Aerospace Systems Engineering
as an Integrating Function
for the Georgia Tech Graduate
Program in Aerospace Systems
Design
Dr. Daniel P. Schrage
Professor and Director
Center of Excellence in Rotorcraft Technology (CERT)
Center for Aerospace Systems Analysis (CASA)
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Presentation Outline
• Overview of the Graduate Program
Aerospace Systems Design Program
• The Evolution from an IPPD to an IPPD
through RDS to a Modern Aerospace
Systems Engineering Approach
• Description of the Graduate Course in
Aerospace Systems Engineering
• Opportunities for Collaboration with the
School of ISYE
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Georgia Tech School of AE
• School of Aerospace Engineering
–
–
–
–
–
One of original six Guggenheim Schools of Aeronautics
34 full time faculty
~600-700 undergraduate students (AE majors)
~250 -300 graduate students
Highest Rated Public Aerospace School (Overall: UG – 2nd
to MIT;GR-3rd to MIT & Stanford, U.S. News & World Report)
• Six Disciplinary Groups (Full A.E. School)
• Aerodynamics and Fluid Mechanics
• Flight Mechanics and Controls
• Structural Mechanics and Materials
• Structural Dynamics and Aeroelasticity
• Propulsion and Combustion
• System Design and Optimization
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Graduate Program in
Aerospace Systems Design
• Includes core and elective courses to:
– Provide a Practice-oriented M.S. Program
– Provide a Integrated-Discovery Focused Ph.D program
• Includes a combination of disciplinary, methods and
synthesis courses for System Design of Complex
Systems:
– Aircraft and Rotorcraft
– Missiles and Space
– System of Systems: Army/DARPA FCS; FAA/NASA NAS
• Integrates Research and Education
– Two active research laboratories, ASDL and SSDL
– Approx. 100 students (~80 supported)
– Approx. 15 research engineers
• Uses an IPPD through RDS Approach and a modern
Aerospace Systems Engineering Course as an
Integrating Function for the Program
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Evolution of the Georgia Tech
Aerospace Systems Design Program
Graduate Program
‘84 - Graduate Rotorcraft Design Program Established
Development
‘89 - Intro to Concurrent Engineering (CE) & Design for LCC courses
‘92 - Graduate, CE/IPPD Fixed-Wing Design Program Established w/ NASA’s USRA
‘94
CE/IPPD
Focus: Affordable Aerospace Systems Design Methodology; ASDL Estab.
‘95 RSM for
Advanced Synthesis
Focus: Pioneering Research into Response Surface
Methodology (RSM) for advanced sizing/synthesis
‘96
Aero +
Structures
Focus: Addressing Economic Uncertainty &
Viability results in Robust Design Simulation
RDS
Probabilistic
‘97
Feasibility AND
Viability
FPI
x2
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
x1
Probability
Customer
Requirements
‘98- Center for
Aerospace Systems
Analysis (CASA)
Initiated
CASA
y1
 $/RPM
y2
yn
FPI
Feasible
Solution
Sizing
Desired
Solution
Econ.
Target
Baseline
Mean
$/RPM
x1
x2
xn
‘95-’96 Space
Systems Design
Laboratory (SSDL)
Established
‘97- NRTC Center
of Excellence
Renewal
Focus: Efficient
Probabilistic Analysis
through Fast Probability
Integration (FPI)
‘98
• Morphological
FLOPS-IMAGE-RSE
Matrices
Interface developed
• Pugh Diagram
Establish
the Need
‘94- NASA MDA
Fellowship Grant
and New
Approaches to
MDO Grant
Focus: Systems & System
of Systems Analysis for
Complex Systems and
Movement toward a Modern
Approach to Systems
Engineering
‘99- Boeing Awards
GTAE/CASA
Faculty Chair in
Aerospace Systems
Analysis
’00 GEAE USA
CERT/CASA
Why it is Unique?
• Is the Only Formal Graduate Aerospace Systems Design Program in
the U.S., and probably throughout the world
• Addresses the System Design of Complex Systems (Not
Conceptual Design) utilizing a Generic IPPD Methodology, as a
modern approach for Systems Engineering
• Provides an engineering approach to Risk Based Management
through Robust Design Simulation (RDS) environment for
Implementing the IPPD Methodology at the “Front End” that can be
continued for Process Improvement and Merging with Six Sigma
methods
• Provides a practical way of incorporating “lean” and other initiatives
into the front end of a complex system’s life cycle
• Has spun off various methods, tools, and techniques from this IPPD
through RDS approach for a variety of customers
• Have moved to address “System of Systems” problems such as
FCS and air transportation architectures for the NAS
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Who are the Primary & Supporting Faculty?
