hyperion uav: an international collaborationciec/proceedings_2013/cipd/cipd443_koster.pdf ·...
TRANSCRIPT
ASEE-CIEC 2013, Mesa, AZ, February 7, 2013
Jean Koster, University of Colorado Boulder
Hyperion UAV: An International Collaboration
ASEE-CIEC 2013
• Opportunities made available by software and internet
• 3D CAD software, Product Lifecycle Management (PLM)
• Common digital environment
• Global companies operate Design Bureaus around the world.
– Opportunities to expedite design work on new systems
– Opportunities to harvest bright minds
– Leveraging expertise and talent
– Limit or eliminate duplication of efforts
• Focus on technological Innovation and diverse approaches to find solutions
– Leverage diverse critical thinking
2
Why a Global Collaborative Project?
-Purpose-
ASEE-CIEC 2013
“If you have an apple and I have an apple and we exchange apples
then you and I will still each have an apple.
But if you have an idea and I have an idea and we exchange these
ideas, then each of us will have two ideas.”
Why Global Collaboration?
-Purpose-
Performance: • Decreasing the learning curve • Responding rapidly to customer needs and inquiries • Preventing “reinvention of the wheel” • Spawning new ideas for products and services • Fast and lean time to (new) market(s)
G.B. Shaw
ASEE-CIEC 2013
Hierarchies Become Networks
-Purpose-
“The corporation as we know it is unlikely to survive the next 25 years. Legally and financially, yes. But not structurally and economically.”
Peter Drucker, 2000
Daly, James (22 August 2000), “Sage Advice: An Exclusive Interview with Peter Drucker,“ Business 2.0.
ASEE-CIEC 2013
A collaborative network is the collection of businesses, individuals and other organizational entities that possess the capabilities and
resources needed to achieve a specific outcome
Collaborative Business Concepts
-Purpose-
Jeffrey Shuman and Janice Twombly, Collaborative Networks Are The Organization, July 2009
Communities of practice are groups of people who share a concern or a passion for something they do and learn how to
do it better as they interact regularly
Etienne Wenger, Communities of Practice - Brief Introduction, June, 2006
ASEE-CIEC 2013
The perspective of communities of practice affects educational practices along three dimensions:
• Internally: How to organize educational experiences that ground school learning in practice through participation in communities around subject matters?
• Externally: How to connect the experience of students to actual practice through peripheral forms of participation in broader communities beyond the walls of the school?
• Over the lifetime of students: How to serve the lifelong learning needs of students by organizing communities of practice focused on topics of continuing interest to students beyond the initial schooling period?
Education for Community of Practice
-Purpose-
Etienne Wenger, Communities of Practice - Brief Introduction, June, 2006
ASEE-CIEC 2013
Benefits of Collaboration
-Purpose-
Need: A better understanding of the process of collaborating and the skills it takes to realize its benefits are required.
Shuman, Jeffrey and Janice Twombly with David Rottenberg (2001), Collaborative Communities: Partnering for Profit in the Networked Economy, Dearborn Trade, Chicago, IL.
ASEE-CIEC 2013
Network Model and Governance
-Purpose-
Daly, James (22 August 2000), “Sage Advice: An Exclusive Interview with Peter Drucker,“ Business 2.0.
ASEE-CIEC 2013
Aircraft Market Diversity is Increasing
-Purpose-
Source: Boeing Commercial Airplanes, 2012 CMO
ASEE-CIEC 2013
• Customers and customer support in 150 countries
– Total revenue in 2011: ~$70 billion
– 70% of commercial airplane revenue historically from customers outside the United States
• Contracts with 22,000 suppliers and partners globally
• 6 research, design and technology-development centers and programs in multiple countries
• Boeing has employees in 50 states and 70 countries
Boeing’s global footprint…
-Purpose-
Stephen Emmert, Global Collaborations PNWER Annual Summit, July 2012.
ASEE-CIEC 2013
Boeing 787 Global Work Breakdown Structure
-Purpose-
• Manufacturing dispersed in many countries
– For Boeing’s Dreamliner, 28 suppliers are located outside USA, e.g.
• Wings produced in Japan
• Ailerons produced in Australia
• Fairings produced in Canada
• Doors produced in France and Sweden
• Final assembly in USA
• Preassembled parts delivered allow for a vastly reduced final assembly crew.
