11

Strategic Alignment of Teaching and Strategic Alignment of Teaching and Research Enabled Through Virtual Research Enabled Through Virtual

Product DevelopmentProduct Development

Richard D. HaleRichard D. HaleAssociate ProfessorAssociate Professor

Aerospace EngineeringAerospace EngineeringUniversity of KansasUniversity of Kansas

10/11/0710/11/07

KUAE Vision and MissionKUAE Vision and MissionVision: Vision:

As a leader in aerospace As a leader in aerospace design education, we'll build design education, we'll build on our 60on our 60--year legacy to be a year legacy to be a world class community of world class community of choice for outstanding choice for outstanding students, educators, and students, educators, and researchers shaping the researchers shaping the second century of flight second century of flight

Mission Mission Educate aerospace Educate aerospace engineering students with engineering students with balanced knowledge/skills in balanced knowledge/skills in advanced design, design advanced design, design integration and manufacturing integration and manufacturing of aerospace vehiclesof aerospace vehicles, and , and serve the needs of Kansas, US serve the needs of Kansas, US industries, and government. industries, and government.

John McMasters, Technical Fellow, The Boeing Company

Virtual Manufacturing

Feature Based Designof Subsystems

Virtual Product Envmt.

Virtual Prototype

Common Geometry

Structures/FEA

Aerodynamics/External Loads

Feature Based Design of Structures

Automatic Int.GeometryPhysics-Based Weights

and CostsRapid Meshing

Rapid Loads

First Key is Engaging Students in Virtual Product Definition, and Web-Enabled Collaboration

Knowledge Base Development for Increased Certification by Analysis

Educational Reform Initiatives Offer Potential for Validating Strategically Aligned Teaching and Research Missions (NSF DLR)

Specialized Depth Domain Knowledge:

Content Domain Knowledge

TLC: Leading Edge CoreIntro. To Aerospace Engrg.

Colloq. & Freshman SeminarIntroduction To Ethics

Diversity: American People

Humanities & Social Science CoreDepth & Breadth, Globalization

Math & Science CoreCalculus – 4 semestersPhysics – 2-3 semestersChemistry – 1 semester

Engrg. Mechanics CoreStatics, Dynamics,

Strength of Materials, Thermodynamics, Circuits

Professional Development Core

Academic progress &Colloquium seminars

Research EnterpriseFaculty & Graduate

student mentors, Problems of global significance

Situated Knowledge:

Applied Domain Knowledge

Applied Computational Methods in Knowledge-Based Engineering

Fluid MechanicsAerodynamics & Performance

Fund. of Aerodynamics

Computer Aided Design

Dynamics of Flight I & II

Reciprocating Propulsion Systems

Fund. of Jet Propulsion

Aerospace Structures I & II

Materials & Processes

Instrumentation Lab.Technical Electives

Capstone Senior Design I & II

Course connection demonstrated Course connection proposed Full Integration

Industry EngagementIdentify collaborativeresearch, in-reach into classroom, assessment

Natural Complement to Educational Natural Complement to Educational MissionMission

Uninhabited Air Vehicle Design-Analyze-Build-Test(AE 507-421-508-510-430)

EvolvingEvolving Complement to Educational Complement to Educational MissionMission

Uninhabited Air Vehicle Design-Analyze-Build-Test(AE 507-421-508-510-430)

88

Prototype Example Prototype Example ---- HawkeyeHawkeye

Design Requirements:Design Requirements:50 lb payload capacity (23 kg)50 lb payload capacity (23 kg)200 nm range (370 km)200 nm range (370 km)Modular Design with no section Modular Design with no section

greater than 1.5 metersgreater than 1.5 metersMust be competitive with Must be competitive with

current UAV marketcurrent UAV market

Hawkeye UAVHawkeye UAV

Increasingly Complex Applications: The Increasingly Complex Applications: The Center for Remote Sensing of Ice Center for Remote Sensing of Ice

Sheets Sheets ---- Science RationaleScience Rationale

What changes are occurring in the mass of the What changes are occurring in the mass of the Earth’s ice cover, and how will those changes Earth’s ice cover, and how will those changes affect the climate?affect the climate?Using autonomous vehicles Polar research can Using autonomous vehicles Polar research can lead to greater spatial and temporal resolution of lead to greater spatial and temporal resolution of data acquisition.data acquisition.Increasing autonomy of UAVs (Multiple aircraft Increasing autonomy of UAVs (Multiple aircraft with single ground station) may lead to with single ground station) may lead to substantial operating cost savings.substantial operating cost savings.

