A strategic planning methodology for aircraft redesign

Due to a progressive market shift to a customer-driven environment, the influence of engineering changes on the product's market success is becoming more prominent. This situation affects many long lead-time product industries including aircraft manufacturing. Derivative development has been the key strategy for many aircraft manufacturers to survive the competitive market and this trend is expected to continue in the future. Within this environment of design adaptation and variation, the main market advantages are often gained by the fastest aircraft manufacturers to develop and produce their range of market offerings without any costly mistakes. This realization creates an emphasis on the efficiency of the redesign process, particularly on the handling of engineering changes. However, most activities involved in the redesign process are supported either inefficiently or not at all by the current design methods and tools, primarily because they have been mostly developed to improve original product development. In view of this, the main goal of this research is to propose an aircraft redesign methodology that will act as a decision-making aid for aircraft designers in the change implementation planning of derivative developments. The proposed method, known as Strategic Planning of Engineering Changes (SPEC), combines the key elements of the product redesign planning and change management processes. Its application is aimed at reducing the redesign risks of derivative aircraft development, improving the detection of possible change effects propagation, increasing the efficiency of the change implementation planning and also reducing the costs and the time delays due to the redesign process. To address these challenges, four research areas have been identified: baseline assessment, change propagation prediction, change impact analysis and change implementation planning. Based on the established requirements for the redesign planning process, several methods and tools that are identified within these research areas have been abstracted and adapted into the proposed SPEC method to meet the research goals. The proposed SPEC method is shown to be promising in improving the overall efficiency of the derivative aircraft planning process through two notional aircraft system redesign case studies that are presented in this study.Ph.D.Committee Chair: Prof. Dimitri Mavris; Committee Member: Dr. Elena Garcia; Committee Member: Dr. Neil Weston; Committee Member: Mathias Emeneth; Committee Member: Prof. Daniel P. Schrag

Assessing system architectures: the Canonical Decomposition Fuzzy Comparative methodology

The impacts of decisions made during the selection of the system architecture propagate throughout the entire system lifecycle. The challenge for system architects is to perform a realistic assessment of an inherently ambiguous system concept. Subject matter expert interpretations, intuition, and heuristics are performed quickly and guide system development in the right overall direction, but these methods are subjective and unrepeatable. Traditional analytical assessments dismiss complexity in a system by assuming severability between system components and are intolerant of ambiguity. To be defensible, a suitable methodology must be repeatable, analytically rigorous, and yet tolerant of ambiguity. The hypothesis for this research is that an architecture assessment methodology capable of achieving these objectives is possible by drawing on the strengths of existing approaches while addressing their collective weaknesses. The proposed methodology is the Canonical Decomposition Fuzzy Comparative approach. The theoretical foundations of this methodology are developed and tested through the assessment of three physical architectures for a peer-to-peer wireless network. An extensible modeling framework is established to decompose high-level system attributes into technical performance measures suitable for analysis via computational modeling. Canonical design primitives are used to assess antenna performance in the form of a comparative analysis between the baseline free space gain patterns and the installed gain patterns. Finally, a fuzzy inference system is used to interpret the comparative feature set and offer a numerical assessment. The results of this experiment support the hypothesis that the proposed methodology is well suited for exposing integration sensitivity and assessing coupled performance in physical architecture concepts --Abstract, page iii

A conceptual design methodology for evaluation of alternate propulsion system modifications on small aircraft