• Faster assembly: 3 days
ASEE-CIEC 2013
• Plan: First Dreamliner test plane to be rolled out on 07/08/07
– Originally planned to enter service in May 2008
• Boeing anticipated 1,200 components for final assembly
• Instead: Partners dumped ~30,000 pieces on Boeing
– Resulted in a delivery date pushback to 2010
– Maiden test flight took place on December 15, 2009,
– Boeing completed flight testing in mid-2011
– First model entered commercial service on October 26, 2011
Huge Organizational Challenges
-Purpose-
Young Engineers need to learn to choreograph
delocalized design and manufacturing
ASEE-CIEC 2013
NASA’s ERA Goals
Reduce:
Aircraft fuel consumption
Emissions
Noise
…Simultaneously!
13
Motivation: Green Aviation
-Motivation-
Image credit: NASA
“In 2009, … [the] United States flew 704 million passengers, a number forecast to reach 1.21 billion by 2030.” – NASA Facts
[1]
ASEE-CIEC 2013
Fuel Problem:
14
Motivation: Reduce Fuel Burn
-Motivation-
In 2008 U.S. Commercial air burned 19.7 Billion Gallons D.O.D. burned an additional 4.6 Billion Gallons
Goals
[1]
+
250,000,000… Tons of Carbon Dioxide (CO2)
Nitrogen Oxide (NOx)
Reduce NOx Emissions:
20% by 2015 50% by 2020
>50% beyond 2025 [1]
Reduce Fuel Burn:
33% by 2015 50% by 2020
>70% beyond 2025 [1]
ASEE-CIEC 2013
Airport Noise Challenge: Aircraft noise regarded most significant hindrance to National Airspace System
15
Motivation: Reduce Noise
-Motivation-
Image credit: NASA
[1]
ASEE-CIEC 2013 16
Motivation: Blended Wing Body
-Motivation -
[2]
Image credit: NASA
ASEE-CIEC 2013
WHY HYPERION?
• Society/ industry needs:
– Aerodynamically & energy efficient aircraft
– Prepare workforce in global environment
• History:
– Colorado students developed hybrid propulsion system
– Boeing interest in follow-the–sun design process
– AIAA-ASM Meeting January 2010, Orlando:
o NASA: “Environmentally Responsible Aviation (ERA) Project”
Boeing X-48B prominently presented
o Focus on aviation alternative fuels, fuel savings, reduced noise
Purpose
-Motivation -
Image credit: NASA
ASEE-CIEC 2013
18
System Configuration
- Hyperion - Hyperion 2012-13
Hybrid-Electric Engine
BWB Carbon Fiber / Composite
Structure
Integrated Control System
ASEE-CIEC 2013
• Increasing complexity in the breadth of technologies • Technical expertise • Diversity in educational programs • Highly educated labor forces in (developing) countries,
including skill sets specialized by region • Special attention shall be paid to skills that are required to
undertake a global collaboration project.
Partner Value
- Valuation -
ASEE-CIEC 2013 20
Goals
-Project Overview-
1. Investigate new technologies for improved capabilities and efficiencies
2. Practice international collaboration in education
1. Conceive, design, build, and test a 2nd generation hybrid propulsion system to be integrated into the Hyperion
Boulder + Stuttgart + Sydney
Undergraduate CU Team
ASEE-CIEC 2013 21
Global Team
- Follow The Sun -
Engineering students need to develop skills in orchestrating (delegating) and coordinating multi‐site teams, not just acquire deep technical knowledge.
Follow-The-Sun
ASEE-CIEC 2013
Pain: Efficiency in Global Industry Collaborations: needs improvement
22
FTS Collaboration Experiment
-Global Collaboration-
Concept 3 Teams, distributed 8 hours apart relay work daily.
Follow-the-Sun (FTS), produces 3 work-days in one 24 hour period
New Challenge: Write Interface Documents for delocalized team Work Breakdown Structures
Project has 3 components: Mechanical, Electronics, Software
ASEE-CIEC 2013
Internet Communication and Cloud File Sharing
Best Practices
-Global Collaboration-
12
IT Plan
- Integration & Testing -
Detail IT Plan
Concept of Operations
Integration
Manufacturing
Develop and define mission phases
Project Requirements
Determine verification method and develop tests
System Architecture
Identify subsystem interfaces and risks
Project Decomposition
Time
Testing
Operation
Verification andValidation
Implement IT Plan
Systems Engineering
ASEE-CIEC 2013
Project teams SHALL have sufficient expertise to address their design problems
– Technical skills are necessary for success – Assess the skills needed to analyze the proposed system – If you don’t have the required technical skills:
• are you committed to learning these skills (“lifelong learning”)?
