How to Design Complex Aero Parts using the 3DEXPERIENCE Platform?

Designing aircrafts is becoming an increasingly complex task these days. As it becomes increasingly sophisticated, the wiring needed to power and control the electrical systems are also becoming complex.

Large OEMs and companies are dependent on electrical CAD systems which will enable them to execute the electrical diagram which will help in 3D Mock-Up and manufacturing preparation. This will help these OEMs and companies to lower production costs and also to reach the market faster than before.

What are the typical challenges with respect to Wire Harness?

  • Multi applications and different data sources
  • Time consuming, repetitive and error prone creation of electrical system
  • Lack of 3D integration with electrical system schematics which will lead to difficulty in understanding the overall design quality
  • No associativity between 3D wire harness design and its manufacturing

How to Design Complex Aero Parts using the 3DEXPERIENCE Platform1

Due to the complexity and stringent safety regulations in the Aerospace sector, virtual testing and validation plays a significant part in design and manufacturing.

How 3DEXPERIENCE addresses these challenges?

Large OEMs and companies have adopted Dassault Systèmes’ 3DEXPERIENCE platform which accelerates the process from design to manufacturing with compliance to required standards.

The 3DEXPERIENCE platform provides end-to-end electrical development environment from schematics through 3D design up to manufacturing.

Some of the solutions which the 3DEXPERIENCE platform offers with respect to Wire Harness are described below:

CATIA 3DEXPERIENCE – 3D Wire Harness Design

  • Shared electrical systems data model which enables schematic to 3D Design synchronization
  • Best-in-class 3D wire harness design solution
  • In-context wire harness modelling and simulation
  • How to Design Complex Aero Parts using the 3DEXPERIENCE Platform1

CATIA 3DEXPERIENCE – Harness Manufacturing Preparation

  • World class wire harness layout solution
  • Automatic generation of full-scale drawings for form-board manufacturing
    How to Design Complex Aero Parts using the 3DEXPERIENCE Platform1
  • Synchronization of flattened harness and automatic drawing updates

Large aerospace OEMs and suppliers have reaped multiple benefits by adopting Dassault Systèmes’ 3DEXPERIENCE platform. Some of these are mentioned below:

  • Integrated process coverage to reduce cycle time from design to manufacturing
  • Detect issues in the early phase of design by validating virtually and avoid expensive errors in manufacturing
  • Automatic propagation of modification from design to documentation
  • Quick electrical space reservation within the product to avoid physical prototypes

Thus, the 3DEXPERIENCE platform and its various applications help OEMs as well as suppliers to design and manufacture complex parts rapidly and with accurate precision while adhering to safety standards.

Scenario-based Flight Training Simulation with robust Presagis solutions

Global flight simulator market is sky-rocketing and projected to reach $7.7 billion by 2025 with a CAGR of 5.2% from 2019. With the increasing demand for commercial and military pilots, virtual flight training and certify methods are being adopted for aviation safety assurance and to cut cost for pilot training.

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Flight simulators are used to train pilots of commercial aircrafts, military aircrafts, helicopter simulators and Unmanned Aerial Vehicles (UAVs). Growth of the aviation industry is driven by the rise in global air traffic. Rise in demand for aircrafts and pilots acts as a stimulus for the growth of flight simulator market. With flight training simulators, the pilots are trained to handle critical system failure to ensure the success mission execution with prioritized safety. Flight training develops situational awareness to recognize certain conditions to anticipate coming situations. Additionally, pilots use judgement, communication and task prioritization tools during a flight.

Aviate, Navigate, Communicate is the golden rule for pilots

For instance, the pilot-in-command of an aircraft operates within the Instrument Flight Rules (IFR) by relying on the on-board flight instruments and equipment to safely complete the mission. Critical system malfunction is not ideal. However, complete electrical failure can hinder with the navigation operations as well as disrupt the communication system. In such a case, the pilot’s judgement, knowledge and task management skills are vital as it determines the mission outcome. Without the navigation and communication systems, the pilot is required to aviate for a successful completion of the mission. As per the golden rule, pilots should prioritize aviation above navigation and communication.