Performance Requirements for Performance Requirements for CReSIS Field TestsCReSIS Field Tests

The UAV shall support the fine survey mission, defined as a The UAV shall support the fine survey mission, defined as a 20km x 20km area with 1km grid line spacing and a 350km 20km x 20km area with 1km grid line spacing and a 350km ingress/egressingress/egress–– Range: 945nm (1,750 km)Range: 945nm (1,750 km)

Ground Speed: 180Ground Speed: 180--220 km/hr220 km/hr–– Driven by SensorsDriven by Sensors

Cruise Speed: >140kts (260 km/hr)Cruise Speed: >140kts (260 km/hr)–– Driven by Wind speeds: 20Driven by Wind speeds: 20--40 kts (3540 kts (35--75 km/hr)75 km/hr)

Operating Ceiling: 15,000 ft (4.6 km)Operating Ceiling: 15,000 ft (4.6 km)Operating Altitude: < 4,900 ft AGL (1,500 m)Operating Altitude: < 4,900 ft AGL (1,500 m)Takeoff and Landing Distance: 1,500 ft (450 m)*Takeoff and Landing Distance: 1,500 ft (450 m)*–– *(enables operation from field camp or remote base)*(enables operation from field camp or remote base)

Heavy Fuel Engines are PreferableHeavy Fuel Engines are Preferable

Payload RequirementsPayload RequirementsThe UAV shall accommodate the magnetometer and the various The UAV shall accommodate the magnetometer and the various radar systems which include radar hardware, antennas, and radar systems which include radar hardware, antennas, and related subsystems. related subsystems. OnOn--board storage: 1 Terabyteboard storage: 1 TerabytePotential Operating Frequency: 100 MHz Potential Operating Frequency: 100 MHz –– 8GHz8GHzPayload Weight: Payload Weight: –– Ideal: 75 lbs (35 kg)Ideal: 75 lbs (35 kg)–– Worst Case: 120 lbs (55 kg)Worst Case: 120 lbs (55 kg)–– Conservative Case: 165 lbs (75 kg)Conservative Case: 165 lbs (75 kg)

Payload Power: 300 WPayload Power: 300 WPayload Volume: 0.5 x 0.5 x 0.2 mPayload Volume: 0.5 x 0.5 x 0.2 mAntennas: 50 x 50 cm EachAntennas: 50 x 50 cm Each–– 66--10 on 50 cm spacing10 on 50 cm spacing

Payload Accommodations:Payload Accommodations:–– Nadir Ports or WindowsNadir Ports or Windows–– External Wing Mounted AntennasExternal Wing Mounted Antennas

The New Meridian UAVThe New Meridian UAV

Aircraft Structural DesignAircraft Structural Design

Misc. StructuresMisc. StructuresWing splice and landing

gear integration

Wing ribs and antenna integration

One gear landing at 2 gPayload hatch

Firewall

Wing ManufacturingWing Manufacturing

Fuselage Manufacturing PlanFuselage Manufacturing Plan

1

2

34

5

6

7

8

9

10

# Part Name Material1 firewall 7075-T6512 frame 110 7075-T6523 frame 120 7075-T6534 fuse skin lwr Carbon/Epoxy5 fuse skin upr Carbon/Epoxy6 payload hatch Carbon/Epoxy7 v tail lead edge Alum. TBD8 ruddervators Fiberglass/Foam9 v tail fwd spar 7075-T65110 v tail aft spar 7075-T651

Fuselage ManufacturingFuselage Manufacturing

Systems Integration Systems Integration –– AvionicsAvionics

Educational use of KnowledgeEducational use of Knowledge--Based Based tools requires extension to missiontools requires extension to mission--

based conceptual designbased conceptual design

ConceptualModel

PreliminaryModel

MissionSpecifications

DetailedModel

Metrics, CostPerformance

Most time spent in

academic and educational

activities

Most time spent in industrial activities

Cost and performance readily quantified through robust geometry

Cost and performance largely “locked-in” by configuration

Adaptive Modeling Rapid Air Vehicle Engineering Adaptive Modeling Rapid Air Vehicle Engineering ((AMRavenAMRaven))

