1. 19-20 May 2005, Eindhoven Presented by G. La RoccaG.LaRocca@LR.TUDelft.NL Development of Design and Engineering Engines to Support Multidisciplinary Design and Analysis of Aircraft

2. 19-20 May 2005, Eindhoven The challenges for the next 20 years of aviation According 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…..

3. 19-20 May 2005, Eindhoven 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

4. 19-20 May 2005, Eindhoven 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.

5. 19-20 May 2005, Eindhoven Paradigm of a Design and Engineering Engine (DEE) The Multi Model Generator (MMG)

6. 19-20 May 2005, Eindhoven Paradigm of a Design and Engineering Engine (DEE) The product model

7. 19-20 May 2005, Eindhoven Paradigm of a Design and Engineering Engine (DEE) The reports writers

8. 19-20 May 2005, Eindhoven 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)

9. 19-20 May 2005, Eindhoven 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 spar Y N Rib=‘FD ? sparn Y Point at root N Eval ? first spar Y N Rib=‘FD ? sparn Y Point at root N A.I. CAD Knowledge Based Engineering Functional requirements INPUTS Size, material, positioning …. GENERATIVE MODEL Product Structure Design Standards Material Characteristic Manufacturing Constrain Engineering Analysis …….. OUTPUTS Drawings, 3-D Models, 2-D Models, Bills of material, Tool Design …. Engineered design Functional requirements Functional requirements INPUTS Size, material, positioning …. GENERATIVE MODEL Product Structure Design Standards Material Characteristic Manufacturing Constraints Engineering Analysis …….. OUTPUTS Drawings, 3-D Models, 2-D Models, Bills of material, Tool Design …. CAD Knowledge Based Engineering Eval ? first spar Y N Rib=‘FD ? sparn Y Point at root N Eval ? first spar Y N Rib=‘FD ? sparn Y Point at root N A.I. Eval ? first spar Y N Rib=‘FD ? sparn Y Point at root N Eval ? first spar Y N Rib=‘FD ? sparn Y Point at root N Eval ? first spar Y N Rib=‘FD ? sparn Y Point at root N Eval ? first spar Y N Rib=‘FD ? sparn Y Point at root N A.I. CAD Knowledge Based Engineering Functional requirements Functional requirements INPUTS Size, material, positioning …. GENERATIVE MODEL Product Structure Design Standards Material Characteristic Manufacturing Constrain Engineering Analysis …….. OUTPUTS Drawings, 3-D Models, 2-D Models, Bills of material, Tool Design …. Engineered design Engineered design Functional requirements Functional requirements INPUTS Size, material, positioning …. GENERATIVE MODEL Product Structure Design Standards Material Characteristic Manufacturing Constraints Engineering Analysis …….. OUTPUTS Drawings, 3-D Models, 2-D Models, Bills of material, Tool Design ….

10. 19-20 May 2005, Eindhoven 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

11. 19-20 May 2005, Eindhoven The building block approach Connection element Wing-Trunk Fuselage-Trunk Engine part

12. 19-20 May 2005, Eindhoven The building block approach Connection element Wing-Trunk Fuselage-Trunk Engine part

13. 19-20 May 2005, Eindhoven The building block approach Connection element Wing-Trunk Fuselage-Trunk Engine part

14. 19-20 May 2005, Eindhoven The building block approach Connection element Wing-Trunk Fuselage-Trunk Engine part

15. 19-20 May 2005, Eindhoven The building block approach Connection element Wing-Trunk Fuselage-Trunk Engine part

16. 19-20 May 2005, Eindhoven Connection element Wing-Trunk Fuselage-Trunk Engine part Generation of many aircraft configurations

17. 19-20 May 2005, Eindhoven Connection element Wing-Trunk Fuselage-Trunk Engine part Generation of variants of one configuration

18. 19-20 May 2005, Eindhoven Generation of variants of one configuration Connection element Wing-Trunk Fuselage-Trunk Engine part

19. 19-20 May 2005, Eindhoven Development of the structural models The 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….

20. 19-20 May 2005, Eindhoven Development of the structural models The 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!

