Collaborative Engineering Paradigm Applied to the Aerospace Industry

Airbus designs and industrializes aircrafts using Concurrent Engineering techniques since decades. The introduction of new PLM methods, procedures and tools, and the need to reduce time-to-market, led Airbus Military to pursue new working methods. Traditional Engineering works sequentially. Concurrent Engineering basically overlaps tasks between teams. Collaborative Engineering promotes teamwork to develop product, processes and resources from the conceptual phase to the start of the serial production. The CALIPSO-neo pilot project was launched to support the industrialization process of a medium size aerostructure. The aim is to implement the industrial Digital Mock-Up (iDMU) concept and its exploitation to create shop floor documentation. In a framework of a collaborative engineering strategy, the project is part of the efforts to deploy Digital Manufacturing as a key technology for the industrialization of aircraft assembly lines. This paper presents the context, the conceptual approach and the methodology adopted.

Proposal for the Conceptual Design of Aeronautical Final Assembly Lines Based on the Industrial Digital Mock-Up Concept

The design of a Final Assembly Line (FAL) is carry out in the product industrialization activity. The phase dealing with the definition of conceptual solutions is characterized by depending heavily on the personnel experience and being time-consuming. To enhance such process, it is proposed a development of a knowledge based software application to assist designers in the definition of scenarios and to generate conceptual FAL alternatives. Both the scenario and the generated FAL solution are part of the industrialization digital mock-up (IDMU). A commercial software application used in the aircraft programmes and supporting the IDMU concepts of: Product, Process and Resource; was selected to implement a software prototype. This communication presents the adopted methodological approach and the architecture of the developed application.

Small aircraft as a means of transport in Spain

Personal aviation represented 9% of the aircraft movement in Europe in 2006, and it is expected to grow over the coming years. According to the European Personal Air Transportation System (EPATS) study, Spain, along with France and Italy, are the European countries with greater growth prospects. The objective of this paper is to present research results focused on the potential growth of the personal aviation market in Spain and its regions. The research is mainly based on the secondary data of a survey (Movilia) from the Spanish Ministry of Public Works and Transport.

Current Mode with RMS Voltage and Offset Control Loops for a Single-Phase Aircraft Inverter Suitable for Parallel and 3-Phase Operation Modes

Rms voltage regulation may be an attractive possibility for controlling power inverters. Combined with a Hall Effect sensor for current control, it keeps its parallel operation capability while increasing its noise immunity, which may lead to a reduction of the Total Harmonic Distortion (THD). Besides, as voltage regulation is designed in DC, a simple PI regulator can provide accurate voltage tracking. Nevertheless, this approach does not lack drawbacks. Its narrow voltage bandwidth makes transients last longer and it increases the voltage THD when feeding non-linear loads, such as rectifying stages. On the other hand, the implementation can fall into offset voltage error. Furthermore, the information of the output voltage phase is hidden for the control as well, making the synchronization of a 3-phase setup not trivial. This paper explains the concept, design and implementation of the whole control scheme, in an on board inverter able to run in parallel and within a 3-phase setup. Special attention is paid to solve the problems foreseen at implementation level: a third analog loop accounts for the offset level is added and a digital algorithm guarantees 3-phase voltage synchronization.

EMI filter design of a three-phase buck-type rectifier for aircraft applications

An EMI filter for a three-phase buck-type medium power pulse-width modulation rectifier is designed. This filter considers differential mode noise and complies with MIL-STD- 461E for the frequency range of 10kHz to 10MHz. In industrial applications, the frequency range of the standard starts at 150kHz and the designer typically uses a switching frequency of 28kHz because the fifth harmonic is out of the range. This approach is not valid for aircraft applications. In order to design the switching frequency in aircraft applications, the power losses in the semiconductors and the weight of the reactive components should be considered. The proposed design is based on a harmonic analysis of the rectifier input current and an analytical study of the input filter. The classical industrial design does not consider the inductive effect in the filter design because the grid frequency is 50/60Hz. However, in the aircraft applications, the grid frequency is 400Hz and the inductance cannot be neglected. The proposed design considers the inductance and the capacitance effect of the filter in order to obtain unitary power factor at full power. In the optimization process, several filters are designed for different switching frequencies of the converter. In addition, designs from single to five stages are considered. The power losses of the converter plus the EMI filter are estimated at these switching frequencies. Considering overall losses and minimal filter volume, the optimal switching frequency is selected

New Considerations in the Input Filter Design of a Three-Phase Buck-Type PWM Rectifier for Aircraft Applications

