The DLR Concurrent Engineering Facility (CEF)

The DLR Concurrent Engineering Facility

(CEF)

January 2011

Andy Braukhane

DLR Institute of Space Systems

Overview

DLR Institute of Space Systems

System Analysis Space Segment (SARA)

Concurrent Engineering (CE)

The Facility

The Team

Phases (of the CE-process)

DLR Approach

CEF Evolution

Design Model

Tools

Studies

Conclusions

Outlook

Further Information

Source: Wilke, 2002

DLR Institute of Space Systems – Overview

New DLR - Institute in Bremen

System Analysis

- Analyses and evaluation of complex space systems with respect to technical, economical and political aspects

System Technology

- Systems Engineering for space crafts and their applications; Research and Development within specific technology areas

Projects

- Co-operations with other DLR institutes, Universities and Research Facilities as well as Industry

CEF

_CEF

DLR Institute of Space Systems – Departments

System Analysis Space Segment System Conditioning Central Avionics System Analysis Space Transportation Navigation- & Controlsystems Transport Systems Orbital Systems & Securitity Exploration Systems & Scientific Missions

System Analysis Space Segment (SARA)

3 Core Areas

System Evaluation and Cost Orbital- and Mission Analysis

System concepts and Concurrent Engineering

Current Project & Activities (excerpt):

Concurrent Engineering Facility (CEF) operation Knowledge Capitalization (ESA-Project)

Data bases for space systems, its subsystems, components and parameters

Small satellite development, e.g.: CLAVIS; AISat Compact satellites, e.g.: AsteroidFinder; CarbonSat

Cost- and mission analysis Concurrent Engineering

Concurrent Engineering – Introduction (1/2)

Conventional Design / Engineering Processes

Centralized Engineering:

Sequential Engineering (with iterations):

Configuration Power Thermal

iteration Power AOCS Configuration Thermal Project Manager/ Systems Engineer Source: ESA Source: ESA

Concurrent Engineering – Introduction (2/2)

Concurrent Design / Engineering Process

The five key elements:

Project Manager/ Systems Engineer

Configuration _Power

AOCS Thermal

- Interdisciplinary expert team

- CE - process

- Integrated Design Model

- Facility / Infrastructure

- Tools (e.g. S/W; Multi-Media)

Concurrent Engineering – What is that? (1/2)

Systems Engineering technique for design, development and technical management

Systematic approach for integrated product development Formalization of the iterative development process

Concurrent (simultaneous) work on a common problem Active involvement of all disciplines and the customer

Focusses primarily on the early phases of a space project

Who does that?

Agencies and research institutes

e.g.: NASA (JPL & GSFC), ESA, DLR, ASI, CNES, JAXA

Industry

e.g.: EADS Astrium, Thales Alenia Space (TAS), J-CDS

Universities

Concurrent Engineering – What is that? (2/2)

Benefits at a glance

Involvement of all disciplines Customer participation

Highly iterative

Common understanding of the problem Immediate design change implementation Quick data exchange

Unambiguous parameters with pre-defined units

Source: vocabase.com Source: JAQAR Concurrent Design Services (J-CDS)

 reduces cost  reduces time  reduces failures

 increases consistency  increases quality

The Facility – Introduction

The Concurrent Engineering Facility is…

… a System Analysis Laboratory … a DLR major research institution

… dedicated for DLR internal as well as external studies / activities

The Concurrent Engineering Facility has…

… 3 design rooms with 21 work stations in total … a secure network

… 2 common servers (Windows; Linux) … a Tandberg videoconference system … a media management system

… a knowledge management system … public LAN/WLAN access

The Facility – Main Design Room (1/2)

Set-up example

The Facility – Main Design Room (2/2)

3 Screens (2x Plasma, 1x Smartboard)

3 Screens (2x Plasma, 1x Smartboard)

12 flexible Work Stations

The Team

The CEF Core Team (i.e. members of SARA dept.) include e.g.:

Team Leader / Moderator

Systems Engineer; Systems Assistant

Optional: Mission, Cost, Risk, … (could also be a domain experts) CEF IT-Manager

Domain experts can be from…

DLR Bremen,

other DLR Institutes, or external institutions

Customers (e.g. PI) can be

Internal departments Agencies (DLR; ESA) Industry / Universities

Phases – Description (1/2)

#1 - Initiation Phase (starts months before using the CEF)

“Customer” (internal group, scientists, industry) contacts CE-team CE-team – customer negotiations

Expected results definition (study objectives) Identification of required disciplines

#2 - Preparation Phase (starts weeks before using the CEF)

Definition of mission objectives (with customer)

Definition of mission and system requirements (with customer) Identification and selection of system concept(s)

Initial mission analysis (if applicable, e. g. based on STK)

Phases – Description (2/2)

#3 - Study Phase (1-3 weeks in the facility)

K/O with presentations of study key elements (goals, requirements) Starting with first configuration approach and estimation of budgets (mass, power, volume, modes, …) on subsystem level

Iterations on subsystem and equipment level in several sessions (2- 4 hours each); e.g. trading of several options

In between offline work: subsystem design in splinter groups Final Presentation of all disciplines / subsystems

#4 – Post-processing Phase

Collecting of Results (each S/S provides input to book captain) Evaluation and documentation of results

Transfer open issues to further project work

DLR Approach – 2 week study example

Session: Moderated (in Main Design Room); data exchange

Post-processing: Free discussions & analyses; working groups

1 week has advantages and disadvantages:

more condensed and focussed; less disturbances (e.g. other projects) less analyses time  requires more effort before and after study

