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Transcript of Evolution of MDO at Bombardier...
Evolution of MDO at Bombardier Aerospace
Pat Piperni
MDO Project Manager
Bombardier Aerospace
Montreal, Canada
6th Research Consortium for Multidisciplinary System Design Workshop
Ann Arbor, Michigan
July 26th - 27th, 2011
2
Contents
Background
Bombardier Aircraft Portfolio
History of MDO at Bombardier Aerospace
Expansion to Multi-Level MDO
MDO governance
Development of Conceptual MDO
Tools & processes
Sample optimization results
Future Development
3
LEARJET 60 XR
Bombardier Aircraft Portfolio
CRJ 700Q 400 CRJ 950 CRJ 1000 CSeries
CHALLENGER 300 CHALLENGER 605 CHALLENGER 850
LEARJET 40 XR LEARJET 45 XR LEARJET 85
GLOBAL 6000 GLOBAL 7000 GLOBAL 8000GLOBAL 5000
LEARJET 60
4
History of MDO Development at Bombardier Aerospace
MDO development at
Bombardier Aerospace was
initiated in the Advanced
Aerodynamics Dept. ~ FY 2000
This capability is being used to
perform aero-structural
optimizations of aircraft wings
Applied to recent Bombardier
aircraft (Lear85, CSeries,
GX7000-8000); does not
supplant manual design, but
adds significant capability to the
design tool kit
Initial scope: assumed fixed a/c
and engine architecture,
snowball effects not captured,
integration of systems not
addressed, business case not
optimized
5
Multi-
Disciplinary
Optimization
StructuresStructures
SystemsSystems
Aerodynamics Aerodynamics
OptimizerOptimizer
MaterialsMaterials
Composite
Metal
LoadsLoads
KEAS
VD
VCVA
2.5
Load
factor
KEAS
VD
VCVA
2.5
Load
factor
Aircraft
Performance
Aircraft
Performance
High-
Performance
Computing
High-
Performance
Computing
Sector Distance
Flight Time & Fuel
Block Time & Fuel
En route Climb
Descent
Approach &
Landing
1500 ft
Initial Cruise
Step Cruise
Takeoff &
Initial ClimbStart-up
&
Taxi-out
Taxi-in
Multi-
Disciplinary
Optimization
StructuresStructures
SystemsSystems
Aerodynamics Aerodynamics
OptimizerOptimizer
MaterialsMaterials
Composite
Metal
Composite
Metal
LoadsLoads
KEAS
VD
VCVA
2.5
Load
factor
KEAS
VD
VCVA
2.5
Load
factor
Aircraft
Performance
Aircraft
Performance
High-
Performance
Computing
High-
Performance
Computing
Sector Distance
Flight Time & Fuel
Block Time & Fuel
En route Climb
Descent
Approach &
Landing
1500 ft
Initial Cruise
Step Cruise
Takeoff &
Initial ClimbStart-up
&
Taxi-out
Taxi-in
Further Development of Aero-Structural Optimization
The aero-structural optimization capability is being further developed with
high-fidelity tools and increasing realism in the problem formulation
6
Expansion of MDO within the
Bombardier Engineering System (BES)
APSB - A/C portfolio strategy
Different tools are needed for different
aircraft design stages
The appropriate level of detail must be
employed at each stage
MDO must be deployed incrementally, as
an evolution of existing engineering
methods
Problem formulation is key, and must be
developed by subject matter experts
7
MDO Levels and Objectives at Bombardier Aerospace
Conceptual MDO (APSB Stages 0-1, BES D1)
– Process owner: Advanced Design
– Objectives: Design space exploration, optimization of MR&O and Business Case,
sizing of airframe and engine, integration of major systems, and
optimization of operations; development of design knowledge,
down-selection to promising configurations, and definition of performance targets
Preliminary MDO (BES D1-D2)
– Process owner: Advanced Aerodynamics
– Objectives: Application of high-fidelity MDO to develop detailed aero lines of the
configuration defined in Conceptual MDO; validation of Conceptual
MDO, and further development of configuration and design knowledge
Detail MDO (BES D2-D4)
– Process owner: Advanced Structures
– Objectives: Application of high-fidelity MDO to develop detailed structure based on
configuration and aero lines developed above; validation of Conceptual &
Preliminary MDO, and further development of configuration and design knowledge
Multiple departments contribute at each MDO level, in iterative process:
– Adv. Design, Aerodynamics, Structures, Loads & Dynamics, Systems,
Flight Sciences, Acoustics, Product Planning, etc.
8
MDO Governance
VP Core Engineering
Steering Committee of Engineering Directors
MDO Project manager
PLM rep
CMDO lead
(Adv. Design)
PMDO Lead
(Adv. Aero)
DMDO lead
(Structures)
MDO focal, Loads
MDO focal, Dynamics
Other MDO focals
(TBD)
(e.g. Systems, Flight
Sciences, Acoustics,
Marketing / Finance, etc.)