• School of A.E.:Primary Faculty
– Dr. Dimitri Mavris, Director of ASDL and Boeing Chair Professor in
Advanced Aerospace Systems Analysis
– Dr. John Olds, Associate Professor and Director of SSDL
– Dr. Jim Craig, Professor and Co-Director of CASA
– Dr. Dan Schrage, Professor and Director, CASA & CERT
– Two recruitments: Lewis Chair in Space Systems Technologies;
Junior Faculty in Design Methodology & Tools
Supporting Faculty: Dr. Amy Pritchett (AE/ISYE), Dr. Eric Johnson, &
Dr. JVR Prasad
• Some Participation from the School of M.E.
– Dr. Farokh Mistree, Professor and Director of SRL
– Dr. Bob Fulton, Professor
• Some Participation from the School of E.C.E
– Dr. George Vachtsevanous, Professor and Director of the
Intelligent Control Laboratory
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Overview of Center for Aerospace Systems
Analysis (CASA)
• Established in1998 based on successful
development of the ASDL from 1992 and the
successful development of the SSDL from 1995;
Serves as oversight for these labs
• Through its laboratories provides the primary
research support to the graduate program in
Aerospace Systems Design which currently has ~
100 students of which over 80 % are U.S. citizens
• Research support provides over $5M per year in
sponsored research and supports ~ 80 students &
15 research engineers
• Provides a modern approach to systems
engineering based on an Integrated
Product/Process Development (IPPD) methodology
executed through Robust Design Simulation (RDS)
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Why Systems Analysis?
• Systems Analysis is a scientific process, or
methodology, which can best be described in
terms of its salient problem-related elements.
The process involves:
– Systematic examination and comparison of those
alternative actions which are related to the
accomplishment of desired objectives
– Comparison of alternatives on the basis of the
costs and the benefits associated with each
alternative
– Explicit consideration of risk
• NASA, DoD, and Industry are realizing that
more emphasis must be placing on enhancing
systems analysis at the front end of the life
cycle using modern systems engineering
approaches
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
CASA’s Laboratories
Aerospace Systems Design Lab
www.asdl.gatech.edu
Space Systems Design Lab
www.ssdl.gatech.edu
B.S.A.E. - M.S. - Ph.D Degrees
Design Frameworks Lab
IPERT Lab
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
Flight Sim Lab
Design, Build, Fly Lab
Uninhabited Aerial Vehicle
Research Facility
CERT/CASA
An Integration and Practice-Oriented M.S.
Program in Aerospace Systems Design
Semester I
Semester II
Design Methods/Techniques
Aerospace
Systems
Engineering
Disciplinary
Electives
Applied
Systems
Design
Design II
Modern
Design
Methods I
Propulsion
Systems
Design
Summer
ISE/PLMC
Development
Special
Project
Applied
Systems
Design
Design IIII
Modern
Design
Methods II
Product
Life Cycle
Management
Safety
By Design
Internship
Design Tools/Infrastructure
Mathematics (2 Required)
Legend:
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
Core Classes
Other Electives
Elective Classes
CERT/CASA
Aerospace Systems Design Education &
Research Philosophy
Industry
Government
Partners:
ONR
NASA
AFRL
NRTC
• Methods Formulation
• Supports Basic Research
• Implementation of Methods
Funding
Relevant
Problems
Data & Tools
Funding
Partners:
GEAE
RRA
LMTAS
Boeing
Sikorsky
Aerospace Systems
Design Laboratory
Methods
Students
Classroom Implementation
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Design Process Paradigm Shift
(Research Opportunities in Engineering Design, NSF Strategic Planning Workshop Final Report,
April 1996)
•
•
•
•
•
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
A paradigm shift is underway
that attempts to change the way
complex systems are being
designed
Emphasis has shifted from
design for performance to
design for affordability, where
affordability is defined as the
ratio of system effectiveness
to system cost +profit
System Cost - Performance
Tradeoffs must be
accommodated early
Downstream knowledge must
be brought back to the early
phases of design for system
level tradeoffs
The design Freedom curve must
be kept open until
knowledgeable tradeoffs can
be made
CERT/CASA
What is IPPD?
