Complex System Design Cycle, Analysis and Test...
Transcript of Complex System Design Cycle, Analysis and Test...
LearningObjectives• UnderstandwhyanalysisandtestiscriCcal
• Whattoanalyze/test
• Developconcreteanalysisandtestplans
• Presentanalysisandtestresults
• WhattoincludeinfabricaConpackages
TheLRS-BwillprovideoperaConalflexibilityacrossawiderangeofmilitaryoperaCons.
Boeing/LockheedMarCnConceptImage
NorthropGrummanConceptImage
LongRangeStrikeBomber
UserNeeds:
• CarryXXtonspayload
• XXmilerangewithoutrefueling
• CompaCblewithairtoairrefueling
• Stealth
EngineeringRequirements:• CarryXXtonsofpayload
• CarryXXtonsoffuel
• WinggenerateXXlbfliX
• TotalweightofaircraX(tons)
• Totalpower
LongRangeBomber
Structure Engines Power PayloadDeployment Comm Electronic
Warfare
- Weight- Power- LiX- Stealth- Thermal- Environmental- Volume
FlightControls Avionics HydraulicThermal/
Cooling
PreliminaryDesignReview
MarketResearchProblemUnderstanding
IdeaCon
TradeStudiesSystemOpCmizaCon
EngineeringRequirementsSpecificaConSheets
Proposal:PreliminaryDesign
CongressionalLobbying
ConceptReFinement
Analysis:DemonstrateDesignFuncConality
PreliminaryDesignReview
TechnologyDevelopment:PreliminaryDesignReview
EngineeringRequirements/SpecificaConSheet
DetailedPreliminaryDesign
TesCng:qualificaConofnewmaterialsanddesigns
PreliminaryAnalysis
PreliminaryDesignReview
SystemDevelopment&DemonstrationCriticalDesignReview
EngineeringRequirements/SpecificaConSheet
DetailedFinalDesign TesCng:AcceleratedLife,
Qual
Analysis
ProducConTestBuild
Design<->Cost
• FailuresinproducCon->majorcost.
F-22:67billion
37.6BillionSunkcost
30BillionFlyawaycost
SystemDevelopmentandDemonstration:ManufacturingReadinessReview
PreliminaryDesignReview
ManufacturingProcessFlowand
Plans
PreProducConRunData
Schedule
DesignCycle:Capstone
DevelopCustomer/Stakeholder
Needs
DevelopEngineeringRequirements
ValidateEngineeringRequirements
DesigntoEngineeringRequirements
• Stakeholderanalysis
• Marketresearch• HouseofQuality
• HouseofQuality
• Specsheet• RegulaCons• Analysis
• IdeaCon• FuncContree&
Morphcharts• Tradestudies• IndustrialDesign• HumanFactors• CAD/Modeling• Mockups• Analysis
• Analysis• Test• Inspect• Prototype
ProducCon
Whydowedoanalysis?• SelecCon:Analysiscanimprovedesign!• Wallthickness• FastenerselecCon• Numberoffasteners• WeightreducCon• MaterialselecCon• Structuralgeometry• ComponentselecCon• Geartraindesign
Dr.JulianRimolihhp://www.magicalrobot.org/BeingHuman/2016/01/related-projects-by-collaborators
Whydowedoanalysis?• ValidaCon:Analysisdemonstratesdesignmeetsengineeringrequirements!• Life• Load• Weight• Geometry• Gain/Phase• Power• Thermal
TypesofAnalysis
Analysis
Structural
Dynamics
Thermal/Fluids
MaterialsControls
SystemOpCmizaCon
Power/Energy
GD&T
DFMA
Youlearnedanalysisin….
• ME1770• MSE2001• ME2016• ME2202• C0E3001• ME3322
…Now,howdoyoudecidewhattoanalyze?
• ME3340• ME3017• ME3345• ME3210• ME3180• ME4315
WhattoAnalyze/Test• Choosingrequirementstodesignto/validatewithanalysis:
• SystemcriCcalrequirements• DesignforfuncCon(operaConalloads)• Designforfailure(limitloads)• FailureModesandEffectsAnalysis(FMEA)
• Life,load,andweight • Chooseyourcomponents/dimensionsfromanalysis!
WhentoAnalyze• Canbevalidatedbyanalysis
• Doesyourteamhavethecapabilitytocompletethisanalysis?• OutsourceanalysiswithtechnicalconsulCngfirms!
• Willgoodresultsvalidatetheproblemwiththecorrectlevelofconfidence?
• Timeefficient
• Expensivetestsetup
• NeedbothtesCngandanalysis• FMEAindicateshighrisk(highprobabilityandseverity)• hhp://www.youtube.com/watch?v=Ai2HmvAXcU0
DevelopinganAnalysisPlan• Whatistherequirement?
• Whatisyourfactorofsafety?• Howwelldoyouknowthedesign/material(heritage?)• HowconfidentareyouinthematerialproperCes?• HowconfidentareyouintheanalysispredicCngthefailuremode?• IsthisrequirementsystemcriCcal?
• DesignforfuncCon:SimulatetheoperaCngenvironment!• Whatareyourknowns?• WhatassumpConsareyoumaking?
• Pointload?• Thermalenvironment?• kf=isthereanythingspecialaboutthisenvironment?Corrosion?PlaCng?• Constrained?BoundarycondiCons?
