A Through-life, Integrated and Concurrent Engineering Methodology for the Responsive Development of Large and Complex Space Systems”

Dipartimento di Ingegneria Meccanica e Aerospaziale
A THROUGH-LIFE, INTEGRATED AND CONCURRENT
ENGINEERING METHODOLOGY FOR THE RESPONSIVE
DEVELOPMENT OF LARGE AND COMPLEX
SPACE SYSTEMS
SECESA Conference – Glasgow (UK)
26-28 September 2018
A. Boschetto, L. Bottini, P. Gaudenzi, M. Gschweitl, M. Lisi, G. Palermo, L. Pollice

14/09/2018 Pagina 2System Engineering
OVERVIEW
 SPACE 4.0 SYSTEMS FEATURES
 TICE© APPROACH
 I CASE-STUDY: OPTIMIZATION METHODOLOGIES FOR THE
PRELIMINARY DESIGN OF SATELLITE CONSTELLATIONS
 II CASE-STUDY: DEVELOPMENT OF INNOVATIVE ADDITIVELY
MANUFACTURED SPACECRAFT STRUCTURES
 CONCLUSIONS
1

New Space Economy market requirements and trends
 Industry 4.0 framework / Third Digital Revolution (computing, communicating, fabricating)
 Direct interaction with society needs / Demand-pull approach
 Space services commercialization / New private stakeholders
 Higher market competitiveness / Stringent cost & time-to-market requirements
 New roles for industry and new cooperative relations with other industrial partners
 “coopetition”
 High rate of technological innovation
 Innovative space mission architectures (space-ground-launch) with more
challenging system requirements for space programs / SoS approach
 New very large constellations of small-satellites to be produced at very high datarate
 Dedicated and flexible launches for smallsats / Alternative ways to space access
 Complementarity and synergy of large and small space systems
 Increasing complexity of product/services  platforms/payload
SPACE 4.0 SYSTEMS FEATURES
2

Future space service infrastructures will be large complex systems, requiring large
initial investments, very expensive to operate and maintain, meant to last for long
periods of time (decades). Three key-features will be must addressed for the
success of future space service infrastructure projects:
 Affordability
 Supportability
 Sustainability
3
BUDGET

Future space service infrastructures will be large complex systems, requiring large
initial investments, very expensive to operate and maintain, meant to last for long
periods of time (decades). Three key-features will be must addressed for the
success of future space service infrastructure projects:
 Affordability
 Supportability
 Sustainability
3
BUDGET
A RADICAL PARADIGM SHIFT IN THE WAY THE SPACE BUSINESS IS CONCEIVED IS MANDATORY.
New organizational, technical and technological formats are required.

A Through-life Integrated Concurrent Engineering (TICE©): concurrent engineering and
through-life perspective integrated with collaborative technologies and large-scale production
best practices. A responsive approach addressing the SPACE 4.0 challenges and needs,
enabling the realization of successful systems, following a systematic and systemic
development process focused on system life-cycle functions and services delivering.
Concept developed by Marco Lisi (ESA)
in collaboration with the Sapienza Space Systems Research Group (led by Prof. Gaudenzi)
 Through-life: all phases of
a space system business
are covered, not just
system development
 Integrated: all disciplines
and expertise are
integrated in a systemic
perspective. All actors and
stakeholders of the
“extended” enterprise are
cooperating towards the
common objective
 Concurrent: concurrent and
collaborative approaches and
IT technologies are widely
adopted
 Engineering: all aspects of
the enterprise are engineered
and optimized with a holistic
development perspective
TICE© APPROACH
4

OPTIMIZATION METHODOLOGIES FOR THE
I CASE-STUDY
iStockphoto
I CASE-STUDY
5

The approach adopted for the development of a general design
methodology is based on the comparative evaluation of a set of alternative
architectures (tradespace exploration) and on a multi-objective
optimization process (Pareto analysis).
I CASE-STUDY
6

Example of metrics considered:
Infrastructure cost [MUSD] Includes:
• RDT&E
• Launch (based on Falcon 9, calculated considering the number of satellites that can be grouped in
one single launch as a function of their mass and their final deployment orbits)
• Ground Segment
• Operations
Average connection datarate [bps]
I CASE-STUDY
7

