Integrating Boeing’s SystemsDesign Environment

Bruce Fritchman

May, 2000

Overview

Talk broadly and generally about the systems designprocess at Boeing

- where we think its going

Talk more specifically about several projects using EASY5that are driving in that direction

What are Aerospace Systems ?

AvionicControl

Electrical Mechanical Propulsion

Navigation

ElectronicsSoftware

PowerEntertainment

HydraulicEnvironmentalFuelThermalMechanisms

Jet EnginesRocket Engines

Cabin ManagementAvionicsFlight Managment

Fuel

Crew Systems

Computers

Integrating Boeing’s Systems Design EnvironmentWhat Does that Mean ?

Integration of design processes:Preliminary design - Detailed design - Verification and test

Integration of Boeing and vendor/supplier teamsIntegration of Boeing with teaming partners

Cross functional integration

Integration of CAE toolsIntegration of CAD and CAE toolsIntegration with Product Data Manager PDM toolsIntegration of “Single-Source” data

Integrated Systems Design and ModelingWhy ?

Moving towards

Reduced Design Cost & Cycle TimeEarly Systems Validation

Reduced MockupsReduced Testing

Improved Design FlowPreliminary Design to Detailed Design

Integrated System Validation

Cross FunctionalVendors / SuppliersTeams and Partners

Move Towards Single-Source Product DataConfiguration Control

Virtual Prototyping

Other Objectives

Enterprise wide- Common processes- Common tools- COTS tools

- Eliminate legacy codes

Aerospace Systems Design ProcessMoving Towards Model-Based Design

ProductDefinition

ConfigurationStudies

FunctionalObjectives

AvionicsHydraulicsElectricPower

Software ECS

ElectricalSystems

MechanicalSystems

FlightSystems

ControlSystems

FuelSystems

SystemsRequirements

Mechanisms

RealTime Sim

EmbeddedCode

IntegratedSimulation LRU’s Schematics

Drawings

PropulsionSystems

PreliminaryDesign

Detailed

Application/ DigitalPreassembly

Design

Proce

ss

Level of Effort

Level ofDetail

higher

lower

Design

Verification

Engines

Integrated Systems Design Processand the SSPD

DiagramsRules

Geometry

Analysis IntegratedReal-timeSimulation

DigitalPreassembly -

ViewsProjections

Abstractions

PDMEnovia

CADDiagrammingTools

Part Libraries

Single Source ofProduct data

Virtual PrototypingThe Holy Grail

Logical Geometry

Manafacture

Requirements Capture

TheDesire

FlightComputer

AutoPilot

HydraulicSystem

Diagramming Tools

Model GenerationAnalysis ToolsDesign Verification

Preliminary Design - Detailed DesignThe Tool Dichotomy

PreliminaryDesign

DetailedDesign

- fast- low detail- low skill level

- fully detailed- high skill level

Many tools do not span the design processNeed tools and infrastructure that can “evolve” the designMaybe we need to pay up front with detailed tools that will span the process

- product definition

EASY5

Vendors / Suppliers and the SSPD

Single Source ofProduct data

Enterprise WideIntegration

Labs

Enterprise WideEngineering

Models

VendorsSuppliersEASY5

Models

GSDS

Boeing’s role as “systems integrator”may be facilitated by providingsystems definition and integrationtools

web based

- Functional- Geometry

Integrated Systems Design EnvironmentBCA View

EASY5

DADSSABER

PSPICE

GSDS

ElectricDriveLibrary

ECSLibrary

PSIM

HydraulicsLibrary

Real-TimeEnvironment

Mechanisms

Auto-Code

Multi-Body

EASY5 COTS

COTS

BCAG IASL

Fluid -TubeSystems

CAD

CAD

CATIA

Electrical

DetailedSchematicDefinition

DetailedSchematicDefinition

?

?

Detailed Diagram Definition

Systems

Supporting Integrated Systems DesignEASY5 Focus Areas

- Improved diagrams and schematics

- CAE tool integrations e.g. GSDS

- Linkages to CAD

- Investigating requirements and structure for PDM

- Real-time

- Develop processes to support teams, vendor/suppliers

- CORBA interface between EASY5 and MAT

- web based

EASY5 DevelopmentDriven by customer Needs

Ongoing Boeing projects driving development

BCA Structures Dynamic Flight Loads

Example - common tools / common models

FlightSystems

Structures

Airframe models

Control system models

Common Analysis Environment

Flight Systems and Structuresengineers see the same picture

The new MAT-based process has been used to compute Flight Loads forall of our commer cial airplane deriv atives since 1996

Example - large-scale process integraton using EASY5 MAT

50% design cycle time reduction - solution phase flight loads analysis

Question - can we achieve similar benefits with our vendors ?

GSDS Auto-code modules may be added as components in EASY5

Integrating GSDS with EASY5BCA Requirements Capture - Detailed Definition - Autocode

EASY5 provides local desktopenvironment for GSDS definitions

BCA IASL Integrated Development EnvironmentEASY5/GSDS/PSIM

IASLFull AirplaneSimulation

ECSHydraulicsConrolsAvionicsStructuresElec Power

PFC SCDReq Doc to suppliersDocument SimulationDocument Lab infrastructureTraining Simulators

Legacy code

MATLAB

Saber

Other tools

ECSHydraulicsConrolsAvionicsStructuresElec Power

PFC SCDReq Doc to suppliersDocument SimulationDocument Lab infrastructureTraining Simulators MATLAB

SaberEmbedded code

Other tools

DesktopModelingAnalysis

EASY5

ElectricDriveLibrary

ECSLibrary

HydraulicsLibrary

PSIM

GSDS

PSIM

GSDSEASY5

ElectricDriveLibrary

ECSLibrary

HydraulicsLibrary

Suppliers

Future

+ Iron Bird

IASLFull AirplaneSimulation

Real-timeExecutive

Real-timeExecutive

777-200 Development

C-17 Iron-Bird

Goal- replace C-17 “iron-bird”physical mockup withdetailed real-time simulation

Driving EASY5 real-time modeling development

- quad-redundant 4000 psihydraulic system

Integrating EASY5 with CAD

Mechanical CAD

FunctionalSchematic

Analysis Model

Definition

Develop framework for central library of

Goal:

to be plugged in - pumps- valves- actuators

Use Generative Design infrastructureto automatically relate fluid system EASY5functional models to CAD definition

Aerospace- hydraulics- environmental- fuels

vendor-supplied component modelsSingle Source of

Product data

Boeing

Suppliers

Rocketdyne RAPID Project

TurbomachineryModel

Control SystemVerification

Optimizer

EngineBalanceModel

TransientEngine Model

Valves&ControlsModels

Controls Software

Geometry

FluidProperties

EASY5

- Integrate analyses

- Eliminate legacy code- Single system model

Rocket engine design optimization process

MAT

EASY5/GSDS

EASY5 Touches Many Facetsof Boeing’s Systems Design Processes

CADDesign

MechanicalSystems

Structures

ElectricalSystems

FluidSystems

Auto-code

Software

ControlSystems

Real-timeSimulation

Aerospace Systems

Analysis

EASY5

Vendors

BoeingDesign and Analysis Processes

PreliminaryDesign Detailed

Design

Design

ProcessExecution

Optimization

EASY5 suited to some systems / design phasesmore than others

In Conclusion

We are involved at high level with process planning, development

We are involved at ground level assisting projects driving both processdevelopment and the development of EASY5

We are striving to expand EASY5’s role as a key tool in the Boeing“enterprise” arsenal of standard processes and tools for

Aerospace Systems Design

and strategy teams