Design Engineering – A need to automate ‘The Need for More Speed’

Design Engineering – A need to automate

‘The Need for More Speed’

Design Engineering – A need to automate

Professor Craig Chapman is Associate Head of Research and Head of Knowledge Based Engineering at Birmingham City University

Carl Barcock is Chief of Design Methods, Design Systems Engineering at Rolls-Royce Plc

The Need for SpeedKnowledge Based EngineeringIndustrial Examples

Presentation Outline =

© 2012 Rolls-Royce plcThe information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc.This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies.

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Rolls-Royce proprietary information

Change to ‘Trusted to deliver excellence’

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Group profile

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We expect to double turnoverin the next ten years

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Civil aerospace

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Success

Speed is needed

Speed gives you options

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Design is Complex

The design process feels a bit like this,

but

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Actually it looks like this

One subsystem, x8 for whole engineMany inter-dependencies between subsystems

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Challenges

It is now not possible to design a competitive gas turbine without the extensive use of Simulation

To keep competitive requires us to develop our capability at an increasing rate.

Hence we Need Speed in automation and integration of simulation tools, methods & the embedding of knowledge .

ie the creation of ‘Design Systems’

10

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What’s the motivation for Simulation?

Design better products – higher performing, lighter, cheaper, more reliable, less polluting……

Design more effectively and efficiently – speed through automation, better accuracy……

Replace testing by Simulation to cut development costs.

Make more effectively and efficiently - reduce scrap and rework in production.

Over to Craig

Question – Do You MAKE Stuff?

Then your doing Knowledge Based Engineering

Knowledge Based Engineering Lab

“Virtual Engineering is aimed at allowing the synthesis, analysis, evaluation and optimal development of a product in a computer environment that mimics the understanding and behaviour of the solution to the realization of that solution in reality”.

Virtual Engineering

Consider all the other required models - FEM, Physics, cost, process – are they coupled


Legislativestandards

Multipletopologies

Its never really been about the ‘Geometry is the Master Model’ & associated documentation - Consider a Simple Shaft

Cost Rules

Standard bar sizeMaterial cost (type, volume, economic batch size)

Direct labour costsOverhead costs per machine (machine/hr rate)

Lowest cost routeExtras pricing band

Manufacturing Rules

Machine capacitiesMachine capacity (tolerance)

Machine set-up timesNC tool path information

Grinding allowancesTooling availability

Material availabilityFastest throughput, route

Material type

Engineering Rules

Bearing size to suit shaft diameterBearing life to suit load and life requirements

Calculation of bearing lifeTapped end hole to suit shaft diameter

Tap length to engineering standardsSurface finish to suit auxiliary components e.g. Oil seal

Calculation of max permissible load (load type: radial, axial, combination)Weld calculations (possible/strength) for hybrid shafts

Shaft diameter for brake sizeFan or non-fan vented

Keyway size to suit diameterTolerance to suit required standard and final assembly

Material propertiesThread and keyway standards

Motor output and phase

Geometric Rules

Extension overall lengthShaft overall lengthExtension diameter

Keyway lengthKeyway width

Bearing diameterRotor groove positions

Fan area diameterChamfer dimensions

Fillet dimensionsUndercut dimensions

Number of extension segments

Multiple ModelRequirements

Engineering Processes


The best way to Understand is by real world examples



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Example of KBE: A Leaner Process

Old Process without KBE System

New Process with KBE System


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Usage and Benefits Delivered: FanUsed on civil and military NPI programmes

£0.5M net benefit to-date in Design and Manufacturing Engineering modelling activities (technical time)

system developed in 4 months

10 fold increase in engineering productivity

Over 40% reduction in overall engineering lead time99% reduction in modelling time for design geometry & finite element mesh99% reduction modelling time for manufacturing stage & tooling geometry

50% reduction in design staff used

100 fold reduction in the number of CAD geometry entities handled by the engineer: 950 surfaces & solid (7000 geometric entities) down to 7 major features, thus reducing scope for human and digital error

Less material used on flat packs & dies

10 fold reduction in data storage requirements

Reverse

engineer

Chrysler uses a system known as Knowledge Based Engineering, a combination of software tools and engineering data.

The program can run simulations to test parts and then adjust those parts instantly. But it goes further than most computer-assisted design programs; it can also adjust every part a new piece touches -- looking at the entire vehicle.

Chrysler's new Dodge Challenger was completed in 21 months, trimming nearly a year off the time it takes to complete most vehicles.

"What literally took months can now be done in weeks," said Pamela Larson, manager of rear-wheel drive virtual development. "Instead of spending our time developing many things, we're refining it."


Gimbal Design and Synthesis

Lockheed Martin\TechnoSoft Inc


Anything in common?


Think STEM

Domain Knowledge

Application Knowledge

Capture Reuse Real Time Collaboration Integrate

A Framework for knowledge


High Fidelity Physics

Nonlinear Aerodynamics

FEM & Flight Loads

Structural Sizing

Smart Product Model - Geometry & analysis models associative - Environment to operate with COTS & LM Aero production tools - System level assessments extract data from analysis models via smart product model

Mission SimulationCombat Effectiveness /

Airframe CostRatio

Scenario Based Structural Configuration and Sizing

Airframe Modeling & Simulation


Proven Technology


The UK’s First Dedicated Knowledge Based Engineering Lab

Knowledge Transfer Research Commercial Education

Give tim

e back to th

e Engineer to Engineer

and the creative, th

e tools to

discover

Thank you for

your attention

[email protected]

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Design Engineering – A need to automate ‘The Need for More Speed’