• Integrated Product/Process Development (IPPD) is a
management methodology that incorporates a
systematic approach to the early integration and
concurrent application of all the disciplines that play a
part throughout a system’s life cycle (Technology for
Affordability: A Report on the Activities of the Working Groups to the Industry
Affordability Executive Committee, The National Center for Advanced
Technologies (NCAT), January 1994)
• IPPD evolved out of the commercial sector’s assessment
of what it took to be world class competitive in the 1980s
• The DoD has required IPPD and the use of IPTs where
practical throughout the DoD Acquisition Process for
Major Systems (DoD 5000.2R)
• Conduct of IPPD requires Product/Process Simulation
using Probabilistic Approaches
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Quality Revolution - Where Competition is
Today
Cost Advantage
Cheap Labor
Hi Volume, Lo Mix Production
Quality
Statistical Process Control
Variability reduction
Customer Satisfaction
Time-to-Market
Cycle time Comparison (JIT)
Integrated Product/Process Development
Product/Process Simulation
Hi Skill adaptable Workforce
Manufacturing
Enterprise
Flexibility
Product Variety
Cost Independent of Volume
Agility
Commercial/Military Integration
Virtual Companies
Company Goodness
Environment
1960
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
1970
1980
1990
2000
NCAT Report, 1994
CERT/CASA
Japanese Auto Industry Made Changes Earlier
Than U.S. Auto Industry
U.S. Company
Japanese
Company
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
+3
Months
Job #1
1-3
Months
14-17
Months
90%
Total Japanese
Changes Complete
20-24
Months
Number of Engineering Product
Changes Processed
Japanese/U.S. Engineering Change Comparison
CERT/CASA
Concurrent vs Serial Approach
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Traditional Design & Development Using only a Top
Down Decomposition Systems Engineering Process
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
IPPD Requires the Computer Integration of Product and Process Models and
Tools for System Level Design Trades and Cycle Time Reduction
CONCEPTUAL
DESIGN
(SYSTEM)
SYSTEM
PROCESS
RECOMPOSITION
SYSTEM
FUNCTIONAL
DECOMPOSITION
Process
Trades
Product
Trades
PRELIMINARY
DESIGN
(PARAMETER)
COMPONENT
PROCESS
RECOMPOSITION
PRELIMINARY
DESIGN
(PARAMETER)
Process
Trades
INTEGRATED
PRODUCT
PROCESS
DEVELOPMENT
DETAIL
DESIGN
(TOLERANCE)
DETAIL
DESIGN
(TOLERANCE)
Process
Trades
Product
Trades
PART
PROCESS
RECOMPOSITION
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
COMPONENT
FUNCTIONAL
DECOMPOSITION
Product
Trades
PART
FUNCTIONAL
DECOMPOSITION
MANUFACTURING
PROCESSES
CERT/CASA
Integrated Product and Process Development
Modeling Flow (Aircraft Example)
MULTI-LEVEL LCC MODEL
Process Recomposition
ENGINEERING MODELS
Product Decomposition
re-design
decision
cost model
req’d inputs
Top-Down
Aircraft
LCC Model
cost
metrics
Integrated
Design
Environment
bottom-up
wing cost
estimate
labor rates
learning curves
Component
Cost Modeling
performance
metrics
product
metrics
process
metrics
Aircraft
Synthesis
(Sizing)
cust. requirements
perf. requirements
wing
planform
geometry
Finite
Element
Analysis
materials
loads
weights
labor hours
material costs
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
KBS
Process
Modeling
structural concepts
alternative processes
CERT/CASA
HSCT Integrated Design & Manufacturing Ph.D
Thesis (W. Marx, 1997)
Wing Point Design Regions
• Representative structure at each location
– upper and lower panels
– rib and spar structure
Aft wing box
–variable chordwise load
intensities due to wing bending
–high spanwise load intensities
Wing tip box
Forward wing box
–stiffness critical due to
aeroelastic effects
–high load intensities
–low load intensities with respect to
wing bending
–minimum gage region
William J. Marx
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Aircraft Life Cycle Cost Analysis (ALCCA) including Economic Analysis
AIRCRAFT
WEIGHTS
ENGINE
THRUST & WGHT.