Conceptual design is often considered to be the most important step in the design of a new product or the modification of an existing product. The important steps in this conceptual design phase is the synthesis of potential solutions into concepts, the evaluation of these concepts within a repeatable and robust design methodology framework and analysis to identify and characterise the preferred solution concept. This research has arisen from problems associated with developing aircraft-based design modification concepts and predicting the impact of these changes as they propagate or flow down through the various aircraft subsystems, impacting engineering design, and leading to certification and operations challenges. This research problem is particularly evident in highly integrated systems such as high-performance military aircraft, helicopters, and complex civil aircraft. To illustrate this methodology the author has selected two case studies which apply two different alternate propulsion system technologies to small aircraft. These case studies were selected to provide a diverse design modification space encompassing differing aircraft roles and mission types, differing technologies and subsystems integration scope, and different data sources collection and analysis methods. In order to combine the elements of design synthesis, evaluation of concept alternatives and analysis of outputs, this thesis has formulated a matrix-based conceptual design methodology. This methodology extends current knowledge by implementing the concepts of design synthesis, evaluation and analysis as an iterative process, and building and linking together existing techniques. This new methodology combined various techniques and methods such as Quality Function Deployment (QFD), quantified morphological matrices (QMM), Pugh’s decision matrices, change options Multiple-Domain Matrices (MDM), and has adapted the Change Propagation Method (CPM). The second extension to current knowledge in this area was the development of Engineering and Certification Domain Mapping Matrix (DMM) techniques based on Design Structure Matrices (DSM). This extension into engineering and certification domain was undertaken to ensure that important modification-related risks and costs were incorporated into the early stages of design. The extension adopted existing DSM and DMM-based techniques and tools to evaluate the impact of changes to subsystems and hence impact of risks and costs resulting from aircraft modifications using change propagation method analysis techniques. The validation of this conceptual design methodology was achieved by verifying and assessing the adequacy of its application through an analysis process which examined (1) coverage of the design space attributes; (2) validation of the methodology against accepted scientific and industry conceptual design frameworks; and (3) confirmation of the existing techniques, structures and tools applied within the methodology

Design techniques to support aircraft systems development in a collaborative MDO environment

The aircraft design is a complex multidisciplinary and collaborative process. Thousands of disciplinary experts with different design competences are involved within the whole development process. The design disciplines are often in contrast with each other, as their objectives might be not coincident, entailing compromises for the determination of the global optimal solution. Therefore, Multidisciplinary Design and Optimization (MDO) algorithms are being developed to mathematically overcome the divergences among the design disciplines. However, a MDO formulation might identify an optimal solution, but it could be not sufficient to ensure the success of a project. The success of a new project depends on two factors. The first one is relative to the aeronautical product, which has to be compliant with all the capabilities actually demanded by the stakeholders. Furthermore, a “better” airplane may be developed in accordance with customer expectations concerning better performance, lower operating costs and fewer emissions. The second important factor refers to the competitiveness among the new designed product and all the other competitors. The Time-To-Market should be reduced to introduce in the market an innovative product earlier than the other aeronautical industries. Furthermore, development costs should be decreased to maximize profits or to sell the product at a lower price. Finally, the development process must reduce all the risks due to wrong design choices. These two main motivations entail two main objectives of the current dissertation. The first main objective regards the assessment and development of design techniques for the integration of the aircraft subsystems conceptual design discipline within a collaborative and multidisciplinary development methodology. This methodology shall meet all the necessities required to design an optimal and competitive product. The second goal is relative to the employment of the proposed design methodology for the initial development of innovative solutions. As the design process is multidisciplinary, this thesis is focused on the on-board systems discipline, without neglecting the interactions among this discipline with all the other design disciplines. Thus, two kinds of subsystems are treated in the current dissertation. The former deals with hybrid-electric propulsion systems installed aboard Remotely Piloted Aerial Systems (RPASs) and general aviation airplanes. The second case study is centered on More and All Electric on-board system architectures, which are characterized by the removal of the hydraulic and/or pneumatic power generation systems in favor of an enhancement of the electrical system. The proposed design methodology is based on a Systems Engineering approach, according to which all the customer needs and required system functionalities are defined since the earliest phase of the design. The methodology is a five-step process in which several techniques are implemented for the development of a successful product. In Step 1, the design case and the requirements are defined. A Model Based Systems Engineering (MBSE) approach is adopted for the derivation and development of all the functionalities effectively required by all the involved stakeholders. All the design disciplines required in the MDO problem are then collected in Step 2. In particular, all the relations among these disciplines – in terms of inputs/outputs – are outlined, in order to facilitate their connection and the setup of the design workflow. As the present thesis is mainly focused on the on-board system design discipline, several algorithms for the preliminary sizing of conventional and innovative subsystems (included the hybrid propulsion system) are presented. In the third step, an MDO problem is outlined, determining objectives, constraints and design variables. Some design problems are analyzed in the present thesis: un-converged and converged Multidisciplinary Design Analysis (MDA), Design Of Experiments (DOE), optimization. In this regard, a new multi-objective optimization method based on the Fuzzy Logic has been developed during the doctoral research. This proposed process would define the “best” aircraft solution negotiating and relaxing some constraints and requirements characterized by a little worth from the user perspective. In Step 4, the formulation of the MDO problem is then transposed into a MDO framework. Two kinds of design frameworks are here considered. The first one is centered on the subsystems design, with the aim of preliminarily highlighting the impacts of this discipline on the entire Overall Aircraft Design (OAD) process and vice-versa. The second framework is distributed, as many disciplinary experts are involved within the design process. In this case, the level of fidelity of the several disciplinary modules is higher than the first framework, but the effort needed to setup the entire workflow is much higher. The proposed methodology ends with the investigation of the design space through the implemented framework, eventually selecting the solution of the design problem (Step 5). The capability of the proposed methodology and design techniques is demonstrated by means of four application cases. The first case study refers to the initial definition of the physical architecture of a hybrid propulsion system based on a set of needs and capabilities demanded by the customer. The second application study is focused on the preliminary sizing of a hybrid-electric propulsion system to be installed on a retrofit version of a well-known general aviation aircraft. In the third case study, the two kinds of MDO framework previously introduced are employed to design conventional, More Electric and All Electric subsystem architectures for a 90-passenger regional jet. The last case study aims at minimizing the aircraft development costs. A Design-To-Cost approach is adopted for the design of a hybrid propulsion system

