Controls, Dynamics, Guidance @ Zeus Numerix

1Build-to-Specifications | Product Approval | Engineering Services | Software Development
Controls, Dynamics, Guidance
@ Zeus Numerix
Presentation on controls, micro-controllers, dynamics,
guidance software
V3
Abhishek Jain

2
©ZeusNumerixPvtLtd:ConfidentialDocument
Presentation Overview
16 May 2019 Controls, Dynamics, Guidance @ Zeus Numerix
 Zeus Numerix – an Introduction
 Journey started from development of 6-DOF codes
 No 1 Know-Why company involved in development of fire control computers, range tables
and guidance algorithms for projectiles
 Non-confidential case studies
 Dynamics
 Controls and Guidance
 Controllers and Related Projects
 Team and Closure
 The presentation is non-confidential and some data may be masked
 Legends in the presentation are not shown purposefully
2

3
3
2004
1st Project Completed
Large Defense Project
2005 2006
1st Software Export
System design software: Korea
2007
2008
CEM Software
UAV RCS Reduced
2009
1st Built-to-Spec project
Supersonic ground
vehicle developed
2010
Fire Safety & Comfort
Building fire and HVAC
2011
Control Software
In-house development
2012
2013
Parallel GPU code Devp
Visualize big data – 4 billion points
2015
Floating Panel Design
Solar Panels in Lake
2017
1st foreign missile project
Integration & Certification
2018
1st MSME TDF Winner
D&D of Composite Sea Water Pump
2019
Incubated at IIT Bombay
Journey Begins with India’s 1st
Commercial CFD software!
400th project completed
Lockheed Innovation
Medal & India Govt
R&D Certificate
CEM Software
CEMILAC Certification
1st Store Separation
project complete
www.zeusnumerix.com/portfolio
The Journey

4
4
Customers List: Partial

5
5
Accolades
R&D Recognition Innovation Medal
DST-FICCI-Lockheed Martin
India Innovation Growth
Medal 2007 for
“Numerical Simulations”
Recognition as an R&D Unit by
the Department of Scientific
and Industrial Research
“Design Approval” by Centre
for Military Airworthiness
and Certification certified
CEMILAC Certificate

6
6
Core Offerings
Product
Development
Initial sizing from first
principles
Detailed analysis
based design
Prototype
development
Testing and validation
Product
Approval
Performance
estimate by analysis
Detailed Report
Generation
Review with approval
agency
Final submission and
product approval
Engineering
Services
Design calculation
reports
Analysis – CFD, FEM,
CEM
Failure analysis and
design suggestions
Multi-disciplinary
design optimization
Software
Development
Pre-processing
Automation
Solver development
from Literature
survey
Visualization, parallel
code CPU/GPU & GUI
System simulation
tools

7
Dynamics, Controls & Guidance
7
Dynamics
• 6 Degree of freedom code
• Corrections: Wind, CG, Coriolis force
• Fire control computer
Controls &
Guidance
• Canard control systems
• Linear and PN guidance
• Autopilot, on-board computer (OBC)
Controller
• Micro-controller based control
• Test rig, monitoring and Visualization
• Coupled problem e.g. store separation
Trajectory Correction Algo

8
Dynamics
Non-confidential examples of completed projects for
projectile dynamics
8

9
Initial Design: SPRDesign™
 Preliminary Design of Solid Propellant Rocket
 Quick performance estimation of spinning rocket
 Includes key modules like Aerodynamics (DATCOM), structural (inertial properties),
internal ballistics (P-t for Finocyl grain) & dynamics (for range & velocity profile)
9

10
6DOF Software for Rockets
 Development of 6DoF software for artillery rockets
 Powered flight up to all burn point – includes effect of mass reduction
 Coasting flight after ABP; effect of wind calculated from input MetCM file
 Range, orientation w.r.t. time estimated
 Effect of big and small brake rings in reducing the range appropriately
10