LABOR
RATES
PRODUCTION
QUANTITY
RDT & E
COSTS
AIRCRAFT
MANUFACTURING
COSTS
LEARNING
CURVES
UNIT
COSTS
CALCULATE
MANUFACTURER
CASH-FLOW
YES
MANUFACTURER
CASH-FLOW
ROI
MANUFACTURER
ROI VS PRICE
AVERAGE
COST
NO
AIRCRAFT MISSION
PERFORMANCE
FUEL, INSURANCE
DEPRECIATION RATES
LABOR & BURDEN
RATES
Airline
Yield
AIRLINE
OPERATING
COST
ROI
PRICE
DIRECT
COSTS
INDIRECT
COSTS
CALCULATE
AIRLINE ROI
Production
Quantity
YES
AIRLINE
RETURN ON
INVESTMENT
AIRLINE
ROI VS PRICE
NO
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
TOTAL
OPERATING
COST
CERT/CASA
Aircraft Process Based Manufacturing Cost
Model
Previous Mfg
Cost Module
Component Weights
Engine Thrust and
Weight
Labor Rates
Production Quantity
Learning Curves
Manufacturing Hours
Quality Assurance Hours
Tooling Hours
from
(Raw Material Costs)
CLIPS
(Buy-To-Fly Ratios)
Material Costs
Material Breakdown
Mfg. Labor Rate
Qual.Assur. Labor Rate
new
Material Burden Rates
ALCC
Mfg. Labor L. Curve
A
QA Labor L. Curve
input
Tooling L. Curve
Material L. Curve
Component
Weights
Engine Thrust
Labor Rates
Production
Quantity
Learning Curves
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
Aircraft
Manufacturing
Costs
Component
Costs
Unit Costs
RDT&E Costs
Avg. Costs
New
ALCCA
output
New Wing Production Module
Aircraft Manufacturing
Wing
Costs
Production
PBC
Module
Theoretical
First Unit
Cost
NonRecurring
& Recurring
Production
Wing TFUC
Manufacturing Hours & Cost
Quality Assur. Hours & Cost
Tooling Hours & Cost
Material Costs
Cost/Time Analysis
Component
Costs
Unit Costs
RDT&E Costs
Average Unit
Costs
CERT/CASA
Cost Time Analysis for Theoretical
Production
Cumul.
time
Cost/Time Curve
End Points for Wide
Range of Projected
Lot Sizes
Finishing
Operations
Largest Run
Production
Theoretical First Unit
Cost
(TFUC)
Setup
Smallest Run
Design
Tools
Cost / Unit
Purchase
Material
Material Cost
Tool Design Cost
Setup
Cost
Production Cost Largest Run
Finishing Operations Cost Largest Run
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
Finishing Operations Cost
Smallest Run
Production Cost Smallest Run
[Source: MIL-HDBK-727]
CERT/CASA
Cost/Time Constraint Curve
for Candidate Selection
Cost/Time Curve
Process A
End Point
Process E
Process B
End Point
Process C
End Point
TIME
Process D
End Point
UNIT COST
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
[Ref. MIL-HDBK-727]
CERT/CASA
Probabilistic Cost/Time Production Analysis
Cumul.
time
Cost/Time Curve
End Points for Wide
Range of Projected
Lot Sizes
Finishing
Operations
Largest Run
Production
Setup
Smallest Run
Theoretical First
Unit Cost
(TFUC)
Design
Tools
Cost / Unit
Purchase
Material
Material Cost
Tool Design Cost
[Ref. MIL-HDBK-727]
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
Setup
Cost
Production Cost Largest Run
Finishing Operations Cost Largest Run
Finishing Operations Cost
Smallest Run
Production Cost Smallest Run
CERT/CASA
Georgia Tech Generic IPPD Methodology
•
Methodology provides a procedural design (trade-off
iteration) approach based on four key elements:
– Systems Engineering Methods and Tools (Product
design driven, deterministic, decomposition approaches; MDO
is usually based on analytic design approach)
–
Quality Engineering Methods and Tools (Process
design driven, nondeterministic, recomposition approaches;
MDO is usually based on experimental design approach)
–
Top Down Design Decision Process Flow (Provides
the design trade-off process)
–
Computer Integrated Design Environment(Information
Technology driven)
•
Methodology has been implemented through Robust
Design Simulation (RDS) for a number of applications
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Georgia Tech Generic IPPD Methodology
COMPUTER-INTEGRATED ENVIRONMENT
QUALITY
ENGINEERING METHODS
PROCESS DESIGN DRIVEN
ESTABLISH
THE NEED
DEFINE THE PROBLEM
SYSTEMS
ENGINEERING METHODS
REQUIREMENTS
& FUNCTIONAL
ANALYSIS
SYSTEM DECOMPOSITION
&
FUNCTIONAL ALLOCATION
ESTABLISH
VALUE
ROBUST DESIGN
ASSESSMENT &
OPTIMIZATION
GENERATE FEASIBLE
ALTERNATIVES
SYSTEM SYNTHESIS
THROUGH MDO
EVALUATE
ALTERNATIVE
ON-LINE QUALITY
ENGINEERING &
STATISTICAL
PROCESS
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
MAKE DECISION
SYSTEM ANALYSIS
&
CONTROL
CERT/CASA
PRODUCT DESIGN DRIVEN
7 M&P TOOLS AND
QUALITY FUNCTION
DEPLOYMENT (QFD)
TOP-DOWN DESIGN
DECISION SUPPORT PROCESS
The Systems Engineering Process
Process Input
• Customer Needs/Objectives/
Requirements
- Missions
- Measures of Effectiveness
- Environments
- Constraints
• Technology Base
• Output Requirements from Prior
Development Effort
• Program Decision Requirements
• Requirements Applied Through
Specifications and Standards
Requirements Analysis
• Analyze Missions & Environments
