Slide 1

The DLR Concurrent Engineering Facility (CEF)

January 2011

Andy Braukhane DLR Institute of Space Systems

System Analysis Space Segment

Slide 2

Overview

DLR Institute of Space SystemsSystem Analysis Space Segment (SARA)Concurrent Engineering (CE)The FacilityThe TeamPhases (of the CE-process)DLR Approach CEF EvolutionDesign ModelToolsStudiesConclusionsOutlookFurther Information

Source: Wilke, 2002

Slide 3

DLR Institute of Space Systems – Overview

New DLR - Institute in BremenSystem Analysis

- Analyses and evaluation of complex space systems with respect to technical, economical and political aspects

System Technology- Systems Engineering for space crafts and their applications;

Research and Development within specific technology areasProjects

- Co-operations with other DLR institutes, Universities and Research Facilities as well as Industry

CEF

Slide 4

CEFCEF

DLR Institute of Space Systems – Departments

System AnalysisSpace

Segment

System Conditioning

Central Avionics

System AnalysisSpace

Transportation

Navigation-

& Controlsystems

Transport Systems

Orbital Systems & Securitity

Exploration Systems & ScientificMissions

Slide 5

System Analysis Space Segment (SARA)

3 Core AreasSystem Evaluation and CostOrbital- and Mission AnalysisSystem concepts and Concurrent Engineering

Current Project & Activities (excerpt):Concurrent Engineering Facility (CEF) operationKnowledge Capitalization (ESA-Project)Data bases for space systems, its subsystems, components and parametersSmall satellite development, e.g.: CLAVIS; AISatCompact satellites, e.g.: AsteroidFinder; CarbonSat

Cost- and mission analysisConcurrent Engineering

Slide 6

Concurrent Engineering – Introduction (1/2)

Conventional Design / Engineering Processes

Centralized Engineering:

Sequential Engineering (with iterations):

Configuration ThermalPower

iteration

Power

AOCS

Configuration

Thermal

Project Manager/ Systems Engineer

Source: ESA

Source: ESA

Slide 7

Concurrent Engineering – Introduction (2/2)

Concurrent Design / Engineering Process

The five key elements:

Project Manager/ Systems Engineer

Configuration Power

AOCSThermal

- Interdisciplinary expert team- CE - process- Integrated Design Model- Facility / Infrastructure- Tools (e.g. S/W; Multi-Media)

Source: ESA

Slide 8

Concurrent Engineering – What is that? (1/2)

Systems Engineering technique for design, development and technical management

Systematic approach for integrated product developmentFormalization of the iterative development processConcurrent (simultaneous) work on a common problemActive involvement of all disciplines and the customerFocusses primarily on the early phases of a space project

Who does that?Agencies and research institutes

e.g.: NASA (JPL & GSFC), ESA, DLR, ASI, CNES, JAXAIndustry

e.g.: EADS Astrium, Thales Alenia Space (TAS), J-CDSUniversities

e.g.: TU Munich, MIT, Stanford; Cranfield; La Sapienza

Slide 9

Concurrent Engineering – What is that? (2/2)

Benefits at a glanceInvolvement of all disciplinesCustomer participationHighly iterativeCommon understanding of the problemImmediate design change implementationQuick data exchangeUnambiguous parameters with pre-defined units

Source: vocabase.com

Source: JAQAR Concurrent Design Services (J-CDS)

reduces cost

reduces time

reduces failures

increases consistency

increases quality

Slide 10

The Facility – Introduction

The Concurrent Engineering Facility is…… a System Analysis Laboratory… a DLR major research institution… dedicated for DLR internal as well as external studies / activities

The Concurrent Engineering Facility has…… 3 design rooms with 21 work stations in total … a secure network… 2 common servers (Windows; Linux)… a Tandberg videoconference system… a media management system… a knowledge management system… public LAN/WLAN access… access to an internal component data base

Slide 11

The Facility – Overview

Slide 12

The Facility – Main Design Room (1/2)

Set-up exampleSet-up example

Slide 13

The Facility – Main Design Room (2/2)

