EDU DeKoning

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FENET THEMATIC NETWORK

COMPETITIVE AND SUSTAINABLE GROWTH

(GROWTH) PROGRAMME

FENET Technology Workshops13-14 J une 2002, Zurich, Switzerland

Industry Sector RTD Thematic Area Date

Aerospace Education and dissemination 14-J un-02

Space industry perspective on integration of CAD and CAE

[email protected] Space Agency

ESTEC / Mechanical Engineering Department

Thermal and Structures Division

Noordwijk, The Netherlands


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(GROWTH) PROGRAMME


Objectives of this presentation

To outline the context in which integration of CAD and CAE takes place

or should take place To give an assessment of the state of practice in space industry

To identify themes for the upcoming FENET Workshop, December 2002 in Prague"Integration Issues for Engineering Analysis Tools & Methods",subtitled: "Including CAD-FEM Data Transfer and Re-use Issues"

To give some examples of what is being done about it in space industry by ESA

NOTE: The field is so wide that this presentation should not be considered as a finalcomprehensive study of the the CAD/CAE integration issues in space industry, butrather as an attempt to highlight a number of the main issues and achievements.


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(GROWTH) PROGRAMME


Why integration of CAD and CAE (engineering analysis)?

To develop a product more efficiently and more effectively

To enable collaborative and concurrent engineering A lot of common data:

Product structure and configuration

hierarchical breakdown

identification of items / parts Basic geometry: main shapes and placement

Materials and material properties

To avoid duplication of work and to minimise inconsistencies

Define geometry and topology once and as much as possible in one place Reuse material assignments across analyses in multiple disciplines

Enable propagation of changes in controlled (semi-)automated manner

To maximise engineer-hours spent on genuine engineering analysis, as opposed to

tedious and error prone data conversion


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(GROWTH) PROGRAMME


State of practice in space industry (1/2)

Many engineering disciplines involved

System engineering, including: Requirement engineering

Risk assessment

Cost analysis

Mission analysis

Mechanical engineering Structural engineering

Thermal engineering

Electrical engineering

Optical engineering

Fluid dynamics engineering

Software engineering

Chemical engineering

Biological engineering

Human factors engineering

Many subsystems involved

Attitude and orbit control Electrical power

Propulsion

Mechanisms, pyros, robotics

Communications

Command and data handling

Instruments & sensors

Life support

Assembly and integration tools

Test facilities and equipment

Ground systems & operations


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(GROWTH) PROGRAMME


State of practice in space industry (2/2)

Regular transfer from CAD to structural FEA

Number of COTS pre-processors / meshers in use:e.g. MSC-PATRAN, EDS I-DEAS, EDS FEMAP, ANSYS

Regular transfer from CAD to CFD codes (COTS and proprietary)

Some transfer from CAD to thermal CAE (mostly proprietary or semi-commercial)

Some integration of analysis model management into PDM initiated Limited use of FEA capabilities inside CAD tools

Some (pilot?) use of CAD quality assessment / enhancement tools

e.g. Transcendata CADIQ, Theorem Solutions CADVerter

Little integration of MCAD and ECAD (e.g. for avionics boxes) Most integration scenarios limited to within one organisation

Not integrated in system engineering approach yet


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(GROWTH) PROGRAMME


Need to integrate with Product Data Management and System Engineering

Integrated development process must take whole product life cycle into account

In order to cope with the inherent complexity of space product developmentthe integrated development process needs:

a PDM function to stay in control of configurations, versions, change, releasestatus and to enable collaboration

a System Engineering (SE) approach to coordinate and ensure consistencybetween disciplines and subsystems, to maintain oversight and to enableoptimisation at system level

Issue: Current CAE tools hardly provide hooks for PDM and SE (meta-)data

CAE models and results are mostly managed as BLOBs,

possibly with some file naming convention and a timestamp


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(GROWTH) PROGRAMME


Issues with transfer / re-use of CAD geometry for analysis

Quality of CAD geometry not good enough for meshers

E.g. small overlaps, gaps, slivers, numerical inaccuracy for points/vertices CAD model needs to be cleaned and/or mesher enhanced

CAD model needs to be designed-for-analysis

I.e. feature or detail suppressing is feasible without too much hassle

In general this means a top-down CSG-like design approach

This may not be the typical, preferred way of working of the CAD engineer

CAD engineer needs to be trained to become analysis-aware

CAE models derived from CAD will in general contain more detail / elements / nodes

CAE tools need to be able to handle the larger numbers

Analysts need more capable pre- and post-processing tools Analysts need to be trained to communicate better with CAD engineers

Some model idealisation algorithms are available but need to be much improved

Different idealisations needed for different engineering analyses


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(GROWTH) PROGRAMME


Data flow in integrated CAD / CAE process related to life cycle stage

During initial / conceptual / preliminary design & analysis-for-design

Sketches / rough configurations from CAD to CAE Shape definition more from CAE to CAD

During detailed design & analysis-for-verification

Detailed 3D models from CAD to CAE

From CAD to CAE works (reasonably) well From CAE to CAD not so mature or only just starting

CADPre-

ProcessorCAE

SolverPost-

Processor


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(GROWTH) PROGRAMME


Need for open data exchange standards

Requirement to support complete product life cycle in integrated process

Life cycle can be 5 30 or more years, much longer than software tool lifetime Space products are always developed by large international teams

Inherently standardisation on one tool(set) is impossible

Therefore the integrated process architecture shall not depend on any specific tools or

tool-specific data formats Only way out is creation and use of reliable open data exchange standards

For file based exchange

For database access

For programming interfaces Open source software development model provides very effective means to promote

the efficient and reliable implemention of open data exchange standards


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(GROWTH) PROGRAMME


What is ESA doing (1/3) ECSS E-10-07 "Exchange of Product Data"

"European Cooperation for Space Standardization" www.ecss.nl

High level umbrella standard specifying clauses in following format:To exchange data from a representationto a representationfor transferring the standard shall be used.