• Identify Functional Requirements
• Define/Refine Performance & Design
Constraint Requirement
System Analysis
& Control
(Balance)
Requirement Loop
Functional Analysis/Allocation
• Decompose to Lower-Level Functions
• Allocate Performance & Other Limiting Requirements to
All Functional Levels
• Define/Refine Functional Interfaces (Internal/External)
• Define/Refine/Integrate Functional Architecture
• Trade-Off Studies
• Effectiveness Analysis
• Risk Management
• Configuration Management
• Interface Management
• Performance Measurement
- SEMS
- TPM
- Technical Reviews
Design Loop
Synthesis
Verification
• Transform Architectures (Functional to Physical)
• Define Alternative System Concepts, Configuration
Items & System Elements
• Select Preferred Product & Process Solutions
• Define/Refine Physical Interfaces (Internal/External)
Related Terms:
Customer = Organization responsible for Primary Functions
Primary Functions = Development, Production/Construction, Verification,
Deployment, Operations, Support Training, Disposal
Systems Elements = Hardware, Software, Personnel, Facilities, Data, Material,
Services, Techniques
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
Process Output
• Development Level Dependant
- Decision Data Base
- System/Configuration Item
Architecture
- Specification & Baseline
CERT/CASA
Modeling and Simulation:
Varying Fidelity of Synthesis and Sizing
Safety
Safety
Economics
Aerodynamics
Aerodynamics
Geometry
Economics
Synthesis & Sizing
Mission
S&C
S&C
Manufacturing
Integrated Routines
Table Lookup
Structures
Conceptual Design Tools
Approximating Functions
Direct Coupling of Analyses
Performance
Manufacturing
Increasing
Sophistication and
Complexity
(First-Order Methods)
Propulsion
Performance
Structures
Preliminary Design Tools
(Higher-Order Methods)
Propulsion
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
The Quality Engineering Process
provides Recomposition Methods & Tools
Knowledge Feedback
Customer
Seven
Management
and Planing
Tools
Quality
Function
Deployment
Robust
Design Methods
(Taguchi, Six Sigma, DOE)
Statistical
Process
Control
Off-Line
Off-Line
Off-Line
On-Line
•Needs
• Identify
Important
Items
•Variation
Experiments
•Make
Improvements
•Hold Gains
•Continuous
Improvement
Having heard the “voice of the customer”, QFD prioritizes where improvements
are needed; Taguchi provides the mechanism for identifying these
improvements
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
CoVE: Collaborative
Visualization Environment
for Complex Systems Design
Funded by the
Defense University Research
Instrumentation Program (DURIP)
February 2003
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
CoVE Objectives
• A semi-immersive, very high resolution, Collaborative
Visualization Environment (CoVE).
• Used to investigate the use of semi-immersive virtual
environments in collaborative design processes.
• Basic concept for the CoVE is a large, high resolution
display wall similar to those developed for media
companies and operations centers.
• It will allow us to apply emerging probabilistic design
methods to problems at an industrial scale.
• It is expected to promote new research in design,
visualization and usability with other leading centers on
campus.
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
CoVE Features
• A single CoVE with a 25 M-pixel resolution curved data
wall measuring 20 ft wide by 12 ft tall.
• Seating for up to 12 participants, each with their own
computers and local displays.
• The basic design will be configured so that it can be
used with another CoVE to execute distributed
collaborative design with another team at a remote
location.
• The CoVE will include both single person and group
video conferencing capabilities.
• Project budget: $630k
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Examples
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Examples
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
1
Unified Trade-off Environment
Morphological Matrix
Define
the
Problem
3
2
4
6
5
Investigate
Design
Space
Modeling
and
Simulation
Define
Concept
Space
7
Identify
Technologies
Feasible
or
Viable?
8
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G
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G
H
G
H
G
G
H
H
H
H
G
3
$ E&TDR
G
F
H
H
F
H
H
F
G
G
G
G
H
G
G
G
G
G
H
G
4
$ noitisiuqcA
F
G
G
H
G
G
G
H
G
H
G
4
$ troppuS
G
G
G
H
G
G
H
G
H
G
G
F
F
F
G
H
H
3
G
ces-fbl 003
fbl 004
7.0
4
3
4
3
5
0.52
0.52
0.76
0.76
0.19
0.331
50.0
50.0
40.0
60.0
40.0
40.0
60.0
80.0
I ezimixaM
J eziminiM
9
3
1
-1
3K FB (lb)
Fixed Requirements, Geometry
6K FB (lb)
ZSDE12
Fan
ZSDE2
Boost
ZSDE25
CPR
ZSDE41
HPT
ZSDE49
LPT
(R)
ZSWC41
HPT
Ch.