3 Screens (2x Plasma, 1x Smartboard)3 Screens (2x Plasma, 1x Smartboard)

12 flexible Work Stations12 flexible Work Stations

Slide 14

The Team

The CEF Core Team (i.e. members of SARA dept.) include e.g.:Team Leader / ModeratorSystems Engineer; Systems AssistantOptional: Mission, Cost, Risk, … (could also be a domain experts)CEF IT-Manager

Domain experts can be from…DLR Bremen,other DLR Institutes,or external institutions

Customers (e.g. PI) can beInternal departmentsAgencies (DLR; ESA)Industry / Universities

PI = Principal Investigator

Slide 15

Phases – Overview

Slide 16

Phases – Description (1/2)

#1 - Initiation Phase (starts months before using the CEF)“Customer” (internal group, scientists, industry) contacts CE-teamCE-team – customer negotiations Expected results definition (study objectives)Identification of required disciplines

#2 - Preparation Phase (starts weeks before using the CEF)Definition of mission objectives (with customer)Definition of mission and system requirements (with customer)Identification and selection of system concept(s)Initial mission analysis (if applicable, e. g. based on STK)Final definition and invitation of expert ensemble, agenda definition

Slide 17

Phases – Description (2/2)

#3 - Study Phase (1-3 weeks in the facility)K/O with presentations of study key elements (goals, requirements) Starting with first configuration approach and estimation of budgets (mass, power, volume, modes, …) on subsystem level Iterations on subsystem and equipment level in several sessions (2- 4 hours each); e.g. trading of several options In between offline work: subsystem design in splinter groups Final Presentation of all disciplines / subsystems

#4 – Post-processing PhaseCollecting of Results (each S/S provides input to book captain)Evaluation and documentation of resultsTransfer open issues to further project workImplementation of lessons learnt into the CE-process

Slide 18

DLR Approach – 2 week study example

Session: Moderated (in Main Design Room); data exchangePost-processing: Free discussions & analyses; working groupsFinal Presentation: Presentation, evaluation and comparison of results

Slide 19

1 week has advantages and disadvantages: more condensed and focussed; less disturbances (e.g. other projects)less analyses time requires more effort before and after study

Approach will be adapted according to personnel and time availability

DLR Approach – 1 week study example

Slide 20

CE-session at preliminary CE-FacilityPresentation Screen 1

Presentation Screen 2

Interactive Smartboard

Switch

Work stations

LEL – Conf. Am

B

C

Presentation Screen 1

Presentation Screen 2

Interactive Smartboard

Switch

Work stations

LEL – Conf. Am

B

C

CE-Coaching with ESA / JAQAR

“Design Work Shop“ (DWS) for CE-Process training

S/W output sheet with CE-results

Lessons Learned

Lessons Learned

Lessons Learned

Lessons Learned

CEF – Evolution (1/2)

Slide 21

CEF – Evolution (2/2)

Slide 22

Design Model – Example: ESA „IDM“

Integrated Design Model (IDM)developed by ESA

MS Excel-basedPhase 0 / ACentralized data pool

Data_exchange.xlsSheets, e.g.

Input CalculationBudgets (e.g. mass)OutputEquipment Summary

1 workbook / disciplineSatellite missions

Slide 23

Design Model – Example: „VirSat“ (1/2)

Virtual Satellite (VirSat)Development at DLR-SC

Simultaneous (controlled) access of all disciplinesContains library with parametric unitsFlexible Tree-viewDrag and Drop from component- to current study-repositoryData storage via „Subversion (SVN)“uses SMP2-Standardbased on Eclipse Quelle: TSTI

Component  Library

Component  Library

Quelle: DLR-SC

“System breakdown”“System breakdown”

Slide 24

Design Model – Example: „VirSat“ (2/2)

Slide 25

Tools

Domain specific and general S/W (systems) installed among others on CEF work stations:

