Evolution of MDO at Bombardier Aerospace 6 th Research Consortium for Multidisciplinary System Design Workshop Ann Arbor, Michigan July 26 th - 27 th, 2011 Pat Piperni MDO Project Manager Bombardier Aerospace Montreal, Canada
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 2
Bombardier Aircraft Portfolio LEARJET 40 XR LEARJET 45 XR LEARJET 60 LEARJET 85 LEARJET 60 XR CHALLENGER 300 CHALLENGER 605 CHALLENGER 850 GLOBAL 5000 GLOBAL 6000 GLOBAL 7000 GLOBAL 8000 Q 400 CRJ 700 CRJ 950 CRJ 1000 CSeries 3
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 4
Further Development of Aero-Structural Optimization Step Cruise Initial Cruise Descent En route Climb 1500 ft Start-up & Taxi-out Takeoff & Initial Climb Sector Distance Flight Time & Fuel Block Time & Fuel Approach & Landing Taxi-in Aircraft Performance Systems High- Performance Computing Load factor 2.5 V A V C KEAS V D Loads Multi- Disciplinary Optimization Optimizer Aerodynamics Materials Structures Composite Metal The aero-structural optimization capability is being further developed with high-fidelity tools and increasing realism in the problem formulation 5
Expansion of MDO within the Bombardier Engineering System (BES) 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 APSB - A/C portfolio strategy 6
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. 7
MDO Governance VP Core Engineering Steering Committee of Engineering Directors MDO Project manager PLM rep MDO focal, Loads CMDO lead (Adv. Design) PMDO Lead (Adv. Aero) DMDO lead (Structures) MDO focal, Dynamics Other MDO focals (TBD) (e.g. Systems, Flight Sciences, Acoustics, Marketing / Finance, etc.) 8
MDO in the Conceptual Design Environment - Accuracy and robustness of Economics analysis tools must be enhanced and manual processes automated for the optimization environment Aerodynamics ( LCC /RC /NRC) Cabin layout & Systems Integration - A multi-fidelity, variable complexity approach is used, including empirical methods, surrogate models, Structures Configuration Database A/C Perf. & S&C (CASPr, SCIPr) and physics-based analysis tools, as appropriate - The goal is to include all critical Weight & Balance ( CATALIST, SKY.NET ) Flutter & Aeroelasticity disciplines in optimization environment, including both technical and financial metrics Rubber Engine (GASTURB) Aircraft & Engine Noise Multi-Objective Optimizer 9
CATALIST - Aircraft Parametric Modeler CATia Advanced Design Linking & Iteration Software & Tool Rapid Parametric Modeling using CATIA Automation Large library of scalable, predefined components available (seats, windows, LDGs, etc.) Complete a/c can be modeled in <1-2 days Over 140 a/c have been modeled 10
CATALIST - Aircraft Parametric Modeler CATia Advanced Design Linking & Iteration Software & Tool Automated process from CAD-based geometry to analysis tools 11
Simultaneous MDO of Airframe and Engine Architecture Working more closely with engine suppliers to couple the airframeengine design process Current Rubber Engine Modeling Long-term goal: business-to-business optimization with major partners 12
Automation of all Aircraft Major Systems in MDO: e.g. Landing Gears Cabin Floor Rear Spar Automated Kinematics Floor Aux. Spar Keel Beam Keel Beam Automated sizing of struts, tires, and brakes 90 o -95 o angle Minimal distances between the gear and its envelope Belly Fairing A/C LG Actual Height Prediction %Error A/C Actual % MAC Prediction % MAC %MAC 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% 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% Landing gear height and position prediction within 1-2% 13
Optimization Workflow in ISIGHT 14
Sample Video of MDO Process 15
Evolutionary Multi-Objective Optimizations Now Routine Aircraft Population Size = 100; 200 Generations, 20,000 Iterations. 16
Current Developments: Optimization of Family Concepts with Varying Degree of Commonality Mission Profiles 17
Multi - Disciplinary Optimization Capability MDO: 5-Year Roadmap Structures Conceptual MDO: Business-to-Business Optimization Preliminary MDO: Integrate CFD-based S&C in Optimization Detail MDO: Integrate Airframe Systems in Structural Opt. 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: 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 Conceptual MDO: + Noise, Emissions, A/C Systems Preliminary MDO: Hi-Fidelity Aero-Structural Opt. Detail MDO: Integrate Wing FEM & Loads Filtering Conceptual MDO: A/C Family Opt., Cost Models, Crit. Airports Preliminary MDO: Multi-Fidelity Aero-Structural Optimization 2011 2012 2013 2014 2015 18
Questions? 19