The framework facilitates rapid vehicle development integrating:–– FeatureFeature--based 3D geometric modeling environment supporting based 3D geometric modeling environment supporting

OML and substructure layout and configuration OML and substructure layout and configuration Major subsystem layout and packaging Major subsystem layout and packaging

–– 3D Parametric meshing 3D Parametric meshing –– Integrated low and high fidelity analyses and simulationsIntegrated low and high fidelity analyses and simulations

Aerodynamics Analysis (CFD, Panel, Empirical)Aerodynamics Analysis (CFD, Panel, Empirical)Structural Analysis and SizingStructural Analysis and SizingThermal AnalysisThermal AnalysisPropulsion AnalysisPropulsion Analysis

–– Weights ComputationWeights Computation–– Trajectory Optimization and Vehicle ClosureTrajectory Optimization and Vehicle Closure–– Operation Modeling and discrete event simulationOperation Modeling and discrete event simulation–– Cost modelingCost modeling–– Design exploration, optimization, and uncertainty analysisDesign exploration, optimization, and uncertainty analysis

Airplane Preliminary Design ProcessAirplane Preliminary Design Process

CLASS II

CLASS I DRAG

WING ANDHIGH LIFT

IS CLASS ICONFIGURATION

OK?

PERFORMANCE

LANDING GEAR DESIGN

STRUCTURE S IZING

WEIGHT AND BALANCE

INSTALLED THRUS T/POWER

IS CLASS IICONFIGURATION

OK?

EMP ENNAGESIZING

CONFIGURATION3-VIEW

CLASS I WEIGHT

WEIGHT & BALANCE

AERODYNAMICS:S & C DERIVATIVES,

HINGEMOMENTS, DRAG

RETRACTION KINEMATICS

WEIGHTS LOADS

TRIM

STICKFORCES

TAB & HORN SIZING

COST

DYNAMICS

SIMULATION

GEAR DIS POS ITION

STRUCTURE S IZING FLYINGQUALITIES

3-VIEWWIRE FRAME/SURFACE

V-n DIAGRAM

FINAL PRELIMINARYDESIGN

MISSION SPECIFICATION

PERF. CONS TRAINTANALYS IS

WEIGHT SIZING

CLASS I

YES

NO

NO

YES

AAARavenAAARaven ImplementationImplementationSupport Airplane Conceptual and Preliminary Support Airplane Conceptual and Preliminary

Design/AnalysisDesign/Analysis

Mission ProfileMission ProfileWeight SizingWeight SizingClass I DragClass I DragPerformance SizingPerformance SizingMaximum LiftMaximum LiftFlap LiftFlap LiftLift DistributionLift Distribution

GeometryGeometryClass I WeightClass I WeightWeight and BalanceWeight and BalanceClass I Moments of Class I Moments of InertiaInertiaVolume MethodsVolume MethodsClass II WeightClass II WeightClass II DragClass II Drag

Implementation Implementation ---- AAARavenAAARavenModel TreeModel Tree

Airplane

Certification

Vehicle Configuration

Primary Mission

Weights

Stability and Control

Primary Mission

Mission Segment

Flight Conditions

Dynamics

Weight and Balance

Performance

AerodynamicsClasses: AMLClasses: AML

CalculationsCalculations

––AMLAML

––Delphi DLL (Code ReDelphi DLL (Code Re--use from AAA)use from AAA)

Benefits of Benefits of AAARavenAAARavenFurther Reduced Design TimeFurther Reduced Design Time–– Replace Manual CalculationsReplace Manual Calculations–– Reduce ErrorsReduce Errors–– 1 King Air 1 King Air →→ 8 MU8 MU--2: 500 Hours2: 500 Hours–– Air Tractor: 200 Hours Air Tractor: 200 Hours →→ 40 Hours40 Hours–– Small Jet: 20 Hours Small Jet: 20 Hours →→ 2 Hours2 Hours

