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WAY TO IMPROVE EFFICIENCY OF MECHANICAL AIT OPERATIONS

WAY TO IMPROVE EFFICIENCY OF MECHANICAL AIT OPERATIONS. Jean-Pierre DUMAS Astrium SAS - Toulouse. CONTENT. An AIT point of view on utilization of virtual simulation tools for spacecraft mechanical AIT activities 1 – Introduction & Objectives 2 - Current situation 3 - Way forward

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WAY TO IMPROVE EFFICIENCY OF MECHANICAL AIT OPERATIONS

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  1. WAY TO IMPROVE EFFICIENCY OF MECHANICAL AIT OPERATIONS Jean-Pierre DUMAS Astrium SAS - Toulouse

  2. CONTENT An AIT point of view on utilization of virtual simulation tools for spacecraft mechanical AIT activities 1 – Introduction & Objectives 2 - Current situation 3 - Way forward 4 - Conclusion DELMIA demonstration (animation) Astrium EF7.PS.DJP.03.00076

  3. 1 – INTRODUCTION 1/2 In the last years, ASTRIUM has conducted several actions in AIT scope in order to improve competitiveness of projects • A major field of actions has concerned processes and structuration of data, with overall implementation of industrial management tool (PDM and MRP) • The other field of optimization in progress deals with a larger and better use of virtual simulation tools in AIT : • For AIT preparation at first • For AIT operation later Astrium EF7.PS.DJP.03.00076

  4. 1 – OBJECTIVES 2/2 • EFFICIENCY improvement in AIT can be developped on two aspects : • To MINIMIZE RISKS :  look foward early detection of problems  virtual simulation allows to start AIT preparation much more in advance than traditional approach and with more accurate representativity - To SAVE TIME, in particular in AIT clean room operations which represents the critical path of a project schedule, at the end of development of a spacecraft  look foward optimization of activities • Most of new programs do not include any more STM models in their development plan.  Need to implement an alternative solution, since STM were a major mean to validate AIT procedures and to train AIT teams  virtual tools can be a good answer Astrium EF7.PS.DJP.03.00076

  5. 2 – ASTRIUM CURRENT SITUATION WHAT IS DONE IN ASTRIUM for AIT PREPARATION 2.1 – USING SPACECRAFT VIRTUAL MOCK-UP (CATIA) 2.2 – USING ADVANCED SIMULATION TOOLS (VPM/DELMIA) Astrium EF7.PS.DJP.03.00076

  6. Digital Assy for S/C Assy Digital Assy for zone & process 2 – ASTRIUM CURRENT SITUATION CATIA VPM DMU HB7 DMU INT10.01 DMU INMARSAT DELMIA DMU PLANT PTO LASER TRACKER DMU PLANT STEVENAGE DMU PLANT PORTSMOUTH DMU PLANT TOULOUSE Astrium EF7.PS.DJP.03.00076

  7. 2.1 – Using spacecraft virtual mock-up (DMU) 1/2 Different kinds of applications for AIT PREPARATION • CONCURRENT ENGINEERING between AIT team and design team, in s/c design phase • Consistancy of architecture & layout with respect to AIT constraints (access, field of view, …) • Support trade-off analysis in multi-discipline environment • CLASH DETECTION / CLEARANCE ANALYSIS • When risks foreseen, for critical assembly operations, MGSE are introduced in the s/c 3D detailed virtual mock-up • Eventually kinematic studies are performed • TEST MECHANICAL SET UP • Define or confirm feasibility of a test configuration inside a specific clean room or test facility • HELP FOR MGSE DEFINITION • 3D spacecraft model allows to define precisely the geometrical functions of MGSE : much clearer and efficient than a classical interface description Astrium EF7.PS.DJP.03.00076

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  11. 2.1 – Using spacecraft virtual mock-up 2/2 THE LIMITATIONS encountered • The s/c virtual mock-up is powerful for static studies. Kinematic studies, though possible, are long to simulate • Low level of interactivity with AIT teams. Ex : - clash analysis : an overnight run - A test set-up : one or two weeks / long iterations • Limited access to the virtual tool for AIT teams • Need of a specialist to handle it • Powerful workstation required Astrium EF7.PS.DJP.03.00076

  12. 2.2 – Advanced simulation tool 1/2 A number of experiences for ASTRIUM Telecom spacecrafts («product line » EU3000 platform) :  use of DELMIA(a digital assembly tool linked the digital spacecraft mock-up) • Clean room occupation scheme, including dynamic simulations of movements validation/optimisation of logistic sequences and of needs for GSE’s • Simulation of a global test sequence (installation for thermal or RF tests) • CLEARANCES between GSE and spacecraft during a dynamic operations :  pre-design of MGSE before detailed specification  compatibility validation after MGSE delivery • Man access feasibility, including a operator simulation (86 dof for the human model) for a complex operation inside the spacecraft OUTPUT = 3D animations Astrium EF7.PS.DJP.03.00076