– Is it reasonably clear how you will make a technical contribution to the project?
– Carefully consider the technical skills needed for each project. A Team Skills Document is 1st deliverable.
24
Team Expertise
- Team -
The team as a whole and each individual team member together are accountable for that delivery!
ASEE-CIEC 2013
1. A good understanding of engineering fundamentals.
2. Possesses a multi-disciplinary, systems perspective.
3. A profound understanding of and commitment to teamwork.
4. A basic understanding of context of engineering practice.
5. An understanding of design and manufacturing processes.
6. Good communicator.
7. High ethical standards.
8. An ability to think both critically and creatively.
9. An ability to think both independently and cooperatively.
10. The ability and self-confidence to adapt to rapid changes.
11. Curiosity and desire to learn for life.
Desired Attributes of An Engineer
-Team -
*A Manifesto for Global Engineering Education, Summary Report of the Engineering Futures Conference, January 22-23, 1997. The Boeing Company & Rensselaer Polytechnic Institute.
ASEE-CIEC 2013
• Filled out by candidate students
• Evaluated by “Project Champion” and faculty
Team Skills
- Team -
0 = minimal experience 1 = proficient 2 = excellent
ASEE-CIEC 2013
Project Manager
Web
Safety Engineer
PAB-Advisor External Advisor
CAD Engineer
Systems Engineer
Subsystem 1 Lead Engineer
Subsystem 2 Lead Engineer
Subsystem 3 Lead Engineer
27
Projects Team Structure
- Team -
Entrepreneurial
Leadership
Manufacturing Engineer
Customer
CFO
Subsystems: Energy and Propulsion Structures & Materials Weights/Mass Properties Handling and Controls Flight Mechanics /Performance Leadership
ASEE-CIEC 2013
Subsystem Design
-Technology Overview-
Manufacturing
Electronics
Aerodynamics
Materials/Structures
Weights
ASEE-CIEC 2013 29
Schedule
-Global Collaboration-
PDR CDR Start Flight
Testing
ASEE-CIEC 2013 30
System Configuration
-Project Overview-
•Hybrid-Electric Engine to explore quiet take-off and landings, quiet loitering, and improved efficiencies (CONOPS dependent)
• Aerodynamic design started by Sydney team
• Raked wingtips & vertical stabilizers designed by Stuttgart team
• Management, electronics, internal structure design & systems integration by CU
See: AIAA-2012-0878
ASEE-CIEC 2013
FTS Example
-Global Collaboration-
Colorado Team • Changes structure component • Does it meet Requirements? • What does this mean for manufacturing
and aerodynamics?
Sydney Team • Evaluates Structural Implications on
Aerodynamic Design • Proposes design changes • Provides aerodynamic feedback
Stuttgart Team • Evaluates Manufacturing implications on
aerodynamic and structural designs • Proposes design changes • Provides manufacturing feedback
8 Hours
8 Hours
8 Hours
ASEE-CIEC 2013 32
Aerodynamics & Structures
-Technology Overview-
½ Scale Wind Tunnel Model Internal Structure Center Body/Integration
Aerodynamic Validation
CFD Validation
Wing Integration/Assembly
ASEE-CIEC 2013 33
Aerodynamic Analysis
-Technology Overview-
L/D greater than 20 Statically stable Stall velocity less than 15 m/s Span efficiency (e) greater than 0.8 Wing loading less than 15 kg/m²
Aerodynamic Requirements: Aerodynamic testing was performed using multiple methods CFD 1/2 scale wind tunnel testing
ASEE-CIEC 2013 34
Manufacturing: Center Body
-Technology Overview-
Project Goal and Objectives Distributed Manufacturing
• Negative molds milled from CAD-data
• Fiberglass-foam-core skin laminated by hand
• Integration of internal structure from University of Colorado
ASEE-CIEC 2013 35
Global Integration Manufacturing
-Integration-
IDT (Interface Dimension
Template)
Device used to ensure German center body matches USA wings
Similar ideas used for wing manufacturing
Winglet Wing
Delocalized manufacturing increases integration risk!
Risk
Mitigation
ASEE-CIEC 2013 36
Global Integration
-Global Collaboration-
“Flat Sat” Approach (Simulation and Test-bed) - Used while center body is in Germany -
• Full Scale Mockup of Center Body
• Wire Length and placement
• Hardware placement platform
• Full system testing for electronics
Need: Electronics integration into plane Problem: Plane center body in Germany!
