Design Engineering – A need to automate ‘The Need for More Speed’

Design Engineering – A need to automate Professor Craig Chapman is Associate Head of Research and Head of Knowledge Based Engineering at Birmingham City University Carl Barcock is Chief of Design Methods, Design Systems Engineering at Rolls-Royce Plc The Need for Speed Knowledge Based Engineering Industrial Examples Presentation Outline =

© 2012 Rolls-Royce plc The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc. This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies. 20 th June 2013 Rolls-Royce proprietary information Change to ‘Trusted to deliver excellence’

20 th June 2013 Rolls-Royce proprietary information Group profile

20 th June 2013 Rolls-Royce proprietary information We expect to double turnover in the next ten years

20 th June 2013 Rolls-Royce proprietary information Civil aerospace

20 th June 2013 Rolls-Royce proprietary information Success Speed is needed Speed gives you options

20 th June 2013 Rolls-Royce proprietary information Design is Complex The design process feels a bit like this, but

20 th June 2013 Rolls-Royce proprietary information Actually it looks like this One subsystem, x8 for whole engine Many inter-dependencies between subsystems

20 th June 2013 Rolls-Royce proprietary information Challenges It is now not possible to design a competitive gas turbine without the extensive use of Simulation To keep competitive requires us to develop our capability at an increasing rate. Hence we Need Speed in automation and integration of simulation tools, methods & the embedding of knowledge. ie the creation of ‘Design Systems’ 10

20 th June 2013 Rolls-Royce proprietary information 11 What’s the motivation for Simulation? Design better products – higher performing, lighter, cheaper, more reliable, less polluting…… Design more effectively and efficiently – speed through automation, better accuracy…… Replace testing by Simulation to cut development costs. Make more effectively and efficiently - reduce scrap and rework in production. Over to Craig 

Question – Do You MAKE Stuff? Then your doing Knowledge Based Engineering Knowledge Based Engineering Lab

“Virtual Engineering is aimed at allowing the synthesis, analysis, evaluation and optimal development of a product in a computer environment that mimics the understanding and behaviour of the solution to the realization of that solution in reality”. Virtual Engineering Consider all the other required models - FEM, Physics, cost, process – are they coupled Knowledge Based Engineering Lab

Legislative standards Multiple topologies Its never really been about the ‘Geometry is the Master Model’ & associated documentation - Consider a Simple Shaft Cost Rules Standard bar size Material cost (type, volume, economic batch size) Direct labour costs Overhead costs per machine (machine/hr rate) Lowest cost route Extras pricing band Manufacturing Rules Machine capacities Machine capacity (tolerance) Machine set-up times NC tool path information Grinding allowances Tooling availability Material availability Fastest throughput, route Material type Engineering Rules Bearing size to suit shaft diameter Bearing life to suit load and life requirements Calculation of bearing life Tapped end hole to suit shaft diameter Tap length to engineering standards Surface finish to suit auxiliary components e.g. Oil seal Calculation of max permissible load (load type: radial, axial, combination) Weld calculations (possible/strength) for hybrid shafts Shaft diameter for brake size Fan or non-fan vented Keyway size to suit diameter Tolerance to suit required standard and final assembly Material properties Thread and keyway standards Motor output and phase Geometric Rules Extension overall length Shaft overall length Extension diameter Keyway length Keyway width Bearing diameter Rotor groove positions Fan area diameter Chamfer dimensions Fillet dimensions Undercut dimensions Number of extension segments Multiple Model Requirements Engineering Processes Knowledge Based Engineering Lab

The best way to Understand is by real world examples Knowledge Based Engineering Lab

© 2012 Rolls-Royce plc The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc. This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies. 20 th June 2013 Rolls-Royce proprietary information Example of KBE: A Leaner Process Old Process without KBE System New Process with KBE System

© 2012 Rolls-Royce plc The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc. This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies. 20 th June 2013 Rolls-Royce proprietary information Usage and Benefits Delivered: Fan Used on civil and military NPI programmes £0.5M net benefit to-date in Design and Manufacturing Engineering modelling activities (technical time) system developed in 4 months 10 fold increase in engineering productivity Over 40% reduction in overall engineering lead time 99% reduction in modelling time for design geometry & finite element mesh 99% reduction modelling time for manufacturing stage & tooling geometry 50% reduction in design staff used 100 fold reduction in the number of CAD geometry entities handled by the engineer: 950 surfaces & solid (7000 geometric entities) down to 7 major features, thus reducing scope for human and digital error Less material used on flat packs & dies 10 fold reduction in data storage requirements Reverse engineer

Chrysler uses a system known as Knowledge Based Engineering, a combination of software tools and engineering data. The program can run simulations to test parts and then adjust those parts instantly. But it goes further than most computer- assisted design programs; it can also adjust every part a new piece touches -- looking at the entire vehicle. Chrysler's new Dodge Challenger was completed in 21 months, trimming nearly a year off the time it takes to complete most vehicles. "What literally took months can now be done in weeks," said Pamela Larson, manager of rear-wheel drive virtual development. "Instead of spending our time developing many things, we're refining it." Knowledge Based Engineering Lab

Gimbal Design and Synthesis Lockheed Martin\TechnoSoft Inc Knowledge Based Engineering Lab

Anything in common? Knowledge Based Engineering Lab Think STEM Domain Knowledge Application Knowledge CaptureReuseReal Time CollaborationIntegrate

A Framework for knowledge Knowledge Based Engineering Lab

High Fidelity Physics Nonlinear Aerodynamics FEM & Flight Loads Structural Sizing Smart Product Model - Geometry & analysis models associative - Environment to operate with COTS & LM Aero production tools - System level assessments extract data from analysis models via smart product model Mission Simulation Combat Effectiveness / Airframe Cost Ratio Scenario Based Structural Configuration and Sizing Airframe Modeling & Simulation Knowledge Based Engineering Lab

Proven Technology

Knowledge Based Engineering Lab The UK’s First Dedicated Knowledge Based Engineering Lab Knowledge Transfer Research Commercial Education Give time back to the Engineer to Engineer and the creative, the tools to discover

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