Addresses all (useful) combinations of all ECSS disciplines

Tailorable list of clauses for use in specific space projects

Refers mainly to ISO 10303, STEP-based, XML-based standards

Similar approach in NASA-STD-2817 (for MCAD / MCAE)

"Computer-Aided Engineering, Design and Manufacturing Data Interchange Standards"Regular contacts with NASA PDE Working Group

Currently completing the WG Draft WG identifying gaps

Start of public review foreseen in 2002-Q3


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(GROWTH) PROGRAMME


What is ESA doing (2/3) NASA-ESA Aerospace PDE Workshop

3rd Workshop held April 9-12, 2002 at ESTEC

63 participants many leading experts in STEP and XML developments

All presentations and many further links available from website:http://www.estec.esa.int/conferences/aerospace-pde-2002

Annual workshop alternating between US and EuropeNext: April 2003 organised by NASA at NIST (near Washington DC)


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(GROWTH) PROGRAMME


What is ESA doing (3/3) STEP-TAS & STEP AP203 to thermal CAE

ESA developed STEP-TAS (Thermal Analysis for Space) protocol and promoted

implementation in all space thermal analysis tools (together with NASA) STEP-TAS Software Development Kit provided at nominal cost

ESA coordinated/funded heuristic filter to recover as much as possible primitive shapesfrom STEP AP203 CAD export (cylinders, discs, rectangles, spheres, )

If no primitive can be recovered then emit original NURBS shape First implementation tested with Catia v4 and ESARAD

ESARAD thermal-radiative raytracing solver enhanced to support NURBS faces

Will be made available free of charge

Future developments

More open PDE standards (o.a. for space environmental effects)

More filters with open standard input and output


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(GROWTH) PROGRAMME


Overview relevant open standards (1/2)

ISO 10303 / STEP

9 Part 11: EXPRESS data modelling language

9 Part 21: Physical file

9 Parts 22,23,24,26: C, C++, Java Programming I/Fs

9 Part 28: Link with XML and XMI data transfer

9 Parts 4x: Generic Resources: product structure, geometry, topology,

9 Parts 5x: Basic blocks engineering analysis: mathematical spaces, functions,

structured/unstructured meshings, properties, results data,

9 PDM schema

9 AP203: PDM + 3D explicit shapes

9 AP209: FE analysis

9 AP210: Electronic assemblies (avionics, PCBs, )

9 AP212: Electro-technical (harnesses, )

9 AP214: Automotive (AP203 + CSG, kinematics, )

9 AP221: Process plant (registries, STEPLib, multi-language)

9 AP232: Technical data packages

9 AP233: Systems engineering

9 AP237: CFD data

ISO 13584 / PLIB

9 STEP-compatible parts libraries

STEP-based standards (ESA developed)

9 STEP-TAS: Thermal Analysis for Space

9 STEP-NRF: Network-model Results Format

Basic ISO standards

9 ISO 31 & 1000: Quantities and units, SI

9 ISO 8879 SGML: Standard Generalized Markup

Language


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(GROWTH) PROGRAMME


Overview relevant open standards (2/2)

IETF

9 LDAP: Lightweight Directory Access Protocol

W3C standards

9 HTTP and URI/URL

9 HTML & XHTML

9 XML: eXtensible Markup Language

9 MathML: Mathematical Markup Language

9 XSL & XSLT & XPath: eXtensible Stylesheet Language

and XSL Transformations & Path

9 XML-Schema9 RDF: Resource Description Framework

Semantic Web

9 DOM: Domain Object Model

9 SOAP: Simple Object Access Protocol

Web Services based on HTTP and XML

9 PNG: Portable Network Graphics9 SVG: Scalable Vector Graphics

OMG standards

9 UML: Information System Modelling

9 CORBA: OO Distributed Processing

9 MDA: Model Driven Architecture

9 XMI: XML Metadata Interchange

9 MDTF: Manufacturing Domain Task Force

Web 3D Consortium

9 VRML: Virtual Reality Modeling Language

ISO/IEC 14772

Public domain standards

9 HDF: Hierarchical Data Format (NCSA)

9 NetCDF: Network Common Data Form (UCAR)


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(GROWTH) PROGRAMME


Open standards based integration between discipl ines (When? ;-)

System Engineering & PDMSystem Engineering & PDM

ERP & Integrated Logistics SupportERP & Integrated Logistics Support

CADCAD

CAE&Sim.

S

tructural

S

tructural

Thermal

T

hermal

......

E

lectrical

E

lectrical

Manufacturing

AssemblyIntegration

Test

Manufacturing

AssemblyIntegration

TestOpera-tional

support

Opera-tional

support

AP232

TDP

STEP-TAS AP210/AP212

AP203/AP209

AP203 CC4

STEP-NRF

PDM

schemaAP203

AP214

AP203 CC1AP203 CC1 PDM schema

PDM schemaAP203 CC1

AP203

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