Solution
Image credit: NASA
Cubesat Broken Down Flat Layout Electronics
ASEE-CIEC 2013
37
Manufacturing – External Structure
- Manufacturing - Hyperion 2012-13
Wing Dissection Small pieces for 3D printer
3D Print Arrangement of pieces inside 3D printer
Mold Pieces 3D printer output Digital Cardboard layout for mold
integration
Stepwise procedure for 4 negative molds
ASEE-CIEC 2013
38
Manufacturing – External Structure
- Manufacturing - Hyperion 2012-13
• 24 pieces for each cradle • dxf file implemented into cutting
table software • Modified fabric cutting machine
Mold Layup Connecting mold pieces together
Cutting cardboard cradle
ASEE-CIEC 2013
39
Wing Integration
- Manufacturing - Hyperion 2012-13
ASEE-CIEC 2013 40
Hybrid Gas-Electric Engine
-Technology Overview-
Project Goal and Objectives Design, build and test a hybrid propulsion system to be integrated into the aircraft
Offset drive
No control system
Focus: Efficiency, proof of
concept
Coaxial drive
Multiple flight mode control
Focus: Reliability, operations
Objective:
See: AIAA-2012-0147
ASEE-CIEC 2013 41
• Test aircraft capability and characteristics.
• Identify unforeseen problems.
• Pilot familiarization
• Test: Taxi, takeoff, cruise, land
• Test: Mass sensitivity, cg
• Test: International analysis of data
Testing
-Technology Overview-
Dynamically (1/2) Scaled Prototype
ASEE-CIEC 2013
• Electric propulsion
– Hybrid Engine fully bench tested, but not flight tested (maturity)
• R/C Piloted – Successful takeoff, cruise, and landing
42
System Testing
Flight Test
http://www.youtube.com/watch?v=OM825EZGhS0 http://www.youtube.com/watch?v=u2qjvbLs_t0
ASEE-CIEC 2013 43
Lessons Learned
-Global Collaboration-
Language and Cultural Barriers Although everyone speaks Englineerish….
Encodes/Writes Message
Decodes/Misinterprets Message
Cloud Noise Filter Can Cause: -Loss of Tone
-Loss of Intent -Misinterpretation
Encodes Counter Productive Feedback Message
Decodes Message
ASEE-CIEC 2013 44
Lessons Learned
-Global Collaboration-
Follow-the-Sun (FTS): • Great for CAD design work • Ideas across border • Dynamic positive synergy • Benefit of diversity in critical thinking • Helps mitigate risk through smaller team delegation • Difficult in academic environment due to schedules
Follow-The-Week (FTW)
• Suited for concept designs • Specialized tasks assignments to small local teams • Finished tasks reviewed by global team • Weekly global team meetings.
ASEE-CIEC 2013
• Project needs managerial infrastructure – Needs strong Project Manager (Choreographer)
– MBA candidate on team
– Economics student on team
• Understand international shipping requirements – International Traffic in Arms Regulations (ITAR)
– Understand international trade and regulations
• Collaboration on “trust” and “respect” – Limited control over non-local teams’ efforts
– Understand skills and capabilities of partners
– Free sharing of information leads to IP issues
• Planning – Extend the planning process significantly!