11
Inbore Ballistics – Artillery Rockets
 Simulation of various phases as shown in the figure to predict tip-off
 Image processing while firing to find the tip-off experimentally
 Lens-aberrations, CCD/CMOS noise, image compression etc. accounted in the software
11
Detent Phase
Tip-off Phase
Tube Guidance
Free Flight
Detectionofrocketimage,removalof
background&calculationofangle

12
External Ballistics
 Dispersion in Fall of Shot for antitank ammunition using Monte-Carlo methods
 Dispersion effect due to Wind gusts, launch yaw rates, barrel erosion etc.
 Oscillations studied & design changes suggested
12
Altitude
Drift

13
Roll Stability and Trajectory
 Rocket trajectory & CEP prediction
 Trajectory of multiple rockets compared with field trials
 Wobbling (dynamic instability) prediction
 CEP improvement due to better prediction
 Extended Kalman Filter to reduce flight data errors
13
ZN Prediction
Comparisonofresults
ZN6-DoFcodeagainstfieldtrials
LegendNormalizedtointegers
Actual Firing

14
Naval Rocket Drift Reduction
 Roll stabilized fire and forget rocket drifting observed
 Aerodynamic and structural fin design change & sensitivity to thrust misalignment, wind,
stability, fin cant & no studies studied
 Drift reduction of 80% achieved in first design iteration
 Custom software developed to simulate effect of fore & aft motor, fins, wind effects etc.
14

15
Design Analysis of Ram Air Parachute
 Opening dynamics (inflation) of the parachute
 CFD for drag prediction and FEM for load on the fabric; change in dynamics due to shape change
 Custom software to perform design iterations on various parachute shapes
15

16
Controls and Guidance
Controls for the projectile to improve the CEP; Linear and non-
linear controls covered
16

17
Aero-structural and Controls of Guided Rocket
 Guidance with range and line correction
 Aerodynamic and structural design of canard for desired Cnδ with Aeroelastic considerations
 Autopilot design for control of rocket in flight
 Design as per available actuators, motors, battery etc.
 CEP achieved below 5 m for an extended range rocket
17
Twolooprollautopilot
Mesh

18
Trajectory Correction System
 Correction of trajectory of spinning missile based on the acquisition of target
 Control algorithm implemented on the rocket
18

19
Missile Guidance and Control for SILS
 Development of plant module for guidance
 Real time code for onboard computer in loop simulation
 Porting the plant code on RS422, MIL STD 1553, Ethernet
 Build PC-in-Loop simulation with modules of Plant, OBC and Target
19
Schematicofthecode
C++codedeveloped
RTOScapabilitykeptinmind

20
Flight Data Analysis of Fighter Aircraft
 Post analysis of flight data received after each sortie
 Comparison of predicted and actual performance
 Aid in development of flight test analysis capture tool
20

21
Controllers, Test Rigs & Coupled
Simulations
Examples of controller developed for ground and aerial system
along with test rigs and data visualization. Coupled dynamics
simulations examples are shown
21

22
Design of High Speed Sled
 Aerodynamic, Structural & Dynamics design of recoverable supersonic land vehicle
 Acceleration and deceleration in given length
 Turnkey project from concept to production drawings
 Multiple concepts designed and analyzed
 Severe aerodynamics loads, weight restrictions and erosion of sliding shoe
22
75% Less Drag,
50% Weight
OldDesign
New Design
Realized and Tested

23
Panel Separation: Coupled CFD+Dynamics
 Freestream flow at 6.5 Mach
 Initial 1-DoF: panel rotates about hinge; 6DoF after hinge breaking
 Panel with nose separates slowly; Thin strakes inside panels modeled
 Large stagnation region behind panels
23
Mach Number

24
Advanced Bomb: Light Store
 Asymmetric configuration and light weight
 Flat wings at ‘bottom’ were matter of concern due to high ‘lift’; required for loiter/glide
 Results match with wind tunnel data
24
Accurate Geometry Not Shown