Flight simulators train pilots to handle dynamic real-life scenarios. It does help in the development of aforementioned skills that pilots can use in such scenarios. Dynamic training is beneficial for aircrew, civilian operators and military mission training operations.

Modern flight training includes flight simulators built on high fidelity & high-quality modules like Presagis’ FlightSIM and HeliSIM solutions maximize efficient training with reduced costs and risks. The training curriculum includes various scenarios, maneuvers, emergency procedures, and so on. In certain cases, pilots might be underprepared to face critical never seen situations. But, with the skills gained from flight training, pilots are capable of handling real-world scenarios.

Let’s consider a slung load transport mission. Operating a helicopter in a hostile environment with a slung load is a tough task. With added interactions with ground control, other aircrafts and hostile forces, the pilot is in for a complex mission with rapid change of events. Training instructors and mission planners are required to replicate such dynamic scenarios with unexpected elements to prepare the pilot for scenarios that are beyond the operation of the aircraft.

To train the pilots in a flexible scenario environment, operators prefer using a representative aircraft simulation model and focus their resources on the design, execute and debrief customized training scenarios for the mission. A representative aircraft model will enable the pilot to focus on the successful mission completion without the distraction of low-quality aircraft models.

Creating a representative aircraft model is effectively done with subjective validation of the simulated aircraft and an experienced pilot. This method highlights specific aircraft behaviors and phenomena for the pilot to learn, recognize and anticipate. For example, with a conventional rotorcraft, pilots expect a decrease in the power required to hover in the proximity to the ground or flying through effective translational lift speed range produces a particular dynamic response. These cues are easily tuned, modeled, and simulated allowing pilots to focus on skill development.

Presagis provides easy-to-use and intuitive graphical user interface useable in multi-disciplinary aircraft design and modelling through FlightSIM and HeliSIM solutions. Users with full data or limited data access hold the provision to create high fidelity or representative aircraft models that can be customized and integrated into dynamic environments.

Applications of Presagis’ FlightSIM & HeliSIM solutions

Advanced technologies for flight simulation training has come a long way in the past decade. These simulators hold functionalities for different types of aircraft flights, cockpits and systems. Flight simulators enable users to easily configure the aircraft flight systems and dynamics with specifications such as rotor blade characteristics, aerodynamics coefficients, environmental parameters, ground interactions and more without any coding.

These solutions are an integral part of flight simulators for fixed wing and rotary wing used by both military and civil class aircrafts. The simulators are used as:

  1. Training devices for pilots and navigators
  2. Engineering test beds by R&D teams
  3. Air traffic management training devices
  4. Wargaming simulators of various degrees, simulate CI, C2, C4I systems etc. and more

Benefits of Presagis’ FlightSIM & HeliSIM solutions

  • Intuitive UI for multi-disciplinary team: Easily simulate the flight models and systems using the enhanced user interface. Tools to view, compare, and modify your model without any coding.
  • Flexible interface to add data packages in any format: Freedom to add data packages, regardless of the format with the solution interface.
  • System simulations: Simulate and configure the Automatic Flight Control Systems (AFCS), gear box, radio navigation, and many more systems.
  • Rapid Integration: Connect to any simulation framework out-of-the-box through CIGI, HLA and DIS. Easily integrate FSTD with third-party software as well.
  • Slung load simulation model (with HeliSIM): Design, configure and hook up a load to the model. Configure the aerodynamic characteristics of the slung load.