 Approach will be adapted according to personnel and time availability

DLR Approach – 1 week study example

CE-session at preliminary CE-Facility Presentation Screen 1 Presentation Screen 2 Interactive Smartboard Switch Work stations LEL – Conf. Am B C Presentation Screen 1 Presentation Screen 2 Interactive Smartboard Switch Work stations LEL – Conf. Am B C

CE-Coaching with ESA / JAQAR

“Design Work Shop“ (DWS) for CE-Process training S/W output sheet with CE-results Lessons Learned Lessons Learned Lessons Learned Lessons Learned

CEF – Evolution (1/2)

Design Model – Example: ESA „IDM“

Integrated Design Model (IDM)

developed by ESA

MS Excel-based Phase 0 / A

Centralized data pool

Data_exchange.xls

Sheets, e.g.

Input

Calculation

Budgets (e.g. mass) Output

Equipment Summary

1 workbook / discipline Satellite missions

Design Model – Example: „VirSat“ (1/2)

Virtual Satellite (VirSat)

Development at DLR-SC

Simultaneous (controlled) access of all disciplines Contains library with parametric units

Flexible Tree-view

Drag and Drop from

component- to current

study-repository

Data storage via „Subversion (SVN)“ uses SMP2-Standard

based on Eclipse

Component 

_{Quelle: TSTI}

Library

Component 

Library

Quelle: DLR-SC

“System breakdown”

“System breakdown”

Tools

Domain specific and general S/W (systems) installed among others on

CEF work stations:

Additional S/W can be installed on request

Mission Satellite Toolkit (STK), version 9/10

Configuration CATIA V5 R19

Cost Small Satellite Cost Model 2007

OS Windows XP Professional

Documentation Microsoft Office 2003

Simulation Matlab/Simulink

All AGI Viewer

S/W = Software OS = Operating System

Studies – Results

Snapshots from the study phase…

L

Mission Analysis

SBC Filter Diplexer A Diplexer B 3dB Coupler RX A S-Band RS422 RX A S-Band RS422 TX A S-Band RS422 TX A S-Band RS422 RX B S-Band RS422 RX B S-Band RS422 TX B S-Band RS422 TX B S-Band RS422 TX A X-Band LVDS TX A X-Band LVDS Low Gain

S-Band Low GainS-Band

High Gain X-Band TX B X-Band LVDS TX B X-Band LVDS Transfer Switch

Telecom.

Power

Budget

Cost

Configuration

Cryo-Kick-Stage (Aldebaran) AsteroidFinder

Studies – Examples (1/3)

In 2008 (* supported by ESA-CDF Team Leader):

Lunar Exploration Lander (in ESTEC-CDF)*

Asteroid Finder I (DWS I)*

Asteroid Finder II (DWS I)*

Lander Package Impacting a Seismometer (LAPIS) (DWS II)*

Cryogenic Kick Stage Study (DWS II)

Studies – Examples (2/3)

In 2009:

AMSAT – P5

MASCOT

MASCOT-XS

AMSAT-Moon (with AMSAT-DL)

VENUS-II_1 (with Astrium)

AMSAT-Mars (with AMSAT-DL)

Studies – Examples (3/3)

In 2010:

MASCOT-DK

VENUS-II_2 (with Astrium)

Compass-II (with FH Aachen)

MallCom (with Y/T)

AHAB (with IUP)

CLAVIS

Conclusions

Concurrent Engineering

- Reduces development cost (by factor 2) and time (by factor 4)

- Minimizes failures  increases consistency

- Mutual education („system view“)

- Very helpful in the early design phases (i.e. Phase 0 / A)

Its all about the Team…

- Data models, tools and infrastructure support the process

- Various models possible / available / under development

- Increased engineers and scientists communication

Other (actual & potential) sectors and applications

- Aeronautics, car industry

- Oil- and gas; offshore plants

- Civil engineering; architecture

Outlook

Process application to higher project phases (Phase B and beyond)

- Integration of the team, models and infrastructure across the entire project life-cycle including disposal

Increased cross-linking of S/W and design model

- Connection of domain specifc tools (DST)

- Advanced Model-based System Engineering (MBSE)

- Virtual pre-views; automatic 3D-models based on parameters

Implementation of internal data bases into the design models

- DLR Space Suppliers and Manufacturers Database (SSAM)

- DLR Concurrent Engineering Reference Database (CERD)

Closer co-operation on national & international level

- Linking of CE-facilities for joint studies

Further Information

DLR CEF Website

http://www.dlr.de/irs/en/desktopdefault.aspx/tabid-7174/ English version to be updated…

Publications

http://elib.dlr.de/56028/1/Status_of_the_Concurrent_Engineering_Facility_at_DLR_Bremen.pdf http://elib.dlr.de/66373/1/Schumann_CSER2010.pdf

http://elib.dlr.de/65913/1/SCHAUS_PAPER.pdf

ESA Concurrent Design Facility (CDF)

http://www.esa.int/esaMI/CDF/index.html

NASA Facilities

JPL - TeamX: http://jplteamx.jpl.nasa.gov/ GSFC – IDC: http://idc.nasa.gov/

JPL = Jet Propulsion Laboratory GSFC = Goddard Space Flight Center IDC = Integrated Design Center

Thank you very much for your attention!

Any questions?

Thank you very much for your attention!

Any questions?

Andy Braukhane

System Analysis Space Segment DLR Institute of Space Systems

+49 421 24420 123 [email protected]