Helicopter

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
ROTOR SYSTEM : A COMPLEX SUBSYSTEM - Dynamics and aerodynamics behaviour prediction requires complex simulations
Page: 3
ROTOR SYSTEM : A COMPLEX SUBSYSTEM - Complex relative motions between numerous parts (flapping masses, control system, ) => kinematics validations are mandatory
Page: 4
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
Page: 5
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
Page: 6
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
Scope
Outer fitting Outer fitting
Elastomeric part Elastomeric part
Inner fitting Inner fitting
Bushing
Elastomeric part = succession of metal and rubber layers

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.
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.
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
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
Page: 12
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
VIVACE FORUM 1 - Warwick 2005 VIVACE Consortium Members. All rights reserved Page: 13
Relevance of the automation


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)

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
Page: 15
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

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

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
Concept choices Feasibility
Pre-design Sub-assembly drawings Pre-development
or ign f lity Des abi in ainta M

Frozen drawing files Development
Page: 18

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
Page: 19
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
VIVACE FORUM 1 - Warwick 2005 VIVACE Consortium Members. All rights reserved Page: 20
Industry

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
Page: 21

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
Page: 22

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
Page: 23

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
Page: 24
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

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
Page: 26

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
Page: 27

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

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
Page: 29
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

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

INTEGRATED DESIGN FOR HELICOPTER ROTOR
QUESTIONS
Page: 32

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INTEGRATED DESIGN FOR HELICOPTER ROTOR INTEGRATED DESIGN FOR HELICOPTER ROTOR

Forum 1 Warwick - September 20-21, 2005

Hugo FALGARONE Benoit FRICERO September 20-21, 2005

- 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

September 20-21, 2005

VIVACE FORUM 1 - Warwick

2005 VIVACE Consortium Members. All rights reserved

September 20-21, 2005

VIVACE FORUM 1 - Warwick

2005 VIVACE Consortium Members. All rights reserved

September 20-21, 2005

Scope of VIVACE activities

Architecture & Technologies selection Kinematics Pre sizing

VIVACE FORUM 1 - Warwick

2005 VIVACE Consortium Members. All rights reserved

September 20-21, 2005

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIOS

Pre sizing Kinematics

Scenario 1.1 Scenario 1.2

VIVACE FORUM 1 - Warwick

2005 VIVACE Consortium Members. All rights reserved

September 20-21, 2005

Outer fitting Outer fitting

Elastomeric part Elastomeric part

Inner fitting Inner fitting

Elastomeric part = succession of metal and rubber layers

VIVACE FORUM 1 - Warwick

2005 VIVACE Consortium Members. All rights reserved

September 20-21, 2005

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.2 KINEMATICS

Relevance of the automation

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.2 KINEMATICS

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 1.2 KINEMATICS

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

September 20-21, 2005

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 2 MAINTAINABILITY TOOLBOX

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 2 MAINTAINABILITY TOOLBOX

s to mean r No p fo ake u s m tive objec

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

Capitalise maintainability knowledge for next projects

Define maintainability objectives Perform maintainability analysis

Maintainability Objectives and constraints

Concept choices Feasibility

Pre-design Sub-assembly drawings Pre-development

or ign f lity Des abi in ainta M

2005 VIVACE Consortium Members. All rights reserved

September 20-21, 2005

INTEGRATED DESIGN FOR HELICOPTER ROTOR SCENARIO 2 MAINTAINABILITY TOOLBOX

Planned from M21 to M24

Planned for M30

VIVACE FORUM 1 - Warwick