Transforming the Aerospace & Defense landscape with industry-specific experiences for enhanced efficiency with digital continuity

Customer expectations are growing with the need for lower costs, higher quality, increased capabilities and the ever-growing complexity making it even more challenging for manufacturers. Complex system requirements challenges OEMs and suppliers to amplify their creativity, collaboration and innovation by upgrading to the factory of the future focused on improved efficiency and production agility. New approaches towards conception, designing, manufacturing, validation and sustenance are required for new air, space and defense vehicles.

Aerospace & Defense companies face a spectrum of challenges as well as growth opportunities with the continued growth of commercial aviation and an increase in the defense budget. With the increasing number of projects, there is an increase in Request for Proposals’ (RFPs) but manufacturers have less time to respond to complex RFPs for multiple components in a competitive environment for better customer experience.

Dassault Systèmes provides a portfolio of industry-specific solutions through the 3DEXPERIENCE platform for Aerospace & Defense manufacturers and suppliers to transform the traditional process with new and latest technologies.

Powered by Dassault Systèmes’ 3DEXPERIENCE platform, EDS Technologies provides industry solution experiences to transform your business processes with enhanced efficiency and digital continuity:

  1. Engineered to Fly accelerates A&D supplier process from idea to delivery with enhanced margins
  2. Co-Design to Target delivers aerospace programs ‘On specification’, ‘On- time’ and ‘On-Budget’

These solutions enable:

  1. Driven & Controlled Execution: Displays the status of current proposals and KPIs regarding costs and risks to enable process visibility. Project execution is driven in a connected process. The intellectual property is secured with traceability for authorities to manage collaborative efforts with multiple customers in a single source environment to ensure OEM certifications.
  2. Operational Efficiency: Predefined proposal templates, automated routing and tracking, clear view of projects to implement, accessibility to design and manufacturing components and collaboration with OEMs help streamline the whole process.
  3. Digital Continuity: From design engineering to manufacturing, best in class engineering tools are in place with quality and efficiency in a controlled environment to maintain digital continuity.

Engineered to Fly

Engineered to Fly is tailored to the aerospace industry with essential features and functionalities. It includes robust tools to help A&D businesses ‘Built-to-print’ or ‘Design-and-build’ to manage their whole business process. Some of the capabilities include addressing RFPs promptly, executing the projects with APQP and quickly adapting new changes in the current manufacturing process.

Project execution is driven and controlled with real-time status tracking throughout the stages of a proposal to product delivery. Validation and quality assurance are integrated for certification to meet the OEM standards. The value chain maintains digital continuity to deliver products with enhanced process efficiency and business profitability.

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For instance, an aircraft’s frame is composed of sheet metal parts comprising 4,700 rivets. With engineered to fly, the sheet metal is designed in 3D to position the rivet holes so the part assembly process is error-free and done right the first time. Also, each part is versioned and tracked for easy access to real-time product data as required to relevant stakeholders through digital continuity.

Digital continuity enables improvements in the holistic process for up to:

  • 30% error reduction
  • 40% productivity boost
  • 40% process changes requested

Benefits

  • Win more business: Significant cut down of the proposal response and turnaround time has helped in the business growth with improved bid quality for up to 25% without additional stakeholders.
  • Stay in control: Execution across multiple organizations through real-time KPIs with full traceability for stakeholders or OEM certifications.
  • Drive design & production efficiency: Digital continuity across all value streams from engineering to manufacturing to eliminate inefficiencies in the design process and ensure product quality.
  • Higher margins: 40% increased productivity with 30% reduce in change process requests and errors with strong controls, rules-based optimization and seamless collaboration

Co-Design to Target

Over 50% of projects miss out on their delivery data due to issues in the later stages that are discovered in the manufacturing process. Designing right the first time can prevent these issues in the first stage with the automated validation and quality assurance against the OEM standards.

Co-Design to Target enables OEMs with disparate tools and processes in a single stream to optimize the form, fit and function within an integrated Digital Mock-Up system (DMU). This system eliminates many integration issues that majorly affect  cost and schedule.