Additional S/W can be installed on request

Mission Satellite Toolkit (STK), version 9/10

Configuration CATIA V5 R19

Cost Small Satellite Cost Model 2007

OS Windows XP Professional

Documentation Microsoft Office 2003

Simulation Matlab/Simulink

All AGI Viewer

S/W = Software

OS = Operating System

Slide 26

Studies – Results

Snapshots from the study phase…L

Mission Analysis

SBC

Filter

Diplexer A Diplexer B

3dBCoupler

RX AS-Band

RS422

RX AS-Band

RS422

TX AS-Band

RS422

TX AS-Band

RS422

RX BS-Band

RS422

RX BS-Band

RS422

TX BS-Band

RS422

TX BS-Band

RS422

TX AX-Band

LVDS

TX AX-Band

LVDS

Low GainS-Band

Low GainS-Band

High GainX-Band

TX BX-Band

LVDS

TX BX-Band

LVDS

TransferSwitch

Telecom.Power Budget

Cost

Configuration

Cryo-Kick-Stage (Aldebaran)

AsteroidFinder

Slide 27

Studies – Examples (1/3)

In 2008 (* supported by ESA-CDF Team Leader):

Lunar Exploration Lander (in ESTEC-CDF)*

Asteroid Finder I (DWS I)*

Asteroid Finder II (DWS I)*

Lander Package Impacting a Seismometer (LAPIS) (DWS II)*

Cryogenic Kick Stage Study (DWS II)

Asteroid Finder III (Review in DSW II)*

Slide 28

Studies – Examples (2/3)

In 2009:

AMSAT – P5

MASCOT

MASCOT-XS

AMSAT-Moon (with AMSAT-DL)

VENUS-II_1 (with Astrium)

AMSAT-Mars (with AMSAT-DL)

CarbonSat (with IUP Bremen)

Slide 29

Studies – Examples (3/3)

In 2010:

MASCOT-DK

VENUS-II_2 (with Astrium)

Compass-II (with FH Aachen)

MallCom (with Y/T)

AHAB (with IUP)

CLAVIS

SolmeX (with Max-Planck)

Slide 30

Conclusions

Concurrent Engineering- Reduces development cost (by factor 2) and time (by factor 4)- Minimizes failures increases consistency- Mutual education („system view“)- Very helpful in the early design phases (i.e. Phase 0 / A)

Its all about the Team…- Data models, tools and infrastructure support the process- Various models possible / available / under development- Increased engineers and scientists communication

Other (actual & potential) sectors and applications- Aeronautics, car industry- Oil- and gas; offshore plants- Civil engineering; architecture- Software engineering

Slide 31

Outlook

Process application to higher project phases (Phase B and beyond)- Integration of the team, models and infrastructure across the

entire project life-cycle including disposal

Increased cross-linking of S/W and design model- Connection of domain specifc tools (DST)- Advanced Model-based System Engineering (MBSE)- Virtual pre-views; automatic 3D-models based on parameters

Implementation of internal data bases into the design models- DLR Space Suppliers and Manufacturers Database (SSAM)- DLR Concurrent Engineering Reference Database (CERD)

Closer co-operation on national & international level- Linking of CE-facilities for joint studies- Standardization of models, parameters and procedures

Slide 32

Further Information

DLR CEF Websitehttp://www.dlr.de/irs/en/desktopdefault.aspx/tabid-7174/

English version to be updated…Publications

http://elib.dlr.de/56028/1/Status_of_the_Concurrent_Engineering_Facility_at_DLR_Bremen.pdfhttp://elib.dlr.de/66373/1/Schumann_CSER2010.pdfhttp://elib.dlr.de/65913/1/SCHAUS_PAPER.pdf

ESA Concurrent Design Facility (CDF)http://www.esa.int/esaMI/CDF/index.html

NASA FacilitiesJPL - TeamX: http://jplteamx.jpl.nasa.gov/GSFC – IDC: http://idc.nasa.gov/

JPL = Jet Propulsion Laboratory

GSFC = Goddard Space Flight Center

IDC = Integrated Design Center

Slide 33

Thank you very much for your attention!

Any questions?

Thank you very much for your attention!

Any questions?

Andy BraukhaneSystem Analysis Space Segment

DLR Institute of Space Systems

+49 421 24420 123andy.braukhane@dlr.de

Source: University of Erfurt