  13. 2.2 – Advanced simulation tool Astrium EF7.PS.DJP.03.00076

  14. 2.2 – Advanced simulation tool Astrium EF7.PS.DJP.03.00076

  15. 2.2 – Advanced simulation tool Astrium EF7.PS.DJP.03.00076

  16. 2.2 – Advanced simulation tool 2/2 Concerns for optimization : • Need to increase AIT team implication in the analysis performed (synergy to improve) • Production of a simulation is a time-taking process • Need of a specialist to handle the tool  great care must be taken on simulation need definition (quality of datas, criteria of optimization, …) • The virtual database of GSE or facilities needs to be generated • Significant time and effort requested to create or convert models from CAD • However they are re-usable data = investment for recurring activities  Applications limited so far to specific and selected requests - in the early phase of AIT preparation - where the added value can be justified in advance to the project manager Astrium EF7.PS.DJP.03.00076

  17. 3 – WAY FORWARD  From these experiences, the next directions of improvement pointed out concern : 1) AIT preparations, to enhance previous studies 2) AIT operations, to introduce virtual technology within the cleanroom Astrium EF7.PS.DJP.03.00076

  18. Next objectives Simulation of the overall AIT sequence flow including MGSE and facilities application on a generic sequence for a S/C family at first (i.e. : EU3000) extension of the approach to a protoflight model Promotion of MGSE concurrent engineering - - to clearly explain with virtual tools the geometrical limitations and performances - to pre-define the GSE with the subcontractor Simulation of critical activities Extend the use virtual model to check and validate the detailed AIT procedure (in replacement of the preliminary operations we used to perform on STM models) Potential benefits / added value Optimization of occupation of AIT facilities Anticipation of changes of the spacecraft configurations An explicite guide for coordination of the various actors within an AIT team A communication mean within the AIT team (tutoring of new participants) and with customers Anticipation of MGSE cost drivers vs satellite constraints : possible iterations Reduction of i/f management efforts Avoid over design of MGSE Keep the level of quality and duration of critical activities without having to perform blank operations in clean room 3.1 – To go further in mechanical AIT PREPARATION Astrium EF7.PS.DJP.03.00076

  19. Next objectives Coodination and communication : training of operators on critical or combined activities =Replace the procedure review meeting by a virtual demonstration of the activities Implement « virtual mechanical procedure » =Replace the wording of a step by step procedure by a drawing sequence available on a screen in clean room Support for leading procedures Visualisation of the current task flow Potential benefits / added value Reduction of risk with A better understanding of the sequence by all actors of the AIT team An easier explanation of critical points Cost reduction in operations since less supervising is required Reduction of time and risks by Reducing to the minimum the misunderstanding we encounter with a textual description Using the most standard language in mechanical field, i.e. drawing such a procedure can be played by any fitter in Europe : no more language limit A better support for a good coordination of multi-discipline / multi national AIT teams 3.2 – Implement virtual technology in AIT OPERATIONS Astrium EF7.PS.DJP.03.00076

  20. Success of implementation of virtual technology in mechanical AIT environment need to go through a structurated approach : Phase a) CONSOLIDATION OF TARGET DEFINITION To identify which applications are worthwhile to be performed in AIT To classify them (visualisation/modeling/dynamic simulation/ ….) To select the right level of model complexity required(complete model / partial model / simplified model / …) in order to « put the right tool on the right place » To define which actors to be implicated and then define at what level it should be handled (Design Office / AIT team / Production / …) To evaluate savings 3.3 – HOW TO PROCEED 1/2 Astrium EF7.PS.DJP.03.00076

  21. 3.3 – HOW TO PROCEED 2/2 Phase b) TOOL SELECTION • To select / evaluate / develop the appropriate tools for each level : CATIA / DELMIA / VISVIEW / others to evaluate • The criteria of choice to consider : - minimize the training efforts to require on AIT teams - analyse operating cost of the process involved - … • Phase c) DEFINITION & IMPLEMENTATION • To define safe process to garanty the accuracy of datas between the different levels of application • To define and implement the new AIT process within the company. Astrium EF7.PS.DJP.03.00076

  22. 4 - CONCLUSION • ASTRIUM experiences in the use of virtual tools for spacecraft AIT has shown a worthwhile potential for mechanical AIT improvement • costs reduction (by better optimisation of activities to be performed) • risk reduction for the critical activities • ASTRIUM proposed improvement roadmap is consistent with a global Virtual Spacacraft Design approach Astrium EF7.PS.DJP.03.00076

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