An EMI filter for a three-phase buck-type medium power pulse-width modulation rectifier is designed. This filter considers differential mode noise and complies with MIL-STD-461E for the frequency range of 10kHz to 10MHz. In industrial applications, the frequency range of the standard starts at 150kHz and the designer typically uses a switching frequency of 28kHz because the fifth harmonic is out of the range. This approach is not valid for aircraft applications. In order to design the switching frequency in aircraft applications, the power losses in the semiconductors and the weight of the reactive components should be considered. The proposed design is based on a harmonic analysis of the rectifier input current and an analytical study of the input filter. The classical industrial design does not consider the inductive effect in the filter design because the grid frequency is 50/60Hz. However, in the aircraft applications, the grid frequency is 400Hz and the inductance cannot be neglected. The proposed design considers the inductance and the capacitance effect of the filter in order to obtain unitary power factor at full power. In the optimization process, several filters are designed for different switching frequencies of the converter. In addition, designs from single to five stages are considered. The power losses of the converter plus the EMI filter are estimated at these switching frequencies. Considering overall losses and minimal filter volume, the optimal switching frequency is selected.

Aircraft trajectory simulator using a three degrees of freedom aircraft point mass model

Aircraft Operators Companies (AOCs) are always willing to keep the cost of a flight as low as possible. These costs could be modelled using a function of the fuel consumption, time of flight and fixed cost (over flight cost, maintenance, etc.). These are strongly dependant on the atmospheric conditions, the presence of winds and the aircraft performance. For this reason, much research effort is being put in the development of numerical and graphical techniques for defining the optimal trajectory. This paper presents a different approach to accommodate AOCs preferences, adding value to their activities, through the development of a tool, called aircraft trajectory simulator. This tool is able to simulate the actual flight of an aircraft with the constraints imposed. The simulator is based on a point mass model of the aircraft. The aim of this paper is to evaluate 3DoF aircraft model errors with BADA data through real data from Flight Data Recorder FDR. Therefore, to validate the proposed simulation tool a comparative analysis of the state variables vector is made between an actual flight and the same flight using the simulator. Finally, an example of a cruise phase is presented, where a conventional levelled flight is compared with a continuous climb flight. The comparison results show the potential benefits of following user-preferred routes for commercial flights.

Analysis of the geometric altimetry to support aircraft optimal profiles within future 4D trajectory management

The use of barometric altimetry is to some extent a limiting factor on safety, predictability and efficiency of aircraft operations, and reduces the potential of the trajectory based operations capabilities. However, geometric altimetry could be used to improve all of these aspects. Nowadays aircraft altitude is estimated by applying the International Standard Atmosphere which differs from real altitude. At different temperatures for an assigned barometric altitude, aerodynamic forces are different and this has a direct relationship with time, fuel consumption and range of the flight. The study explores the feasibility of using sensors providing geometric reference altitude, in particular, to supply capabilities for the optimization of vertical profiles and also, their impact on the vertical Air Traffic Management separation assurance processes. One of the aims of the thesis is to assess if geometric altitude fulfils the aeronautical requirements through existing sensors. Also the thesis will elaborate on the advantages of geometric altitude over the barometric altitude in terms of efficiency for vertical navigation. The evidence that geometric altitude is the best choice to improve the efficiency in vertical profile and aircraft capacity by reducing vertical uncertainties will also be shown. In this paper, an atmospheric study is presented, as well as the impact of temperature deviation from International Standard Atmosphere model is analyzed in order to obtain relationship between geometric and barometric altitude. Furthermore, an aircraft model to study aircraft vertical profile is provided to analyse trajectories based on geometric altitudes.

Understanding time-drift for different aircraft descent guidance strategies

In this paper the effect of different aircraft automated descent guidance strategies on fuel burn and the temporal predictability of the executed trajectory is investigated. The paper aims to provide an understanding of how airborne automation can be permitted by Air Traffic Control to remain in control of the descent in the presence of disturbances while providing sufficient predictability. Simulations have been performed investigating different guidance strategies. While each strategy has its advantages and disadvantages, results indicate that improved temporal predictability comes at the cost of additional fuel burn and loss of predictability in other dimensions of the trajectory.

Aircraft flight trajectory deviation in the standard instrument departures. Operators penalties.