(%W25)
ZSWC42
HPT
NCh.
(%W25)
WT_ADDER
Wt.
Adder
(lbs)
Technology Metrics
CDF
Criterion 2
ZTH41
TH41
JPM
(lines of constant
probability)
z2max
Empty Weight
CFD Visualization
JPDM
Alternative 1
Area of
Interest
Area of Interest
EDF
(plotting
sample data)
Normal Distribution
Mean = 1.0
z2min
Std Dev = .007
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
Beta Distribution
Alpha = .052
Beta = .0076
Scale = 1.145
Installed Power [SLS,MCP]
Alternative 2
Alternative 3
z1min
XIRTAM
gnortS
muideM
kae W
FOOR
soP gnortS
evitisoP
evitageN
geN gnortS
Technology Impact Matrix
Fan Dia (in) Enge Wt (lb) Range (nmi)
ZPQD25
PQD25
ecnatropmI evitaleR
STHGIE W
SFC (1/hr)
Output CTQs
ZOPRD
OPRD
Design Variables
tsoC metsyS
ces 50.0
0.531
11.0
40.0
ces-fbl 2
5
0.99
30.0
Fixed Requirements, Technology Set
Technology
Profiles
ecnatropmI etulosbA
S WORRA
Snapshot 3
1
ytluciffiD lanoitazinagrO
0.56
50.0
5
0.56
50.0
X8
$ lasopsiD
stegraT
3
2 gnitaR AHSO
3
0.68
ces/ged 027 ,ged 54
mbl/utb 00052
5
0.28
20.0
sraey 03
1
1
50.0
20.0
ni 84
0.671
90.0
ni 25
3
0.44
70.0
mbl 009
3
30.0
g 02
0.87
30.0
1
40.0
-1
lasopsiD
4
Technology Dials
Snapshot 2
Fixed Geometry, Technology Set
RAM Model
efiL egarotS
4
H
0.97
Vehicle Attributes
Snapshot 1
ycaruccA
H
0.34
 Responses
2
H
0.35
 Responses
4
F
ytilibayolpeD
F
H
stnemeriuqeR remotsuC
G
ytilibapaC
G
G
H
0.46
200 nm
daolyaP
G
G
H
G
0.111
100 nm
egnaR
4
H
F
F
1
1
4
F
F
H
H
Torpedo Range
Mission Requirements
tsooB tsoP nametuniM
metsyS noisluporP
tnemevorpmI fo noitceriD
H
3
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F
I
G
1
 Responses
J
ecnatropmI remotsuC
noitcarF ssaM leuF
M
F
H
I
etaR/egnaR labmiG
N
I
tsurhT laixA
M
J
eslupmI laixA
F
I
emiT esnopseR
H
F
J
eslupmI metsyS
H
noitcarF ssaM leuF
H
H
F
gnitaR drazaH AHSO
N
tnetnoC ygrenE
H
G
M
N
efiL egarotS
thgie W latoT
G
H
J
G
F
M
N
I
G
H
M G
M
N M
F
I
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N
F
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G
retemaiD
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G
F
J
4
5,000 nm
F
J
3
750 nm
J
3000 ft.
F.L.=11,000 ft.
50 nm
H
G
N
I
G
N M
N
I
metsyS enignE
3
8. Abort
J
metsyS edutittA
epyT leuF
21
7. Loiter
M=0.6
2. Climb
1. Taxi & T.O.
Video Conference
Torpedo Noise
Torpedo Length
H
M
I
erutcurtS
%57
M=0.9
10. Land
F.L.= 11,000 ft.
I
G
N M
M
R
raey/rh 04
35,000 ft.
Constraint Analysis
9. Reserve
M=0.6
Technology Space
(Technology Dials)
I
N M
N
M
N
V
tf.uc/mbl 07
M=2.4
4. Climb
3. Cruise
Concept Space
(Vehicle Attributes)
Torpedo Velocity
50,000 ft.
1
STOC %
5. Cruise
67,000 ft.