25
Micro-Controller Design for Space Probe
 Servo-based motor system for controlled initiation of unlocking mechanism
 In-flight deployment with substantial vibration loading
 Control of 5 servo motors from the micro-controller
 System designed to handle wide variety of input voltages and had simple trigger mechanism
25
Balloongondolawith
deployedbooms
Servo-ControllerBoard

26
Altitude Hold Controller for Airship
 Development of controller to hold the altitude constant for the demo airship
 Four powering motors controlled by the new controller
 CG balancing to get the airship level
26
Controller
Inflated airship

27
Develop Embedded Software for RFID Reader
 Pallet tracking inside a petrochemical plant using Motorola RFID
 Tagging from pallet commissioning at bagging line to storing in bay and dispatch
 System to fit in existing system with no modification to PLC
27

28
Modal & Rigid Body Analysis for Chain Drive
 Modal analysis of the chain drive mechanism for structural integrity
 Rigid body analysis of the chain at different RPM and chain tension
28

29
Design, Development of Thrust Cradle
 IC Engine powered Airship requires testing of thrust, fuel flow rate, temperature
 Thrust cradle designed, integrated, tested and delivered to lab
 Integrated sensors with the mechanical model and developed GUI for visualization
29
Electronic sensors
GUI for sensor data
Mechanical Cradle

30
Team and Closure
Details of the team and consultants and summary of
presentation
30

31
Core Team
31
 Prof Gopal Shevare (Chairman) – PhD IIT Bombay with 40+ years research exp
 Expert in MDO, fluid dynamics, numerical methods and simulation product development
 Basant Kumar Gupta (CEO) – Masters IIT Bombay with 16 years experience
 Expert in preliminary design, project management,
 Irshad Khan (COO) – Bachelor Mechanical with 22 years experience
 Expert in mesh generation, drawings, product development and vendor management
 Sumit Jana (Head – Solver Devp) – Masters IIT Kharagpur with 12 years exp
 Expert in parallel solver development for CFD, Electromagnetics and free surface flows
 Suman Mohandas (Head – Software Devp & Visualization) – Bachelors Computer
 Expert in new software development, visualization, parallelization and GUI
 Ten engineers certified by CEMILAC including above

32
Consultants and Collaborations
32
 MOUs and Collaborations
 Centre for development of advanced computing – HPC usage in Teraflops
 NIT Nagpur – Joint R&D projects in coupled problems (CFD+FEM)
 IIITDM – Joint projects of analysis adding to product development
 Expert Panel (partial)
 Mr. SG Joshi – 40+ years experience in pump design and manufacturing
 Prof S C Lakkad – 45+ years experience in composite design and manufacturing process
 Prof K Sinhamahapatra – 20+ years experience in acoustic prediction
 Mr S Panse and H Ketkar – 35+ year exp in tool room, jigs/fixture design, special projects
 Mr V Kamat – 40+ years experience in hydraulic machine design, fabrication & maintenance
 Mr A Patki – 40+ years experience in space systems for reliability and weight reduction

33
Closure
33
 Experience of 400+ high tech projects in both strategic and industrial sectors
 Engineers trained in Aerospace grade quality and confidentiality
 Robust engineering software development experience
 Modular code development with high reusability
 Experience of parallelization and cloud computing
 Domain expertise in aforementioned sectors
 Contribution by the engineering team enhanced to design suggestions
 Flexible engagement model
 Fixed cost, Time and Material, Cost plus or models as per problem statement
 Unafraid to take R&D projects – Test Us

34
www.zeusnumerix.com
+91 98190 09836
Abhishek Jain
abhishek@zeusnumerix.com
Thank You !

Controls, Dynamics, Guidance @ Zeus Numerix

Recommended

Recommended

More Related Content

Similar to Controls, Dynamics, Guidance @ Zeus Numerix

Similar to Controls, Dynamics, Guidance @ Zeus Numerix (20)

More from Abhishek Jain

More from Abhishek Jain (20)

Recently uploaded

Recently uploaded (20)

Controls, Dynamics, Guidance @ Zeus Numerix

Editor's Notes