Digital Continuity allows driving projects with a real-time view of KPIs across the organization with multiple stakeholders, sites and suppliers to proactively sustain the project as per the timeline.

For instance, hundreds of engineers work on  detailed product development in the design phase. Thousands of specifications cascade to sub-systems and components based on top-level requirements. Project targets are met with lean development through efficient integration of engineering teams. With Co-Design to Target, these teams work with parallel timelines and collaborate in real-time for quick and easy detailed definitions of each component and system within the finished product.

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Benefits

  • Manage programs in real-time: Stakeholders can review the real-time status of projects with a quick view of all KPIs with full traceability until delivery. The works-in process is consolidated with various different tools for program controls, systems engineering, design engineering, contracts management, subcontract administrations, configuration management, and data management. Comprehensive management and real-time process visibility improve the success, profitability and value to customers.
  • Achieve manufacturing excellence by design: Design, engineering and manufacturing processes are efficiently integrated and validated with the digital mock-up function to evade costly issues in the later stages. This solution simplifies the product development process by integrating value streams. Transformation in the development phase significantly lowers the cost and time of projects with Co-Design to Target.
  • Reduce costs and improve quality: Program execution is enhanced with multi-discipline simulations to guarantee the delivery of performance, reliability and cost targets. Reducing the complexity in product development stage enables organizations to reap the profits at a lower recurring and non-recurring costs. Co-Design to Target industry-specific solution transforms the product development phase to ensure significant reduction in cost with improved quality.

To know more about our aerospace & defense industry-specific solutions, submit an inquiry to speak to our senior technical experts.

Integrate Mold and Tooling with 3DEXPERIENCE Platform for first-time-right design

Major challenge for tool makers is the quick turn around and reduce design to manufacturing cycle time as required in every industry. Every manufacturer’s goal is constant innovation to manufacture products with ever improving quality at the right cost. Maximizing efficiency and reliability of tooling regardless of human and resource related contingencies will accelerate the product delivery.

Tool makers work as a collaborative team and the latest product data is misplaced with the collect, exchange, translate and duplicate of data. Tool makers also collaborate with designers. There are multiple iterations of product data from designer to toolmaker and vice versa. With numerous collaborators, there is bound to be numerous iterations due to defects from manufacturability issues. It is necessary to have various iterations to reach at a refined final product but leads to delays in the tooling delivery.

Other challenges faced by tool makers are:

  • Collaborators use different software for design, simulation and manufacturing leading to high data translation cost.
  • Significant amount of time is spent in integrating product design changes due to excessive engineering and poor standardization.

Integrate Mold and Tooling with 3DEXPERIENCE Platform for first-time-right design

mold

With CATIA Mold and Tooling solution, companies are able to create first-time-right collision-free tool paths  through the fully integrated and collaborative 3DEXPERIENCE platform. Easy access to designs to create the appropriate tooling in a single environment is helpful to interact with collaborators, eliminating the need for data translation and to easily freeze product design.

Features of CATIA Mold and Tooling solution

  • Powerful, flexible, and highly customizable experience to address the mold making requirements and challenges
  • Increased design productivity, standardize tooling design practices, automate design tasks and assist decision-making from simple to complex projects
  • Added value to manufacturing companies to produce high quality products
  • Avoid modification cycles and attached costs with design right the first time
  • Consistently deliver high quality tooling
  • Minimize risk of critical situations
  • Increase competitive edge

3 Key Benefits of CATIA Mold and Tooling solution

  1. Increase productivity and reduce cycle time:
    1. Dedicated capabilities addressing toolmakers’ specific needs
    2. Ease to capture, reuse and grow company resource
  2. Promote standardization and ensure lifecycle integrity:
    1. Single software platform for integrated tooling design and manufacturing
    2. Full 3D visual simulation for reference throughout the process
  3. Enhance quality and bolster innovation:
    1. Automate tasks and assist user decision and enable collaborative engineering

Contact us to know more about how CATIA 3DEXPERIENCE can aid your team for first-time-right design.