UAV for Medical Equipment Distribution

This Final Design Review report documents the senior project participating in the Vertical Flight Society’s 38th Annual Student Design Competition sponsored by The Boeing Company. The goal of this project and competition is to develop an unmanned vertical lift for medical equipment distribution capable of safely delivering a 50 kg payload over distances up to 200 km. This system must be autonomous and have a backup plan to land if any part of the system malfunctions. We discuss the research and justification that drove the selection of the aircraft configuration, a winged quadcopter with a rear propeller. Furthermore, we document our reasoning and analysis for sizing and shaping of the rotors, propeller, and wings, selecting a hybrid-electric turbogenerator for the powerplant, designing the payload release mechanism, and sizing and shaping of the semi-monocoque structure. We provide analysis that numerically verifies our UAV’s ability to meet the requirements for payload capacity, range, mission time, and geometric envelope

A methodology for rapid vehicle scaling and configuration space exploration

Drastic changes in aircraft operational requirements and the emergence of new enabling technologies often occur symbiotically with advances in technology inducing new requirements and vice versa. These changes sometimes lead to the design of vehicle concepts for which no prior art exists. They lead to revolutionary concepts. In such cases the basic form of the vehicle geometry can no longer be determined through an ex ante survey of prior art as depicted by aircraft concepts in the historical domain. Ideally, baseline geometries for revolutionary concepts would be the result of exhaustive configuration space exploration and optimization. Numerous component layouts and their implications for the minimum external dimensions of the resultant vehicle would be evaluated. The dimensions of the minimum enclosing envelope for the best component layout(s) (as per the design need) would then be used as a basis for the selection of a baseline geometry. Unfortunately layout design spaces are inherently large and the key contributing analysis i.e. collision detection, can be very expensive as well. Even when an appropriate baseline geometry has been identified, another hurdle i.e. vehicle scaling has to be overcome. Through the design of a notional Cessna C-172R powered by a liquid hydrogen Proton Exchange Membrane (PEM) fuel cell, it has been demonstrated that the various forms of vehicle scaling i.e. photographic and historical-data-based scaling can result in highly sub-optimal results even for very small O(10-3) scale factors. There is therefore a need for higher fidelity vehicle scaling laws especially since emergent technologies tend to be volumetrically and/or gravimetrically constrained when compared to incumbents. The Configuration-space Exploration and Scaling Methodology (CESM) is postulated herein as a solution to the above-mentioned challenges. This bottom-up methodology entails the representation of component or sub-system geometries as matrices of points in 3D space. These typically large matrices are reduced using minimal convex sets or convex hulls. This reduction leads to significant gains in collision detection speed at minimal approximation expense. (The Gilbert-Johnson-Keerthi algorithm is used for collision detection purposes in this methodology.) Once the components are laid out, their collective convex hull (from here on out referred to as the super-hull) is used to approximate the inner mold line of the minimum enclosing envelope of the vehicle concept. A sectional slicing algorithm is used to extract the sectional dimensions of this envelope. An offset is added to these dimensions in order to come up with the sectional fuselage dimensions. Once the lift and control surfaces are added, vehicle level objective functions can be evaluated and compared to other designs. For each design, changes in the super-hull dimensions in response to perturbations in requirements can be tracked and regressed to create custom geometric scaling laws. The regressions are based on dimensionally consistent parameter groups in order to come up with dimensionally consistent and thus physically meaningful laws. CESM enables the designer to maintain design freedom by portably carrying multiple designs deeper into the design process. Also since CESM is a bottom-up approach, all proposed baseline concepts are implicitly volumetrically feasible. Furthermore the scaling laws developed from custom data for each concept are subject to less design noise than say, regression based approaches. Through these laws, key physics-based characteristics of vehicle subsystems such as energy density can be mapped onto key system level metrics such as fuselage volume or take-off gross weight. These laws can then substitute some historical-data based analyses thereby improving the fidelity of the analyses and reducing design time.Ph.D.Committee Chair: Dr. Dimitri Mavris; Committee Member: Dean Ward; Committee Member: Dr. Daniel Schrage; Committee Member: Dr. Danielle Soban; Committee Member: Dr. Sriram Rallabhandi; Committee Member: Mathias Emenet