• Designforfailure:worstcasescenario
• Determineanalysisbasedoffof:• Textbooks(Shigley’s,Roarks,CRChandbooks)• Standards:ASME,MILSTD,ect.• Literature(Googlescholar),Expertsinthefield
CommonAnalyses(Mechanical)• GD&T:ToleranceStackUp(WorstCaseScenario)
• StaCcLoading:VonMises:(bending,axial,torsion,shear)
• FaCgue:(Goodman)
• CoefficientofThermalExpansion:• Geometry• CTEmismatch
• Fasteners:Preload,Shear
• Components:life/load
• GearTrains:torque,HP,gearraCos
• Modelanalysis(VibraCon,naturalfrequency),Shock
WhentoTest• Analysisisnotagoodpredictoroffailuremode• FaCguefailures• Shockfailures• FracturepropagaCon• Corrosion,environmentaltests• hhps://www.youtube.com/watch?v=_jfXX7qppbc
• Easiertotestthantorunanalysis• TimeconsumingsimulaCon
• Failuredependentonmanufacturingprocessormaterial• Materiallotscreening• Manufacturabilityscreening
• NeedbothtesCngandanalysis• FMEAindicateshighrisk(highprobabilityandseverity)
TestingClassS(SpaceFlight)MicroelectronicCircuit• MILSTD883:• Openelectricaltest• -100x(highpower)visualinspecConofsemiconductorandpackage• ThermalCycle(-65Cto165C)• Centrifuge(30,000g)• ParCcleImpactNoiseDetecCon(mini-vibraContest)• GrossLeakTesCng• FineLeakTesCng• ExternalVisualInspecCon• Electronic‘Burnin’test
• DestrucCveTests:(Doneonsmallpercentofpackagesforqual)• ResidualGasAnalysis *InternalvisualinspecCon• DropTest *CrosssecCon• Acceleratedlifetests *X-Ray
DevelopingaTestPlan• Whatistherequirement?
• WhatistheoperaCngcondiCon?• Thermal?• Mechanical?• Geometry?• Environmental?
• Whattestsarealreadydonefortheserequirements/condiCons?• MILHNDBKJ,ASTM,MILSTD883• NIST
• Whatarethepasscriteria?• VisualinspecConat20x:novisualcrackingorfracture• CTscan/X-ray:nointernalfracture• Dyepenetrantcheckforfracture• Yieldat>50ksi• Electricalperformance
• Whatisyourplanforeachpossibleoutcomeofthetest?
VascularGraft(Bypass)- LiquidCght- SutureretenCon:1.20±0.23N- WithstandstaCcpressure:
200mmHg(systolic)
- Withstanddiastolic/systoliccycleforpaCentlife:4.2X109repeCCons
- Promotelaminarbloodflow
- BiocompaCable
• “Itdoesn’tmaherhowsmartyouareifyoucan’texplainyouranalysistotheprogrammanagerandthecustomer.”-ChiefEngineer,HamiltonSundstrand
Presenting/ReportingAnalysis• Whatwastherequirementthatdrovethisanalysis?
• Whatisthemodeoffailureyourconcernedabout?Whattypeofanalysisdidyoucomplete?• Shearpullout?• GoodmanfaCgue?
• Whatarethekeyassump@onsintheanalysis?• BoundarycondiCons?• MaterialproperCes?• Loading?• Nodesandelements?
• Howdoesyouranalysisshowthisrequirementhasbeenvalidated?• Factorofsafety?• Gainandphasemargin?
Analysis:CheckValveAssembly• Withstandpressureloadingduetopreloadpersource:X114283-D002Rev.2
MaterialYieldStrength 35MaterialUl@mateStrentgth 42
Loaca@on Stress@860psiksi
LimitMarginofSafety
Loc#1 28.15 0.24Loc#2 22.85 0.53Loc#3 16.45 1.13
FEModelResults-VonMisesStressatLoc1DuetoPreload
LocaCon1-3marginofsafetyacceptableperprogramrequirements.
Presenting/ReportingTestResults• Whatwastherequirementthatdrovethistest?• SatellitemustwithstandthermalvariaConsinGEOorbitandlaunchof-65Cto
125C.
• Whattypeoftestdidyoucomplete?Whatdocumenta@onorspecoutlinedtestrequirements?• ThermalcyclingperMILSTD883method2050programclassK
• Whatarethekeyvariablesinthetest?• 50cycleseachwith10minutesat-65Cand20minutesat120C
• Howdoesyouranalysisshowthisrequirementhasbeenvalidated?• VisualinspecConbeforeandaXertesttoensurenocracksordelaminaConin
electroniccircuitsperMILSTD883method2010programclassK• ElectronicburnouttestbeforeandaXerthermalcyclingtoensureelectrical
performancemeetsprogramspecsperclassK
FabricationPackage• FabricaConPackage–Drawings(asAppendixwithinreport).ThissecConshouldfocussolelyonthedetailsofthefabricaCon,assemblyof,andmanufactureofyourdesign,asifthissecCon,asastand-alonedocument,wouldbeprovidedtoamanufacturer.ItshouldNOTbeintroducingordescribingfuncCons,specificaCons,etc.• Provideassemblyviewdrawing(s),explodedviews,etc.• Providefullydimensionedworkingdrawingsforthecustompartsofyourdesign
• ProvideadetailedBillorMaterialsand/orpartslist,includingvendors,partnumbersandprice
TopMistakesNewGradsMake• ChiefEngineersandDirectorsforHamiltonSundstrandUTC
• TurninworkforgradinginsteadofcompleCon
• PresentaConandreportclarity• Itdoesn’tmaherhowsmartyouareifyoucannotexplainit
• Workhard
• StressAnalysts• FBDiswrong• UnderstandingthedifferencebetweenprincipalandeffecCvestresses• BoundarycondiConsarewrong• MaterialproperCesarenotfromthecorrectsource