The DLR Concurrent Engineering Facility (CEF)
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1 The DLR Concurrent Engineering Facility (CEF) January 2011 Andy Braukhane DLR Institute of Space Systems System Analysis Space Segment Slide 1
2 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 Slide 2
3 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 Slide 3
4 DLR Institute of Space Systems Departments CEF System Analysis Space Segment System Analysis Space Transportation Navigation- & Controlsystems System Conditioning Transport Systems Exploration Systems & Scientific Missions Central Avionics Orbital Systems & Securitity Slide 4
5 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 Slide 5
6 Concurrent Engineering Introduction (1/2) Conventional Design / Engineering Processes Sequential Engineering (with iterations): Configuration Power Thermal Source: ESA iteration Centralized Engineering: Configuration Power Project Manager/ Systems Engineer Thermal AOCS Source: ESA Slide 6
7 Concurrent Engineering Introduction (2/2) Concurrent Design / Engineering Process Configuration Project Manager/ Systems Engineer Power Thermal AOCS Source: ESA The five key elements: - Interdisciplinary expert team - CE - process - Integrated Design Model - Facility / Infrastructure - Tools (e.g. S/W; Multi-Media) Slide 7
8 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 e.g.: TU Munich, MIT, Stanford; Cranfield; La Sapienza Slide 8
9 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 reduces cost reduces time reduces failures increases consistency increases quality Source: JAQAR Concurrent Design Services (J-CDS) Source: vocabase.com Slide 9
10 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 access to an internal component data base Slide 10
11 The Facility Overview Slide 11
12 The Facility Main Design Room (1/2) Set-up example Slide 12
13 The Facility Main Design Room (2/2) 3 Screens (2x Plasma, 1x Smartboard) 12 flexible Work Stations Slide 13
14 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 PI = Principal Investigator Slide 14
15 Phases Overview Slide 15
16 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) Final definition and invitation of expert ensemble, agenda definition Slide 16
17 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 Implementation of lessons learnt into the CE-process Slide 17
18 DLR Approach 2 week study example Session: Post-processing: Final Presentation: Moderated (in Main Design Room); data exchange Free discussions & analyses; working groups Presentation, evaluation and comparison of results Slide 18
19 DLR Approach 1 week study example 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 Slide 19
20 CEF Evolution (1/2) CE-session at preliminary CE-Facility Presentation Screen 1 Interactive Smartboard Presentation Screen 2 C Design Work Shop (DWS) for CE-Process training B LEL Conf. Am Switch Work stations CE-Coaching with ESA / JAQAR Lessons Learned Lessons Learned Lessons Learned S/W output sheet with CE-results Lessons Learned Slide 20
21 CEF Evolution (2/2) Slide 21
22 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 Slide 22
23 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 System breakdown Component Library Quelle: TSTI Quelle: DLR-SC Slide 23
24 Design Model Example: VirSat (2/2) Slide 24
25 Tools Domain specific and general S/W (systems) installed among others on CEF work stations: 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 All Matlab/Simulink AGI Viewer Additional S/W can be installed on request S/W = Software OS = Operating System Slide 25
26 Studies Results Snapshots from the study phase SBC L RS422 RX A S-Band RS422 TX A S-Band RS422 RX B S-Band RS422 TX B S-Band LVDS TX B X-Band LVDS TX A X-Band Diplexer A Diplexer B Power Budget Cryo-Kick-Stage (Aldebaran) 3dB Coupler Telecom. Transfer Switch Filter Low Gain S-Band Low Gain S-Band High Gain X-Band Mission Analysis Configuration Cost AsteroidFinder Slide 26
27 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) Asteroid Finder III (Review in DSW II)* Slide 27
28 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) CarbonSat (with IUP Bremen) Slide 28
29 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 SolmeX (with Max-Planck) Slide 29
30 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 - Software engineering Slide 30
31 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 - Standardization of models, parameters and procedures Slide 31
32 Further Information DLR CEF Website English version to be updated Publications ESA Concurrent Design Facility (CDF) NASA Facilities JPL - TeamX: GSFC IDC: JPL = Jet Propulsion Laboratory GSFC = Goddard Space Flight Center IDC = Integrated Design Center Slide 32
33 Thank you very much for your attention! Any questions? Andy Braukhane System Analysis Space Segment DLR Institute of Space Systems Source: University of Erfurt Slide 33
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