Simulation Process Improvement for S/C Structures at RUAG Space

Franck MouriauxSenior Manager Engineering & DevelopmentRUAG Space, ZürichBusiness Unit StructuresEATC 201323-24. April 2013

EATC 23-24. April 2013RUAG Space, Zürich2

Why Process Improvement?

"Throughput time" or "Time to Market" is a key element for Spacecraft Structures.

For the Customer, the structure is the first element required to start the integration of the spacecraft and it is essential that it can be delivered in time.On the other hand, inputs for the design of the structure can bedelivered very late depending on the development of the equipments which are mounted on it.

For the Contractor, the duration of the project has a direct influence on the costs and there as well on-time delivery is crucial.However, late inputs require flexibility and efficiency to limit the impact on the development and manufacturing time.

EATC 23-24. April 2013RUAG Space, Zürich3

Small Geo - Automatic Notching Small Geostationary satellite platform for commercial telecom

market

EATC 23-24. April 2013RUAG Space, Zürich4

Small Geo - Automatic Notching

Automation & Standardisation of Notching for Equipments Process integrated into the post-processing tool Controlled and secured process Automatic generation of notching curves for all equipments Automatic generation of outputs for documentation Analysis loops need only link to new Nastran output files, no manual

repetition of post-processing work

Based on ALTAIR HyperWorks Solution

EATC 23-24. April 2013RUAG Space, Zürich5

Small Geo - Automatic Notching

EATC 23-24. April 2013RUAG Space, Zürich6

Small Geo - Automatic Notching

Definition of the launcher input data:

Nominal Sine Input

Quasi-Static Accelerations

Angle Steps

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Small Geo - Automatic NotchingTypical Notched Input Spectrum

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Small Geo - Automatic NotchingTypical Notched Equipment Response

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Small Geo - Automatic Notching

More than 300 notched response plots for the corresponding equipments in Sine X, Sine Y and Sine Z environments, for two satellite configurations with different Propellant Tank filling ratios, after the application of the corresponding envelope input profile (6 launchers processed) summing up to a total of more than 1800 plots!

Previously, 1 week including copy-paste work on top of the difficulties to handle a large amount of data with a self made excel based tool.

With HyperWorks, <1 day to complete the post-processing, from the import of the Nastran punch file up to the MS Word report ready with captions.

EATC 23-24. April 2013RUAG Space, Zürich10

Small Geo – Qualification Testing

EATC 23-24. April 2013RUAG Space, Zürich11

Small Geo – Qualification Testing

Automation & Standardisation of Test Data Processing Import and visualisation of test data almost on real time Comparison with predictions Identification and quantification of deviations Support to decision process for final qualification test

Based on ALTAIR HyperWorks Solution

EATC 23-24. April 2013RUAG Space, Zürich12

Small Geo – Qualification Testing

Verification of channels that would trigger notching when applying nominal inputs

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Small Geo – Qualification Testing

Prediction of automatic notch on top of the manually notched profile for the sensitive channels.

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Small Geo - Automatic Notching

Fastest spacecraft dynamic qualification test campaign ever!!

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Solar Orbiter – Panel Inserts Definition

Scientific ESA satellite platform for close-up study of our Sun

EATC 23-24. April 2013RUAG Space, Zürich16

Solar Orbiter – Panel Inserts Definition

Automation & Standardisation of Panel Insert Definition Process integrated into the post-processing tool Controlled and secured process Automatic generation of panel I/F fluxes from the FEM outputs Automatic definition of number of inserts per panel edge Analysis loops need only link to new Nastran output files, no manual

repetition of post-processing work

Based on ALTAIR HyperWorks Solution

EATC 23-24. April 2013RUAG Space, Zürich17

Solar Orbiter – Panel Inserts Definition

EATC 23-24. April 2013RUAG Space, Zürich18

Solar Orbiter – Panel Inserts Definition

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Solar Orbiter – Panel Inserts Definition

Gain per analysis loop > 3 weeks! (including programming of the tool)

Similar potential gain for Offers and Proposals

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Why Process Automation?…and why HyperWorks?

High level of integration and standardisation for processes directly integrated into the post-processing tool

High level of robustness in the processes no risk of uncontrolled modifications like in Excel sheets

High level of customisation possibility to replicate any analysis process possibility to define specific GUI’s adapted to the user Possibility to define any output format

High gain in development time Automation of standard analyses possibility to focus on the specificities of each structure

EATC 23-24. April 2013RUAG Space, Zürich21

Thank you for your attention!

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