Better Product: IterationsBetter Product: Iterations–– More Alternative DesignsMore Alternative Designs–– Improved QualityImproved Quality–– Higher Fidelity (Physics Based: CFD, FEA)Higher Fidelity (Physics Based: CFD, FEA)

Further Reduced Design CostFurther Reduced Design Cost

3D Geometry Errors3D Geometry Errors

Integration and TestingIntegration and TestingApplicable to most Applicable to most Types of AirplanesTypes of Airplanes–– Single Engine PropSingle Engine Prop–– MultiMulti--engine Propengine Prop–– FighterFighter–– BomberBomber–– AirlinerAirliner–– UAVUAV–– Business JetBusiness Jet–– FAR23, FAR25, FAR23, FAR25,

Military, LSAMilitary, LSA

Validation Exercises for Existing or Validation Exercises for Existing or Emerging AircraftEmerging Aircraft

AAI Shadow 600AAI Shadow 600Adam A500Adam A500Bede BDBede BD--1010BeechJet 400ABeechJet 400ABoeing 737Boeing 737--900900Boeing 747Boeing 747--400400Boeing 777Boeing 777--200200Bombardier Learjet Bombardier Learjet 24F24FCessna 172R Cessna 172R SkyhawkSkyhawkCessna 208Cessna 208Cessna 210 Cessna 210 CenturionCenturionCessna 310Cessna 310Cessna 525 Cessna 525 CitationJetCitationJet

Cessna CJ2Cessna CJ2Cirrus SR20Cirrus SR20Diamond DA40Diamond DA40Eclipse 500Eclipse 500Embraer EMBEmbraer EMB--312 Tucano312 TucanoEmbraer EMBEmbraer EMB--120 Brasilia120 BrasiliaFAFA--22 Raptor22 RaptorFairchild TFairchild T--4646Falcon 20Falcon 20Global HawkGlobal HawkLearfan 2100Learfan 2100Lockheed Martin FLockheed Martin F--16 16 Fighting FalconFighting FalconPiper PAPiper PA--30 Twin Comanche30 Twin ComancheRaytheon Premier 1Raytheon Premier 1KU KU CReSISCReSIS MeridianMeridian

Validation for New Aircraft Validation for New Aircraft –– LSA DesignLSA Design

UL 260i, 95 HPUL 260i, 95 HPPowerplantPowerplant

120 kts at 5,000 ft120 kts at 5,000 ftMax. Cruise Max. Cruise SpeedSpeed

5,000 ft maximum5,000 ft maximumAltitudeAltitude

1 crew, 1 passenger (190lb 1 crew, 1 passenger (190lb each and 10 lb baggage each and 10 lb baggage each)each)TOGW 1320 lbTOGW 1320 lb

WeightWeight

1,000nm at full payload at 1,000nm at full payload at 5,000 ft and 10% reserves5,000 ft and 10% reserves

RangeRange

21 3

5

6

7

Engine Start and Warmup

Taxi

Take-off

Cruise

Descent

Landing, TaxiShutdown

4Climb

Maximum stall Maximum stall ––45 knots.45 knots.Maximum speed in level flightMaximum speed in level flight–– 120 knots.120 knots.Single or twoSingle or two--seat aircraft only.seat aircraft only.Single, reciprocating engineSingle, reciprocating engineFixed or groundFixed or ground--adjustable propeller.adjustable propeller.UnpressurizedUnpressurized cabin.cabin.Fixed landing gearFixed landing gear

ConclusionsConclusions

Earliest adoption of 3D Geometry : Prevent Earliest adoption of 3D Geometry : Prevent Geometry ErrorsGeometry ErrorsRobust geometry enables interdisciplinary Robust geometry enables interdisciplinary and and multidiscplinary multidiscplinary inquiryinquiryTools enable transition from historicalTools enable transition from historical--based based to physicsto physics--based modeling earlier in designbased modeling earlier in designEducational environment ideal for lowEducational environment ideal for low--cost cost validation of simulations, supporting the validation of simulations, supporting the emerging virtual product workforceemerging virtual product workforceEducational and research goals are Educational and research goals are synergisticsynergistic