In the recent years many problems are emerging due to the aircraft noise on the airport surrounding areas. The solution to this problem is not easy considering that the neighbourhood asks for the reduction of the number of aircraft operations and the airlines ask for a growing demand in the number of operations in the major airports. So the airport and regulatory authorities try to get a solution imposing a fine to the aircraft which its actual trajectory differs from the nominal one more than a lateral deviation. But, which is the value of this deviation?. The current situation is that many operators have to pay a lot of money for exceeding a deviation which has been established without operational criteria. This paper presents the results of a research program which is being carried out by the authors which aims to determine the "delta" deviation to be used for this purpose. In addition it is proposed a customized method per SID and per airport to be used for determining the maximum allowed lateral deviation by which if the aircraft is within it, then none fine will be imposed.

Analysis and optimized design of a distributed multi-stage EMC filter for an interleaved three-phase PWM-rectifier system for aircraft applications

Different possible input filter configurations for a modular three-phase PWM rectifier system consisting of three interleaved converter cells are studied. The system is designed for an aircraft application where MIL-STD-461E conducted EMI standards have to be met and system weight is a critical design issue. The importance of a LISN model on the simulated noise levels and the effect of interleaving and power unbalance between the different converter modules is discussed. The effect of the number of filter stages and the degree of distribution of the filter stages among the individual converter modules on the weight and losses of the input filter is studied and optimal filter structures are proposed.

Development of a 3-Dimensional Mathematical Collision Risk Model Based on Recorded Aircraft Trajectories to Estimate the Safety Level in High Density En-Route Airspaces

Como en todos los medios de transporte, la seguridad en los viajes en avión es de primordial importancia. Con los aumentos de tráfico aéreo previstos en Europa para la próxima década, es evidente que el riesgo de accidentes necesita ser evaluado y monitorizado cuidadosamente de forma continúa. La Tesis presente tiene como objetivo el desarrollo de un modelo de riesgo de colisión exhaustivo como método para evaluar el nivel de seguridad en ruta del espacio aéreo europeo, considerando todos los factores de influencia. La mayor limitación en el desarrollo de metodologías y herramientas de monitorización adecuadas para evaluar el nivel de seguridad en espacios de ruta europeos, donde los controladores aéreos monitorizan el tráfico aéreo mediante la vigilancia radar y proporcionan instrucciones tácticas a las aeronaves, reside en la estimación del riesgo operacional. Hoy en día, la estimación del riesgo operacional está basada normalmente en reportes de incidentes proporcionados por el proveedor de servicios de navegación aérea (ANSP). Esta Tesis propone un nuevo e innovador enfoque para evaluar el nivel de seguridad basado exclusivamente en el procesamiento y análisis trazas radar. La metodología propuesta ha sido diseñada para complementar la información recogida en las bases de datos de accidentes e incidentes, mediante la provisión de información robusta de los factores de tráfico aéreo y métricas de seguridad inferidas del análisis automático en profundidad de todos los eventos de proximidad. La metodología 3-D CRM se ha implementado en un prototipo desarrollado en MATLAB © para analizar automáticamente las trazas radar y planes de vuelo registrados por los Sistemas de Procesamiento de Datos Radar (RDP) e identificar y analizar todos los eventos de proximidad (conflictos, conflictos potenciales y colisiones potenciales) en un periodo de tiempo y volumen del espacio aéreo. Actualmente, el prototipo 3-D CRM está siendo adaptado e integrado en la herramienta de monitorización de prestaciones de Aena (PERSEO) para complementar las bases de accidentes e incidentes ATM y mejorar la monitorización y proporcionar evidencias de los niveles de seguridad. ABSTRACT As with all forms of transport, the safety of air travel is of paramount importance. With the projected increases in European air traffic in the next decade and beyond, it is clear that the risk of accidents needs to be assessed and carefully monitored on a continuing basis. The present thesis is aimed at the development of a comprehensive collision risk model as a method of assessing the European en-route risk, due to all causes and across all dimensions within the airspace. The major constraint in developing appropriate monitoring methodologies and tools to assess the level of safety in en-route airspaces where controllers monitor air traffic by means of radar surveillance and provide aircraft with tactical instructions lies in the estimation of the operational risk. The operational risk estimate normally relies on incident reports provided by the air navigation service providers (ANSPs). This thesis proposes a new and innovative approach to assessing aircraft safety level based exclusively upon the process and analysis of radar tracks. The proposed methodology has been designed to complement the information collected in the accident and incident databases, thereby providing robust information on air traffic factors and safety metrics inferred from the in depth assessment of proximate events. The 3-D CRM methodology is implemented in a prototype tool in MATLAB © in order to automatically analyze recorded aircraft tracks and flight plan data from the Radar Data Processing systems (RDP) and identify and analyze all proximate events (conflicts, potential conflicts and potential collisions) within a time span and a given volume of airspace. Currently, the 3D-CRM prototype is been adapted and integrated in AENA’S Performance Monitoring Tool (PERSEO) to complement the information provided by the ATM accident and incident databases and to enhance monitoring and providing evidence of levels of safety.