– Better understand skills and capabilities of partners
– Each partner should have own funding
45
Lessons Learned
- Global Collaboration-
ASEE-CIEC 2013
• Successes:
– Designed, built, and flew HYPERION in 9 months
• Planning for 3 months
• Design layout within 4 months
• Aerodynamics and structures analysis using FTS
• Controls system development
• Delocalized manufacturing in 3 months
• Under mass and finance budgets
• Successful maiden flight
Conclusion
ASEE-CIEC 2013
• Current Project Charter:
– Design and Manufacturing shared by Stuttgart and Colorado
– New wing design
From Flying Wing to Blended Wing Body
– Autonomous Control System
– FAA COA
– Integrate hybrid propulsion system and flight test
47
Current Development
- Current -
ASEE-CIEC 2013
48
Project Papers
- Papers - Hyperion 2012-13
The Hyperion 2.1 Green Aircraft Project, AIAA-2013-0817 (Best Paper DETC)
The HYPERION 2 Green Aircraft Project, AIAA-2012-0878 (Best Paper DETC)
HYPERION UAV: An International Collaboration, AIAA-2012-1223
Design of a Hybrid Propulsion System for Aircraft. AIAA-2011-1011 (Best Paper DETC)
Design of a Blended Wing Body UAS with Hybrid Propulsion, ASME-IMECE2011-62126
Work Force Development for Global Aircraft Design, ASME-IMECE2011-62273
SOLSTICE, AIAA-2012-0147 -1st Place at AIAA Region V Student Competition 2011
ASEE-CIEC 2013
Student Global Team
-Team-
Michaela Cui Tyler Drake Arthur Kreuter Gavin Kutil Brett Miller Corey Packard Marcus Rahimpour Gauravdev Soin
Mart in Arenz Holger Kurz David Pfei f fer Matthias Seitz Bar is Tunal i Jonas Schwengler Pascal Weihing Benjamin Arnold
Kai Lehmkuehler Matthew Anderson Joshua Barnes Byron Wi lson Andrew McCloskey
Julie Price Eric Serani Tom Wiley
Richard Zhao Kristen Brenner Corrina Gibson
Nathan Jastram Michael Johnson
Eric Kenney
49
Jeremy Klammer Lydia Mcdowell Boris Papazov
Taylor Petersen Robert Whitehill Ben Benjamin
Andrew Haynes Andrew Gilbert
Greg Nelson
Pierce Martin Zach Dischner Vibin Mahdev
Adil Ali Wes Willits Alex North
Lucas Miller Sean Ortiz
ASEE-CIEC 2013 50
Acknowledgements
-Acknowledgements-
A special thanks to… Mike Kisska of Boeing Frank Doerner of Boeing Blaine Rawdon of Boeing Tom Hagen of Boeing Dr. Robert Liebeck of Boeing/USC Steven Yahata of Boeing Norman Princen of Boeing Diane Dimeff of eSpace Brian Taylor of NASA Joseph Tanner of CU Trent Yang of RASEI Dr. Donna Gerren of CU Prof. Eric Frew of CU Matt Rhode of CU Trudy Schwartz of CU Prof. Claus-Dieter Munz of Stuttgart Prof. Ewald Kraemer of Stuttgart Dr. KC Wong of Sydney Dr. Dries Verstraete of Sydney
Skip Miller of Skip Miller Models
James Mack of RECUV (Pilot)
Questions? Contact: [email protected]
ASEE-CIEC 2013
Customer Requirements → Project Definition (PDD)
–Background, Goal, Objectives, Functional Block Diagram, Concept of Operations
–Top level Project Requirements (0.PRJ.x)
–Top level System Requirements (0.SYS.x)
–Minimum Requirements for Success
–Deliverables
–Technical and Financial Risks
–Team Formation and Team Expertise
–Resources
52
Deliverable 1 (PDD)
- Deliverable -
ASEE-CIEC 2013
Project Definition → Conceptual Design (CDD) – Team information
– System Architecture (3 design options)
– Requirements (3-5 most important Reqs., rank)
– Feasibility (for top ranked architecture option)
– Testing and Verification requirements for key systems
– Assess key risks and mitigation options
– Assess team qualifications
– Respond to criticism received on PDD
– Resources update
53
Deliverable 2 (CDD)
- Deliverable -
ASEE-CIEC 2013
Conceptual Design → Preliminary Design (PDR) – Development and assessment of system design options; arguments for chosen architecture
• Flow-down from functional needs to identified requirements
– System Design-To specifications. Development and assessment of subsystem design options and design-to specifications
• Preliminary itemization of required performance parameters
– Project Feasibility Analysis and Risk Analysis • Define high risk sub-system for prototyping • Back-of-the-envelope, Matlab, preliminary analysis or test • Define optional “off-ramps”
– Project Management Plan (preliminary) • Myers-Briggs analysis
54
Deliverable 3 (PDR)
- Deliverable -
ASEE-CIEC 2013
• System Architecture is fully documented at CDR
• All subsystems are checked for feasibility and are given a “go”
• Sub-system decomposition and integration is understood
– Mechanical, electrical, and software elements are analyzed
– All blue-prints are ready to enter the fabrication process
• Interfaces between sub-systems are working well
– Integration of sub-systems into units is understood
• Manufacturing and System Integration Plan
• The Testing and Verification Plan is finalized
– Test concepts of operation are documented
• Project Management Plan (PMP) is finalized
• The System Engineer signed off on the proposed design
• Manufacturing of components starts after successful completion of CDR.
55
Deliverable 4 (CDR)
- Deliverable -
B. S. Blanchard, W.J. Fabrycky, Systems Engineering and Analysis, Prentice Hall,2006.