Best Practices of Innovative Engineering with Simcenter … · Flexible multi body simulation for estimation of A350 XWB main landing door actuator load Cosimulation Simcenter Motion

Best Practices ofInnovativeEngineering withSimcenter

Realize innovation.Restricted © Siemens AG 2017

Unrestricted © Siemens AG 20172017.MM.DDPage 2 Siemens PLM Software

Product development needs paradigm shiftFrom complicated to complex aircraft

• Model-based systems engineering needed• Enable department model exchange• Front-load integration verification

Complex

Complex aircraft

• Document-based systems engineering• Isolated departments• Integration verification at the end of

development

Complicated

Complicated aircraft

With aircraft ever-increasing complexity, it becomes offoremost importance assess earlier in the design cyclethe interactions among systems


Addressing the aerospace industry painsKey enabler to improve program performance

Improved concept processè -50% accumulated rework

Improved detailed designè -10% development cost

Improved verification processè -20% testing cost

Cost overruns

Schedule overruns

Missed requirements

Supplier alignment

Integration problems

Unforeseen complexity

Increasing model-based approach will be crucialSimulation of engineering physics and business processes


The aviation industry is on the verge of a major shift towardselectrified propulsion

2016 – 2020Hybrid Electric Systems Project• Hybrid Ground Demonstrator,

10 MW platform• <2 MW potential platform applications vertical

take off and landing (VTOL), door-to-door

2028Regional Aircraft100 passengers, 6-8 MW

2035+Short Range Aircraft150-200 passengers, 20MW

Maintenance,modific.,

insur., fees

Crew

15%14% 100%

TCOFuel

20%

Purchase

51%

1. Reduction of fuel consumption: main lever to reduce aircraft TCO(example 737-800)

2. Projected emission goals: can only be reached with disruptive concepts 1)

Industry: various hybrid electric propulsion roadmapdefined for demonstration (TRL‘s) and product developmentuntil 2035, e.g.

2005 205020402030202020102010 2030 2050

CO2 mn ton

3. Customer perspective: extension of potential operating hours through noisereduction

1) IATA technology roadmap, June 2013

Possible through innovation ofexisting technologies

EU agreement “Flight-path 2050”:75% CO2 emission reduction (per PK) 2)

Requires biofuels and/or disruptiveconcepts (e.g. eAircraft)


From work in silos…

ECSHydraulicsFlightcontrols Electric

Fuel LandinggearEngine


…To a collaborative approachsupported by virtual integrated aircraft

ECS

Hydraulics

Flightcontrols

Electric Fuel

Landinggear

Engine


Customer Process Today… Integrating System Behaviour @ Higher Level = Misery

ATA 24:ElectricalATA 24:Electrical

ATA 21, 24, 30, 36:Pneum. / ECSATA 21, 24, 30, 36:Pneum. / ECS

ATA 71+…Engine SystemsATA 71+…Engine Systems

ATA 27, 32:FCS, Landing GearATA 27, 32:FCS, Landing Gear

ATA 29:Hydraulics, FUEL,...ATA 29:Hydraulics, FUEL,...

+ Additional Coding for Thermal + Additional Coding for Thermal + Additional Coding for Thermal + Additional Coding for Thermal + Additional Coding for Thermal

?

Mechanism Simulation Tool A Fluids Simulation Tool B Engine Simulation Tool C Electrical Simulation Tool D Pneumatic Simulation Tool E


Integrated Aircraft Performance

Siemens PLM Systems Simulation… allowing Thermal Behavior Synthesis at Aircraft Level

ATA 24:ElectricalATA 24:Electrical

ATA 21, 24, 30, 36:Pneum. / ECSATA 21, 24, 30, 36:Pneum. / ECS

ATA 71+…Engine SystemsATA 71+…Engine Systems

ATA 27, 32:FCS, Landing GearATA 27, 32:FCS, Landing Gear

ATA 29:Hydraulics, FUEL,...ATA 29:Hydraulics, FUEL,...

ü + Thermal ü + Thermal ü + Thermal ü + Thermal ü + Thermal

TeamcenterSimcenter System Synthesis

Simcenter Amesim

ü


Supporting the entire supply chain

Aircraft OEMAirbus

Assembly and validation

TIER 1Safran Landing Systems

Landing gear

TIER 2Safran Landing Systems

Braking and steering

TIER 3Zodiac Hydraulics

Valves and pumps

Less energyconsumption

More efficientand lighter

Smaller pumpLow leakages

Simcenter


Airbus HelicoptersReducing prototype costs by a factor of 4

From component and system engineering to real-time simulation

• Shortened hydraulic systemoptimization cycle by a factor of 3

• Decreased prototype costs by afactor of 4

• Avoided late delivery penalties“Being able to anticipate a problem is a significant source of cost and riskreduction.”

Nicolas Damiani, Expert in Simulation and Operational Analysis

• Ensure accuracy of plant and real-time hydraulics models• Enhance flight simulators’ fidelity

Real-time models for full flight simulatorsDynamic analysis of hydraulic systems


IRKUT builds Virtual Integrated Aircraft using a secure and optimizedmodeling process

Business challenges:• Predict subsystem and system behavior once

integrated into aircraft• Consider design options without mobilizing

considerable financial and human resources• Minimize the number of errors discovered at the

verification phase• Obtain optimal design within the shortest timeline

Keys to success:• Perform thermal analysis of the avionic bay• Assess system interaction early and accurately• Apply the VIA processResults:• Reduced modeling time by a factor of 5• Established a secured and optimized modeling process• Enhanced model, architecture and configuration

management

“Compared to our previous solution, LMS Amesimallows us to reduce time spent in building our mostcomplex models by a factor of 5.”