2
rY/rHMM
Mission Space
(Mission Requirements)
6. Descent
3
J
Example ASDL Application
Mission Profile
4
daolyaP
M
N
srotarteneP #
5
scitsigoL
sdiA noitarteneP #
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V
V
scitsiretcarahC tcudorP
remotsuC
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tpecnoC SPBP weN
V
htgnertS/thgie W lairetaM
 Responses
W
Select
Technologies
Evaluate
Technologies
z1max
Criterion 1
CERT/CASA
nd
2
Weber
Floor Site
Operations
1
DN.
DOWN
STAGE
5A/460/0
UP
STAGE/3A/460/0
STAIR
CIR/5A/235
DOWN
Video
Conferencing
STAIR CIR/15B/235
CLS
CLS
CLS
CLS
Observers
Data Wall
LECTURE RM.
4/2440/90
LECTURE RM.
5/2440/90
LECTURE RM.
LECTURE RM.
3/2440/90 3/2440/90
Participants
CoVE Conceptual Layout
PROJECTION RM.
PROJECTION RM.
PROJECTION RM.
CLS
CLS
CLS
2D
2D
STAIR
LOUNGE - 6/700
CIR/5D/820
CIR/5C/305
DOWN
2D
2D
2D
STAIR
CIR/5E/305
DOWN
0 2 4 6 8 10
APPROXIMATE SCALE:
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
CoVE Tentative Schedule
•
•
•
•
•
•
Award announcement: February 2003
Final specifications: April 2003
Site preparations: May 2003
Construction & Installation: July 2003
Testing: September 2003
Acceptance: October 2003
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Aerospace Systems Engineering Course:
AE 6370
• Introduces new graduate students to Aerospace Systems Engineering
and a methodology for Implementing it through IPPD through Robust
Design Simulation (RDS)
• Consists of covering traditional systems engineering methods and
tools; introduces quality engineering methods and tools; introduces
multi-attribute decision methods; and introduces the need for a
computer integrated environment
• Course consists of a mid-term exam and team projects (~5 students
per team) addressing the concept formulation for complex systems or
system of systems
• Utilizes a simple set of integrated tools to allow the teams to conduct
the first iteration through a complex system design
• Will be offered as a distance learning course for the first time in Fall
2003
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Aerospace Systems Engineering Taught
using an Integrated Set of Tools
QFD
alt. concepts
HOWs
Tech. Alternative
Identification
Baseline
Engine Type
3 Stage
Mid-Tandem
Fan
2 Stage
Combustor
Conventional
RQL
Nozzle
Conventional
Conventional +
Acoustic Liner
Circulation
Control
criteria
Fan
Weights
Aircraft
Technologies
MFTF
1 st Option
None
2 n d Option
Turbine Bypass
LPP
No Fan
Mixer Ejector
Nozzle
Hybrid Laminar
Flow Control
Morphological Matrix
Pugh Evaluation Matrix
MADM
Best
Alternative
Subjective Evaluation
(through expert opinion,
surveys, etc.)
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Ten Complex System Formulation Projects from
AE6370, Fall 2002
•
•
•
•
•
•
•
•
•
•
AIAA Graduate Student Missile Design Competition: “Future Target Delivery
System(Missile Multipurpose Target”
RFP for a “High Firepower Payload for Missile Defense (Missile
Interceptor)
NASA Sponsored University Competition for the “Conceptual Design of a
Titan (Saturn’s largest moon) Vertical Lift Aerial Vehicle”
AHS/NASA Student Design Competition for “VTOL Urban Disaster Response
Vehicle”
NASA “Personal Air Vehicle Evaluation Program: to identify VTOL and
ESTOL Concepts”
RFP for a “Quiet Supersonic Business Jet” in conjunction with Gulfstream
Aerospace Company
DoD Potential Joint Program for an “Air Maneuver & Transport Concepts for
the Objective Force”
AIAA Student Competition for “Subsonic Commercial QuEST”
AUVS International Aerial Robotics Competition and DARPA Project:
“Intelligent Uninhabited Aerial Vehicle (UAV) using Software Enabled
Control (SEC)”
Army Aviation Recapitalization Program: “Technology and Risk Assessment
for the Army’s UH-60M Helicopter Improvement Program”
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
What is IPPD Through RDS
• Integrated Product/Process Development (IPPD) means applying
Concurrent Engineering at the front end of a system’s life cycle
where design freedom can be leveraged and product/process design
tradeoffs conducted in parallel at the system, component, and part
levels
• Implementation of IPPD requires moving from a deterministic point
design approach to a probabilistic family design approach to keep
the design space open and from committing life cycle cost before the
system life cycle design trade-offs can be made
• Robust Design Simulation (RDS) provides the necessary simulation
and modeling environment for executing IPPD at the System level
• Continuation of RDS along the system life cycle implies the creation of
a Virtual Stochastic Life Cycle Design Environment
• An Overall Evaluation Criterion (OEC) based on System
Affordability should be identified early and its variability tracked along
the life cycle time line
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Roadmap to Affordability Through RDS
Robust Design Simulation
Subject to
Robust Solutions
Design & Environmental
Constraints
Technology
Infusion
Objectives:
PhysicsBased
Modeling
Activity and
ProcessBased
Modeling
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
Synthesis
& Sizing
Simulation
Economic &
Discipline
Uncertainties
Operational
Environment
Economic
Life-Cycle
Analysis
Impact of New
TechnologiesPerformance &
Schedule Risk
Schedule
Budget
Reduce LCC
Increase Affordability
Increase Reliability
.....