9
MDO in the Conceptual Design Environment
Rubber Engine
(GASTURB)
Configuration
Database
( CATALIST,
SKY.NET )
Economics
( LCC /RC /NRC)
Aerodynamics
Structures
Multi-Objective
Optimizer
Aircraft &
Engine Noise
A/C Perf. & S&C
(CASPr, SCIPr)
Cabin layout &
Systems
Integration
Weight &
Balance
Flutter &
Aeroelasticity
- Accuracy and robustness of
analysis tools must be enhanced
and manual processes automated
for the optimization environment
- A multi-fidelity, variable
complexity approach is
used, including empirical
methods, surrogate models,
and physics-based analysis
tools, as appropriate
- The goal is to include all critical
disciplines in optimization
environment, including both
technical and financial metrics
10
CATALIST - Aircraft Parametric Modeler
CATia Advanced Design Linking & Iteration Software & Tool
• Rapid Parametric Modeling
using CATIA Automation
• Large library of scalable, pre-
defined components available
(seats, windows, LDGs, etc.)
• Complete a/c can be modeled
in <1-2 days
• Over 140 a/c have been
modeled
11
CATALIST - Aircraft Parametric Modeler
CATia Advanced Design Linking & Iteration Software & Tool
Automated process from
CAD-based geometry to
analysis tools
12
Simultaneous MDO of
Airframe and Engine Architecture
Working more closely
with engine suppliers to
couple the airframe-
engine design process
Long-term goal:
business-to-business
optimization with major
partners
Current Rubber Engine Modeling
13
Automation of all Aircraft Major Systems in MDO:
e.g. Landing Gears
A/C LG Actual
Height
Prediction %Error
CL-605 54.81 54.053 1.38%
GX 68.706 68.299 0.59%
CS-100 121.96 121.278 0.56%
CL-300 54.81 54.618 0.35%
A/C Actual
% MAC
Prediction
% MAC
%MAC
Error
CL-605 49.43% 50.04% -0.61%
GX 55.40% 54.93% 0.47%
CS-100 55.55% 55.00% 0.55%
CL-300 54.53% 53.54% 0.99%
Keel Beam
Rear Spar
Aux. Spar
Cabin
Floor
Landing gear height and position prediction within 1-2%
Keel
Beam
Belly
Fairing
Floor
Minimal distances
between the gear
and its envelope 90o -95o
angle
Automated Kinematics
Automated sizing of
struts, tires, and brakes
16
Evolutionary Multi-Objective Optimizations Now Routine
Aircraft Population Size = 100; 200 Generations, 20,000 Iterations.
17
Current Developments: Optimization of
Family Concepts with Varying Degree of Commonality
Mission
Profiles
18
MDO: 5-Year RoadmapM
ult
i -
Dis
cip
lin
ary
Op
tim
iza
tio
n
Ca
pa
bilit
y
2011 2012 2013 2014 2015
Conceptual MDO: A/C Family Opt., Cost Models, Crit. Airports
Preliminary MDO: Multi-Fidelity Aero-Structural Optimization
Conceptual MDO: + Noise, Emissions, A/C Systems
Preliminary MDO: Hi-Fidelity Aero-Structural Opt.
Detail MDO: Integrate Wing FEM & Loads Filtering
Conceptual MDO: Concurrent Optimization of Configurations & Operations
Preliminary MDO: Multi-Point & Off-Design Hi-Fidelity Aero-Structural Opt.
Detail MDO: Integrate Fuselage FEM & Wing-to-Fuse Attachment
Multi-
Disciplinary
Optimization
StructuresStructures
SystemsSystems
Aerodynamics Aerodynamics
OptimizerOptimizer
MaterialsMaterials
Composite
Metal
LoadsLoads
KEAS
VD
VCVA
2.5
Load
factor
KEAS
VD
VCVA
2.5
Load
factor
Aircraft
Performance
Aircraft
Performance
High-
Performance
Computing
High-
Performance
Computing
Sector Distance
Flight Time & Fuel
Block Time & Fuel
En route Climb
Descent
Approach &
Landing
1500 ft
Initial Cruise
Step Cruise
Takeoff &
Initial ClimbStart-up
&
Taxi-out
Taxi-in
Multi-
Disciplinary
Optimization
StructuresStructures
SystemsSystems
Aerodynamics Aerodynamics
OptimizerOptimizer
MaterialsMaterials
Composite
Metal
Composite
Metal
LoadsLoads
KEAS
VD
VCVA
2.5
Load
factor
KEAS
VD
VCVA
2.5
Load
factor
Aircraft
Performance
Aircraft
Performance
High-
Performance
Computing
High-
Performance
Computing
Sector Distance
Flight Time & Fuel
Block Time & Fuel
En route Climb
Descent
Approach &
Landing
1500 ft
Initial Cruise
Step Cruise
Takeoff &
Initial ClimbStart-up
&
Taxi-out
Taxi-in
Integrate Multi-Level MDO Capability :
Connect CMDO & PMDO & DMDO
processes in multiple Bombardier sites
with centralized Optimization Server Conceptual MDO: Optimization of Business Case; Uncertainty
Preliminary MDO: Integrate Dynamic Aero-Elastics
Detail MDO: Increase # of Load Cases; Gear Optimization
Conceptual MDO: Business-to-Business Optimization
Preliminary MDO: Integrate CFD-based S&C in Optimization
Detail MDO: Integrate Airframe Systems in Structural Opt.