Upskill Yourself with EDST e-Learning

EDST e-Learning is an online learning initiative by EDS Technologies leveraging 25 years of industry experience as the largest Engineering and Enterprise Solutions company in India. The online courses are curated by industry experts and academic subject-matter leaders.

EDST Technologies is a Certified Education Partner to Dassault Systèmes and an authorized Academic Partner to Autodesk ensuring certified industry-specific programs enabled through these partnerships. EDS Technologies has developed training programs tailor-made for students, beginners and advanced users in Automotive, Aerospace, Industrial Equipment, AEC and other industries. It has trained more than 60 thousand users and has experience of 6 million training hours in the last 25 years.

EDST Technologies capitalized years of experience in training and launched online learning platform EDST e-Learning. It specializes in Mechanical Engineering, Civil Engineering, and Industry based skills courses. Courses are meticulously curated by a team of industry experts and academicians. Currently, e-learning courses range from Product Design, Domain Courses, Industry CAD applications such as CATIA, AutoCAD, Solidworks Inventor, and Revit and is extensively working on launching new courses.

The industry is amidst the Industry 4.0 revolution and it is going to transform the workplace through technology innovations such as Artificial Intelligence, Cognitive Automation, Advanced Analytics Internet of Things and Advanced Robotics. As per Deloitte Consulting, there will be 4.6M manufacturing jobs to fill from 2018–2028 however skill gap may leave an estimated 2.4 million positions unfilled. EDST e-Learning’s vision is to bridge this skill gap and upskill the workforce of the future.

INFO

Digital Manufacturing: A Sustainable Future in Manufacturing for You

For the past decade, Digital Economy is transforming the traditional manufacturing process with modern digital systems. Digital Manufacturing has improved the Quality, Efficiency, and Sustainability of Manufacturing. Manufacturers are now open to new and improved business practices to start their digital transformation journey.

Traditional manufacturing has worked well so far for mass production by being cost-effective with short cycle times. However, extensive manufacturing equipment generates more waste with inventory overflow and high energy consumption. Whereas, digital manufacturing is sustainable, efficient, and flexible with boundless manufacturing opportunities.

Digital Manufacturing is modern manufacturing with end-to-end technology including hardware and software integration. Manufacturers have realized the need to optimize their business model to align with the modern market and start their digital transformation journey.

Each stage of the digital systems is connected, aligned, and improved. The digital simulations of 3D CAD models generated by PLM software enable product feedback and corrections. The design is digitally refined by addressing the issues and updating the product without affecting the time and cost of production. The product blueprint is finalized only after complete quality control and then sent for production.

Customers now seek customizable and unique products for their needs. It is easy to customize the product design as per customer requirements with reduced time consumption and manual labor.

Product testing is another important process in product manufacturing. Digital manufacturing enables the production of small batches for product testing and also provides better inventory control. This ensures further refining of the product to deliver better and more quality products in an efficient automated system. Also, it enables the ability to switch production and product design with the change in market trends and product demand. Digital transformation in manufacturing ensures a reduction in waste generation, time, and fuel consumption reinforces sustainability in the whole manufacturing process.

According to ‘Investing for a Sustainable Future,’ an MIT report, Sustainable Business Models are likely to generate twice the profit. By adopting Digital Manufacturing technology practices, manufacturers are saving time, cost, and conserving natural resources. Digital Manufacturing creates an automated process that helps project managers make informed decisions for efficient and faster production.

The future of digital manufacturing is bright and beaming with numerous opportunities for a sustainable world. At EDS Technologies, we strive to be part of the Movement for Global Sustainability in Business with our solutions. We also encourage our customers who are manufacturing companies to start their digital transformation journey with our engineering solutions such as DELMIA, CATIA, SIMULIA, ENOVIA and 3DEXPERIENCE for a better world.

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