A set-based approach to passenger aircraft family design

In today's highly competitive civil aviation market, aircraft manufacturers develop aircraft families in order to satisfy a wide range of requirements from multiple airlines, with reduced costs of ownership and shorter lead time. Traditional methods for designing passenger aircraft families employ a sequential, optimisation-based approach, where a single configuration and systems architecture is selected fairly early which is then iteratively analysed and modified until all the requirements are met. The problem with such an approach is the tendency of the optimisers to exploit assumptions already 'hard-wired' in the computational models. Subsequently the design is driven towards a solution which, while promising to the optimiser, may be infeasible due to the factors not considered by the models, e.g. integration and installation of promising novel technological solutions, which result in costly design rework later in the design process. Within this context, the aim is to develop a methodology for designing passenger aircraft families, which provides an environment for designers to interactively explore wider design space and foster innovation. To achieve this aim, a novel methodology for passenger aircraft family design is proposed where multiple aircraft family solutions are synthesised from the outset by integrating major components sets and systems architectures set. This is facilitated by integrating set theory principles and model-based design exploration methods. As more design knowledge is gained through analysis, the set of aircraft family solutions is gradually narrowed-down by discarding infeasible and inferior solutions. This is achieved through constraint analysis using iso-contours. The evaluation has been carried out through an application case-study (of a three-member passenger aircraft family design) which was executed with both the proposed methodology and the traditional approach for comparison. The proposed methodology and the case-study (along with the comparison results) were presented to a panel of industrial experts who were asked to comment on the merits and potential challenges of the proposed methodology. The conclusion is that the proposed methodology is expected to reduce the number of costly design changes, enabling designers to consider novel systems technologies and gain knowledge through interactive design space exploration. It was pointed out, however, that while the computational enablers behind the proposed approach are reaching a stage of maturity, allowing a multitude of concepts to be analysed rapidly and simultaneously, this still is expected to present a challenge from organisational process and resource point of view. It was agreed that by considering a set of aircraft family solutions, the proposed approach would enable the designers to delay critical decisions until more knowledge is available, which helps to mitigate risks associated with innovative systems architectures and technologies

Aerospace management techniques: Commercial and governmental applications

A guidebook for managers and administrators is presented as a source of useful information on new management methods in business, industry, and government. The major topics discussed include: actual and potential applications of aerospace management techniques to commercial and governmental organizations; aerospace management techniques and their use within the aerospace sector; and the aerospace sector's application of innovative management techniques

Systems Engineering

The book "Systems Engineering: Practice and Theory" is a collection of articles written by developers and researches from all around the globe. Mostly they present methodologies for separate Systems Engineering processes; others consider issues of adjacent knowledge areas and sub-areas that significantly contribute to systems development, operation, and maintenance. Case studies include aircraft, spacecrafts, and space systems development, post-analysis of data collected during operation of large systems etc. Important issues related to "bottlenecks" of Systems Engineering, such as complexity, reliability, and safety of different kinds of systems, creation, operation and maintenance of services, system-human communication, and management tasks done during system projects are addressed in the collection. This book is for people who are interested in the modern state of the Systems Engineering knowledge area and for systems engineers involved in different activities of the area. Some articles may be a valuable source for university lecturers and students; most of case studies can be directly used in Systems Engineering courses as illustrative materials