Marina GrishinaEngineer Engineering and Simulation

IRKUT


Move quicker towards full electric aircraft

• Optimize your power budget andnetwork quality wrt. missionprofile

• Validate architecture choicebefore integration

• Ensure safety by optimizingthermal management strategies


Airbus FranceFlexible multi body simulation for estimation of A350 XWB main landingdoor actuator load

Cosimulation Simcenter Motion - Simcenter Amesim

• Simcenter Amesim accurate shockabsorber model created

• Simcenter Motion for rigid andflexible structure creation enablingparametric aero loads

• Improved numerical performancewith Simcenter Amesim compiled inSimcenter Motion

“Simcenter Amesim is used to create an accurate shock absorber model incomparison with experiments, giving physical insight. It takes around 2-3 min for adoor extension simulation.”

Boris Nahmias, Airbus France, 2015 LMS European Aerospace Engineering Conference

• Create multi body components with Simcenter Motion• Launch co-simulation between Simcenter Motion and Simcenter Amesim including

special DLL for aerodynamic loading on flexible bodies

Integration of Simcenter Amesim output andinput control block

Creation of multibody components withSimcenter Motion

Actuator

Sensor

Motion ModelSystem Model

Actuator

Sensor

Motion ModelSystem Model


Engineering ChallengesDevelopment cycles continue to grow; quality challenges

Example

Boeing KC-46 delays& cost overrun

Electro-mechanical co-design failure. Wiringbundles did not meetrequirements.

DefenseNewsOctober 2017

… the company has now had to cough upabout $2.9 billion in pretax fees as delaysand cost overruns mount …


Engineering ChallengesCritical Failure Under Operation

Uncertainty in certificationLoad Cases

Disconnected engineeringprocesses Missed targets

Design / ComponentEngineering

Test

Systems andControls

Weight

Strength

Weight

Strength

vs.


Simcenter 3D Solutions3D CAE for the Digital Twin

Broad range of physicssimulation solutions in a

single environment

§ Fast and accurate solvers§ Fully coupled multi-physics solutions§ Scalable performance on high performance

computing (HPC)§ Licensing flexibility : cloud, tokens§ Backed by Siemens industry expertise


Example: Simulate, optimize, build (Drop Test + Full / AC)

• Validate Landing Gearperformance with virtual test

• Gain full insight from co-Simulation with physics basedlibraries of Simcenter Amesim

• Correlate models withmeasurement data


Example: Simulate, optimize, build (Drop Test + Full / AC)

• Leverage optimized andvalidated models

• Perform analysis forassembled Aircraft

• Optimze aircraftlanding/maneuveringperformance


Challenging Requirements for the Engineering Teams

Delivering Cost Effective, Configurable,Smart & Attractive Vehicle Performance

Managing Complexity of requiredMechatronic System Innovations


Example: KAMAZ Truck Mobility


Simcenter 3D Solutions for automotive industryMultiple physics working together for increased accuracy

ThermalAnalysis

Thermo-Mechanical

Analysis

Topologyoptimization

StructuralAnalysis

Fluid-MotionAnalysis

Heatexchanges

Motion Analysis

Thermal-Mechanical-

Flow Analysis

Thermal FlowSimulation

Flow Analysis

Motion withflexible bodies

Fluid-Structure interactionsMotion Control

Analysis


Simcenter 3D Solutions for automotive industryStructural analysis and more

Nonlinear Analysis : static,transient, contact, plasticity,

implicit, explicit

Linearizedconfigurations

Damage and fracture mechanics

Metallic and compositematerials

Condensationmethods (SE)

Durability and fatigueLinear Analysis :static, modal,

buckling

Thermal Analysis :conduction, convection,conjugated heat transfer,

radiation

Thermo-MechanicalAnalysis

Temperature dependentmaterials

Frequency andTransient response,

random


Durability PerformanceCombining Best of Simulation & Testing

UnderstandingOperational loads

Target setting & TestProcedures

Physical ProductOptimisation &

Validation

Design Optimisation VirtualProduct Validation

Final ProductValidation

Durability EngineeringØ A unique portfolio of services, products & technologies covering the full durability process

Ø Realistic design and validation through representative loading conditionsØ Assess durability performance in earlier in the design process

Ø Accelerate field and lab testing

Load data analysisRough road field dataacquisition Numerical simulation Rig testing Product sign-off


Vehicle NVH & AcousticsTransfer Path Analysis – a way to breakdown NVH issues

X =Source Transfer Receiver

Quantifying the structureborne sourcesTransfer Path Analysis

Engine

Road input

Transmission

Steering wheelvibrations

Seat vibrations

Noise issues

• Structured way of approaching noise issue instead of time consumingtry-and-error approaches

• Identification of weak panels and sensitive paths for noise issue• Deeper insights in load strength and noise transfer sensitivity• Reusability of identified loads for simulation

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Gabriel Ruiz Dr.-Ing.Manager EMEA CoE SC 3DSiemens Industry Software NV

[email protected]

Documents

Best Practices of Innovative Engineering with Simcenter … · Flexible multi body simulation for estimation of A350 XWB main landing door actuator load Cosimulation Simcenter Motion