21. 19-20 May 2005, Eindhoven MMG links with the analysis tools: How different experts look at the same product

22. 19-20 May 2005, Eindhoven Models generation for aerodynamics tools (HF/LF) ICAD environment Aero analysis environment

23. 19-20 May 2005, Eindhoven Non Structural Items masses: Weight & C.G. location table item 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 -6368.1 490.0 OPERATIONAL_ITEMS_(half) 157.5 3000.0 0.0 0.0 CABIN_ARRANGEMENTS_(half) 40.0 3000.0 0.0 0.0 FLUIDS_(half) 3.0 3000.0 0.0 0.0 GROUP_WING_(left_half) TED_4_(iw_ins) 309.1 43256.9 -15067.4 2543.5 TED_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 4990.1 ANTI-ICING-SYSTEM_(wl) 80.0 47962.0 -39490.0 5531.1 GROUP_PROPULSION_(left_half) CENTER_ENGINE_(half) 3751.2 43758.0 0.0 4142.9 CENT_ENG_.. 980.7 43758.0 0.0 2185.7 LEFT_ENGINE 7502.3 39750.0 -7501.0 5410.5 LEFT_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 - 1298.6 INNER_LANDING_RETRACTED 3415.7 33984.0 -3991.0 -87.1 OUTER_LANDING_RETRACTED 3415.7 33984.0 -7501.0 381.5 Lumped mass representation

24. 19-20 May 2005, Eindhoven The MMG automatically detects the NSM-items to be attached to the various mainframe parts. Non-Structural Masses connectivity This connectivity information is stored as an attribute of the given structure part.

25. 19-20 May 2005, Eindhoven 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 fragments Skin 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.

26. 19-20 May 2005, Eindhoven FEM environment Meshable surfaces surface_ID_number 2000023 Isoparametric? T membership INNER-WING-INSIDE type QUAD-SEGMENT design_variable_group 2010203 material AL_ZI_PLATE thickness_(mm) 6.0 Attach_non_struc_mass DE-ICE_SYSTEM Other information …………. number_of_nodes 4 node_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 tools KBE environment

27. 19-20 May 2005, Eindhoven 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

28. 19-20 May 2005, Eindhoven Generation of components models for manufacturing feasibility study, tooling design and cost analysis Examples of movable surfaces moulds models and tooling

29. 19-20 May 2005, Eindhoven 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

30. 19-20 May 2005, Eindhoven The Design and Engineering Engine (DEE) Framework

31. 19-20 May 2005, Eindhoven The Design and Engineering Engine (DEE) Framework

32. 19-20 May 2005, Eindhoven 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

33. 19-20 May 2005, Eindhoven Four actors: Specialist (Disciplinary Tools) Integrator (Helper Agent, DEEF development) Operator (Operation of DEE) Maintainer (Operation of DEEF) SOFTWARE FRAMEWORK FOR DEEs Four Functions: Resource Management Resource Interfacing Process Execution Support Information Flow Control Management functions Facilitating functions

34. 19-20 May 2005, Eindhoven 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 DEEs Collection of Agents wrapped disciplinary tools form a DEE Tool process viewed strictly as capacity Agent & Tool can take part in group process

35. 19-20 May 2005, Eindhoven 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 SOFTWARE FRAMEWORK FOR DEEs

36. 19-20 May 2005, Eindhoven EXAMPLE of A DESIGN SCENARIO

37. 19-20 May 2005, Eindhoven 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 wing Disciplines/tools involved : Multi model generator (MMG), Aerodynamics, FEM DEE SERVER DEE Client: Structure List of registered DEE clients and provided services register THE DEE IN ACTION: an example

38. 19-20 May 2005, Eindhoven 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. DEE SERVER DEE Client: Structure List of registered DEE clients and provided services register MMG URL for TOPOLOGY and META-DATA Request for TOPOLOGY and META-DATA THE DEE IN ACTION: an example

39. 19-20 May 2005, Eindhoven 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. DEE SERVER DEE Client: Structure List of registered DEE clients and provided services register DEE Client: MMG URL for AERODYNAMIC PRESSURE Request for TOPOLOGY and META-DATA DEE Client: Aerodynamics Request for AERODYNAMIC PRESSURE URL for TOPOLOGY and META-DATA THE DEE IN ACTION: an example

40. 19-20 May 2005, Eindhoven 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. DEE SERVER DEE Client: Structure List of registered DEE clients and provided services register DEE Client: MMG URL for AERODYNAMIC PRESSURE Request for TOPOLOGY and META-DATA DEE Client: Aerodynamics URL for TOPOLOGY and META-DATA URL for AERODYNAMIC TOPOLOGY Request for AERODYNAMIC TOPOLOGY Request for AERODYNAMIC PRESSURE THE DEE IN ACTION: an example

41. 19-20 May 2005, Eindhoven 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.

42. 19-20 May 2005, Eindhoven …QUESTIONS ?