 20-21.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 2 MAINTAINABILITY TOOLBOX Status at M21 Functional specification Detailed specification: .data links model . 2005 .user interfaces .Warwick © 2005 VIVACE Consortium Members.access rights .treatment Demonstrator development About to be issued Planned from M21 to M24 Planned for M30 VIVACE FORUM 1 . 2005 . All rights reserved Page: 20 Industry September 20-21. traceability and project steering and reporting 1/ Define Design to Market methods and organisation 2/ Build a design to market tool Means : Programs and chief eng.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 3 DESIGN TO MARKET Scope Scope : to deploy Design to Market methodology in terms of data management.Warwick © 2005 VIVACE Consortium Members. Procurements Multidisciplinary database Design office Customer service VIVACE FORUM 1 . INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 3 DESIGN TO MARKET Scope & AS IS TO BE 100% High SAP Configuration Mgt + Data Mgt prevailing Intensity of steering activities Functional need Support DtM methodology VPM SAP VIVACE As-is Low To-be No tools VIVACE Pre-Development VIVACE VIVACE Feasibility Development VIVACE FORUM 1 . All rights reserved Page: 21 September 20-21.Warwick © 2005 VIVACE Consortium Members. 2005 . All rights reserved Page: 22 September 20-21. 2005 .Warwick © 2005 VIVACE Consortium Members.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 Communication with existing Eurocopter IS Main topics… Costing data reported Configuration Management Opportunities Steering & Reporting Multidisciplinary Database Centralization Communication of results & hypothesis Capitalization Dashboard Accessibility to data Opportunities Parameters assessment & hypothesis Knowledge Management VIVACE FORUM 1 . All rights reserved Page: 23 September 20-21.Warwick © 2005 VIVACE Consortium Members. 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 Traceability Communication with existing Eurocopter SI Costing data reported Configuration Management …along a project process Market objectives Pre-dev Faisability Dev Opportunities Steering & Reporting Multidisciplinary Database gn to Desi et Mar k Target cascading Communicatio n of results & hypothesis Centralization Parameters assessments Trade-off perfo-cost Management By Objective (MBO) Capitalization Dashboard Accessibility to data Opportunities Parameters assessment & hypothesis Knowledge Management DtC application for purchase DtC know-how capitalisation VIVACE FORUM 1 . user interfaces .INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 3 DESIGN TO MARKET Status at M21 Functional specification Detailed specification: .treatment Demonstrator development About to be issued Planned from M21 to M24 Planned for M30 VIVACE FORUM 1 . 2005 .data links model . All rights reserved Page: 24 September 20-21.access rights .Warwick © 2005 VIVACE Consortium Members. INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING Scope Tolerances analysis are essential in order : .to ensure the functional requirement. Real 3D analyses can't be treated this way. > Important number of parts in an assembly. > Tolerances are defined in order to ensure assembling. control and mounting processes. 2005 .to optimise the manufacturing. All rights reserved Page: 25 September 20-21.Warwick © 2005 VIVACE Consortium Members. important number of tolerances on a part: Important duration of non-conformity analyses > No requirements / analysis storage file VIVACE FORUM 1 . . AS IS description > CATIA V4 environment > 1D Tolerance analyses are realised manually. but without any generic rules: Tolerancing depends on the designer expertise. Answer the requirements dossier 2 . 2005 .Discussions with Manufacturing and Quality offices 4 .Control VIVACE FORUM 1 . All rights reserved Page: 26 September 20-21.Definition of manufacturing and control processes 5 .INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING AS IS description Toleranced drawings based on designers experience and knowledge 1D tolerance analyses Development 1 .Manufacturing Validated toleranced drawings Industrialisation TO BE IMPROVED 6 .Warwick © 2005 VIVACE Consortium Members.Functional validation (interchangeability included) 3 . efficient 3D analyses (how to do? How to understand the results?) . 2005 .the traceability from the functions to the specifications .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 VIVACE FORUM 1 . 3DCS from DCS and Anatole from EADS CRC) .INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING TO BE description Tolerances analysis are based on new methodology and tools ensuring .Warwick © 2005 VIVACE Consortium Members.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 6σ from SIGMETRIX. All rights reserved Page: 27 September 20-21.the relevance and the traceability of the tolerances analyses . Manufacturing Non conformity analysis 7 .Definition of manufacturing and control processes 6 . 2005 .Tolerances breakdown on the basis of the functional analysis 4 . All rights reserved Page: 28 VIVACE FORUM 1 .Warwick September 20-21.INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING TO BE description 1 .Control © 2005 VIVACE Consortium Members.Answer the requirements dossier Functional analysis taking into account manufacturing and control constraints Drawings Development 2 .Functional validation (interchangeability included) Toleranced drawings Validated toleranced drawings thanks to 3D analyses Industrialisation 5 .Parts design 3 . All rights reserved Page: 29 September 20-21. 2005 .INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING Status at M21 EC statement of work : tolerance management EC statement of work : respect of ISO standards Done 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 VIVACE FORUM 1 .Warwick © 2005 VIVACE Consortium Members. Warwick © 2005 VIVACE Consortium Members.INTEGRATED DESIGN FOR HELICOPTER ROTOR CONCLUSION PRE PROJECT Pre sizing Kinematics DEVELOPMENT Detailed design Drawings Stress Tolerancing CATIA V5 Integration GAIA IT ENVIRONMENTS AND TOOLS INTEGRATION VIVACE FORUM 1 . 2005 . All rights reserved Page: 30 September 20-21. All rights reserved Page: 31 September 20-21.INTEGRATED DESIGN FOR HELICOPTER ROTOR CONCLUSION PRE PROJECT Maintainability Pre sizing Kinematics Design to Market & Multidisciplinary database DEVELOPMENT Detailed design Drawings Stress Tolerancing N/A within VIVACE SKILLS DEVELOPMENT & COMMUNICATION IMPROVEMENT VIVACE FORUM 1 . 2005 .Warwick © 2005 VIVACE Consortium Members. INTEGRATED DESIGN FOR HELICOPTER ROTOR QUESTIONS VIVACE FORUM 1 . All rights reserved Page: 32 September 20-21.Warwick © 2005 VIVACE Consortium Members. 2005 .