UPM Activities on Sensitivity and Uncertainty Analysis of Assembly Depletion

UPM Activities on Sensitivity and Uncertainty Analysis of Assembly Depletion

Desarrollo de un sistema basado en el conocimiento para la definición de líneas de montaje aeronáuticas en la fase conceptual : Aplicación a una aeroestructura aeronáutica

La presente Tesis persigue la definición y el desarrollo de un sistema basado en el conocimiento que permita la generación de modelos de líneas de montaje durante la fase conceptual de definición de una aeroestructura aeronáutica. Para ello, se propone la definición de un modelo formal del proceso en concurrencia asociado al diseño de líneas de montaje en la fase conceptual, y de un modelo de la estructura de datos básica para soportar dicho proceso. Ambos modelos sirven de base para el desarrollo de una aplicación de prueba de concepto en el entorno del sistema comercial CAX-PLM CATIA v5. Los modelos de línea generados integran las tres estructuras básicas definidas en el modelo propuesto: producto, procesos y recursos. Los modelos generados son estructuras “de montaje”, basadas en estructuras de producto “de fabricación” a su vez derivadas de estructuras “de diseño”. Cada modelo generado se evalúa en términos de cuatro estimaciones básicas: dimensiones máximas del nodo producto, distancia de transporte y medio a utilizar, tiempo total de ejecución y coste total. La generación de modelos de línea de montaje se realiza en concurrencia con la función diseño de producto, teniendo por tanto la oportunidad de influir en la misma e incluir requerimientos de fabricación y montaje al producto en las primeras fases de su ciclo de vida, lo que proporciona una clara ventaja competitiva. El desarrollo propuesto en esta Tesis permite sentar las bases para realizar desarrollos con objeto de asistir a los diseñadores durante la fase conceptual de generación de diseños de líneas de montaje. La aplicación prototipo desarrollada demuestra la viabilidad de la propuesta conceptual que se realiza en la Tesis. ABSTRACT The current thesis proposes the definition and development of a knowledge-based system to generate aircraft components assembly line models during the conceptual phase of the product life cycle. With this objective, the definition of a formal activity model to represent the design of assembly lines during the conceptual phase is proposed; such model considers the concurrence with the product design process. Associated to the activity model, a data structure model is defined to support such process. Both models are the basis for the development of a proof of concept application within the environment of the commercial CAX-PLM system CATIA v5. The generated assembly line models integrate the three basic structures defined in the proposed model: product, processes and resources. The generated models are “As Prepared” structures based on “As Planned” structures derived from “As Designed” structures. Each generated model is evaluated in terms of four basic estimates: maximum dimensions of the product node, transport distance and transport mean to be used, total execution time and total cost. The assembly line models generation is made in concurrence with the product design function. Therefore, it provides the opportunity to influence on it and allows including manufacturing and assembly requirements early in the product life cycle, which gives a clear competitive advantage. The development proposed in this Thesis allows setting the foundation to carry out further developments with the aim of assisting designers during the conceptual phase of the assembly line design process. The developed prototype application shows the feasibility of the conceptual proposal presented in the Thesis.

Interleaved multi-cell isolated three-phase PWM rectifier system for aircraft applications

Recently there has been an important increase in electric equipment, as well as, electric power demand in aircrafts applications. This prompts to the necessity of efficient, reliable, and low-weight converters, especially rectifiers from 115VAC to 270VDC because these voltages are used in power distribution. In order to obtain a high efficiency, in aircraft application where the derating in semiconductors is high, normally several semiconductors are used in parallel to decrease the conduction losses. However, this is in conflict with high reliability. To match both goals of high efficiency and reliability, this work proposes an interleaved multi-cell rectifier system, employing several converter cells in parallel instead of parallel-connected semiconductors. In this work a 10kW multi-cell isolated rectifier system has been designed where each cell is composed of a buck type rectifier and a full bridge DC-DC converter. The implemented system exhibits 91% of efficiency, high power density (10kW/10kg), low THD (2.5%), and n−1 fault tolerance which complies, with military aircraft standards.