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INTEGRATED DESIGN FOR HELICOPTER ROTOR INTEGRATED DESIGN FOR HELICOPTER ROTOR

Forum 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

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

VIVACE FORUM 1 - Warwick

2005 VIVACE Consortium Members. All rights reserved

Page: 4

September 20-21, 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 - Warwick

2005 VIVACE Consortium Members. All rights reserved

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September 20-21, 2005

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIOS


PRE PROJECT
Architecture definition & technologies selection Maintainability Design to Market & Multidisciplinary database

Pre sizing Kinematics

=> =>

Scenario 1.1 Scenario 1.2

DEVELOPMENT
=> Scenario 2 Detailed design Drawings Stress Tolerancing => N/A within VIVACE N/A within VIVACE N/A within VIVACE Scenario 4 => Scenario 3

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2005 VIVACE Consortium Members. All rights reserved

Page: 6

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 2005 VIVACE Consortium Members. All rights reserved Page: 7 September 20-21, 2005

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 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 - Warwick 2005 VIVACE Consortium Members. All rights reserved Page: 8 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 2005 VIVACE Consortium Members. All rights reserved Page: 9 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 2005 VIVACE Consortium Members. All rights reserved Page: 10 September 20-21, 2005

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.1 UPPER HUB PRE SIZING
TO BE description
Intput data file Loads Fc, , , , Temp Geometry Ri, Re, , ne, nm, ee, em, Materials Output data file Stiffnesses Kr, K, K, Stresses & strains

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 2005 VIVACE Consortium Members. All rights reserved Page: 11 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 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

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2005 VIVACE Consortium Members. All rights reserved

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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
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Relevance of the automation


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 0 3.5 2.4 1.9 1c 0.2 0.3 0.5 1s 0.1 -0.1 0.2 0 4.5 3.3 2.6 1c 0.5 0.3 0.1 1s -0.3 0.2 0.2 0 1c 1.1 0.3 0.7 0.1 0.4 -0.1 1s 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 2005 VIVACE Consortium Members. All rights reserved Page: 14 September 20-21, 2005

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.2 KINEMATICS


Status at M21
Functional description - environments, - inputs, outputs, formats, - performances, 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 - Warwick

2005 VIVACE Consortium Members. All rights reserved

Page: 15

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

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
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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

Pre-design Concept choices Sub-assembly drawings Feasibility Pre-development

VIVACE FORUM 1 - Warwick

2005 VIVACE Consortium Members. All rights reserved

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

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September 20-21, 2005

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 2 MAINTAINABILITY TOOLBOX


Status at M21

Functional specification Detailed specification: - user interfaces - data links model - access rights - treatment Demonstrator development

About to be issued

Planned from M21 to M24

Planned for M30

VIVACE FORUM 1 - Warwick

2005 VIVACE Consortium Members. All rights reserved

Page: 19

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 1/ Define Design to Market methods and organisation 2/ Build a design to market tool

Means :

Programs and chief eng. Procurements

Multidisciplinary database

Design office

Customer service
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Industry
September 20-21, 2005

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 - Warwick

2005 VIVACE Consortium Members. All rights reserved

Page: 21

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 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 - Warwick

2005 VIVACE Consortium Members. All rights reserved

Page: 22

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 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 - Warwick

2005 VIVACE Consortium Members. All rights reserved

Page: 23

September 20-21, 2005

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 3 DESIGN TO MARKET


Status at M21

Functional specification Detailed specification: - user interfaces - data links model - access rights - treatment Demonstrator development

About to be issued

Planned from M21 to M24

Planned for M30

VIVACE FORUM 1 - Warwick

2005 VIVACE Consortium Members. All rights reserved

Page: 24

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
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INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING


AS IS description
Toleranced drawings based on designers experience and knowledge 1D tolerance analyses

Development

1 - Answer the requirements dossier 2 - Functional validation (interchangeability included) 3 - Discussions with Manufacturing and Quality offices 4 - Definition of manufacturing and control processes 5 - Manufacturing

Validated toleranced drawings

Industrialisation

TO BE IMPROVED

6 - Control

VIVACE FORUM 1 - Warwick

2005 VIVACE Consortium Members. All rights reserved

Page: 26

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

VIVACE FORUM 1 - Warwick

2005 VIVACE Consortium Members. All rights reserved

Page: 27

September 20-21, 2005

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 4 TOLERANCING


TO BE description
1 - Answer the requirements dossier Functional analysis taking into account manufacturing and control constraints Drawings

Development

2 - Parts design 3 - Tolerances breakdown on the basis of the functional analysis 4 - Functional validation (interchangeability included)

Toleranced drawings

Validated toleranced drawings thanks to 3D analyses

Industrialisation

5 - Definition of manufacturing and control processes 6 - Manufacturing Non conformity analysis

7 - Control
2005 VIVACE Consortium Members. All rights reserved Page: 28

VIVACE FORUM 1 - Warwick

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. All rights reserved

Page: 29

September 20-21, 2005

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 - Warwick 2005 VIVACE Consortium Members. All rights reserved Page: 30 September 20-21, 2005

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


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INTEGRATED DESIGN FOR HELICOPTER ROTOR

QUESTIONS

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2005 VIVACE Consortium Members. All rights reserved

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September 20-21, 2005