Customer
Satisfaction
CERT/CASA
Interactive RDS Environment
FPI
FPI
/ MC
Criterion 2
or Requirement 2
100%
Probability
DISCIPLINARY RSEs
CDF
Aero
0%
Structures
JPDM
Objective
Weights
Metrics/Objectives
Metrics/Objectives
 Responses
Requirements
Space
Constraints
Metrics/Objectives
 Responses
Constraints
 Responses
Technology
Space
Constraints
SYNTHESIS & SIZING
Criterion 1
or Requirement 1
Concept Space
Etc.
ce
pa
S
on
ati
r
i
p
As
1
TWR
RSEs
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
Dynamic
Contour
Plots
²%$/RPM
TOFLmod
SLNmod
-1
-1
SW
1
CERT/CASA
Risk & Uncertainty are Greatest at the Front
KNOWNS
KNOWN-UNKNOWNS
UNKNOWN-UNKNOWNS
CONCEPT VALIDATION
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
FULL
PRODUCTION DEVELOPMENT
SCALE
DEVELOPMENT
CERT/CASA
Coninuous RDS along the System Life Cycle to link the
“fuzzy front end” to the “process capability approaches”
Continuous Product Improvement / Innovation
Uncertainty
Overall
Evaluation
Criterion
(OEC)
Risk Management/Reduction
Fuzzy Front End
Upper Specification
Response
OEC Target
Lower
Bring the Development Process
Under Control, C
p =1
Define Distributions
System Definition
&
Tech. Development
(Conceptual/System)
Traditional C
System Design
(Preliminary/Parameter)
p
and C
pk
Specification
Approach Six-Sigma,
1<C p <2
System Integration
(Detail/Tolerance)
Manufacturing
(On-Line Quality)
Approach for Continuous, On-line Process Improvement
Overall
Evaluation
Criterion
(OEC)
Upper Specification
Response
OEC Target
Lower
Specification
Six-Sigma Achieved,
Cp = 2
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
Initial Distribution
Reduced Variability and Improved Mean Response
Time
CERT/CASA
The VSLCDE- Key Characteristics
The purpose of VSLCDE is to facilitate design decisionmaking over time (at any level of the organization) in the
presence of uncertainty, allowing affordable solutions to be
reached with adequate confidence. It is a research testbed.
Virtual . . . Simulation-based system life-cycle prediction
Stochastic . . . Time-varying uncertainty is modeled; temporal decision-making
 Life-Cycle . . . the design, engineering development, test, manufacture, flight test,
operational simulation, sustainment, and retirement of a system. The operational
simulation includes virtual testing, evaluation, certification, and fielding of a vehicle in the
existing infrastructure, and tracking of its impact on the economy, market demands,
environment.
 Design . . . Implies that the environment’s main role is to provide knowledge for use by
decision-makers, especially for finding robust solutions
 Environment . . . Implies the support of geographically distributed analyses and people
through collaboration tools and data management techniques


Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA
Some Opportunities for Collaboration between
the Schools of AE and ISYE
• Integration of ISYE Logistics with AE Aerospace Systems Design
Program for a variety of customers (Industry and Government)
• With Lockheed Martin on a Modern Systems Engineering Approach
(addressing Product Life Cycle tradeoffs from the Outset) based on the
Joint Strike Fighter (JSF) Development Approach successes and
Lessons Learned (POC: Bill Kessler, LM Lean Enterprise Mgr and Tom
Burbage, LM JSF VP)
• With OSD/DOD/USAF New Focus on Systems Engineering Education
and Research
• With USAF – GT(CEE) Initiative in taking over the Lean Sustainment
Initiative from MIT
• With NASA Langley National Institute of Aerospace (NIA) and with
NASA Ames Engineering of Complex Systems (ECS) programs
• Others?
Dr. Daniel P. Schrage
Georgia Institute of Technology
Atlanta, GA 30332-0150
www.asdl.gatech.edu
CERT/CASA