• RDT&E
• Ground Segment
• Operations
Example of a set of major decisions (architectural variables) adopted for the
architectural matrix:
I CASE-STUDY
7

• RDT&E
• Ground Segment
• Operations
Example of a set of major decisions (architectural variables) adopted for the
architectural matrix:
Example of Enumeration and Analysis:
I CASE-STUDY
7

Example of application of the methodology to infrastructure lifecycle
(progressive deployment of a satellite constellation)
I CASE-STUDY
8

The analysis of the results allows to identify,
within the subset of optimal solutions found,
which solution is the most appropriate for each
specific intended application
Example of progressive deployment strategy
Example of application of the methodology to infrastructure lifecycle
(progressive deployment of a satellite constellation)
I CASE-STUDY
9

DEVELOPMENT OF INNOVATIVE ADDITIVELY
II CASE-STUDY
DEVELOPMENT OF INNOVATIVE ADDITIVELY MANUFACTURED
SPACECRAFT STRUCTURES
II CASE-STUDY
10

II CASE-STUDY
- AM: Additive Manufacturing
A new manufacturing paradigm
- D4AM: Design For AM
An innovative design thinking
- Advanced Systems and Concurrent Engineering:
a powerful design framework and a set of useful
methodologies (methods, processes and tools)
- TICE: an interdisciplinary integrated approach
INNOVATIVE SATELLITE ARCHITECTURES
The SAPIENZA-RUAG
D4AM Project
II CASE-STUDY
11

II CASE-STUDY
II CASE-STUDY
11
of AM technologies on a “standard” satellite systemTHALES-RUAG-SIRRIS
courtesy

II CASE-STUDY
II CASE-STUDY
11
S/C LATERAL PANEL
as a scalable representation of a:
- spacecraft platform
- methology benchmark
Main constraints:
• time  PhD activity of few
months
• space  building volume
• high innovation degree to
manage
Main driving factors:
• Mechanical/Physical
Performance
• Integration of functions
(wirings, heat-pipes)
• Programmatics aspects
(development time&cost)

SAPIENZA-RUAG
CE TEAM
• SYSTEM ARCHITECT
• SYSTEM ENGINEER
• M&P EXPERT
• SRUCTURAL SYSTEM ENGINEER
• ANALYSIS AND DESIGN EXPERT
• MECHANISMS EXPERT
• D4AM EXPERT
• AIT EXPERT
• SYSTEM
ARCHITECT
+
for a Phase A / pre-Phase A
feasibility analysis
THE METHODOLOGY
CONCURRENT
ENGINEERING
(CE)
WITH A
THROUGH-LIFE
PERSPECTIVE
12

• SYSTEM
ARCHITECT
+
 6 meetings or sessions (1 per week)
 Deadline: 31 January 2018
 2 hours per meeting with some rounds + briefing/debriefing
 Tasks and goals definition per meeting
CE MANAGER & SYSTEMS ARCHITECT
LUCIANO POLLICE
THE METHODOLOGY
12
CONCURRENT
ENGINEERING
(CE)
WITH A
THROUGH-LIFE
PERSPECTIVE

• SYSTEM
ARCHITECT
+CONCURRENT
ENGINEERING
STAKEHOLDERS
NEEDS
& BUSINESS
OPPORTUNITIES
VALUE GOALS
& MISSION
DEFINITION
CONCEPT
TRADESPACE
EXPLORATION
ARCHITECTURE
DEFINITION
DEVELOPMENT
& OPERATIONS
THE METHODOLOGY
12

• SYSTEM
ARCHITECT
+ SYNTHESIS
 ANALYSIS
 ANALYSIS
 SYNTHESIS
 DEVELOPMENT
Reducing ambiguity
Applying creativity
Reducing ambiguity
and managing
complexity
Managing complexity
THE METHODOLOGY
12

THE DECISION SUPPORT TOOL or CONCURRENT DESIGN TOOL (CDT)
A requirements-forms-functions MULTIDOMAIN MATRIX (MDM)
DESIGN MATRIX
Reqs  Main Functions
MORPHOLOGICAL MATRIX (+ F.A.M.)
Main Functions  Form alternatives
DESIGN STRUCTURE MATRIX
Form alternatives Form alternatives
II CASE-STUDY
13

A sensitivity analysis tool is also available to validate the metrics weights
DESIGN DRIVERS
DESIGN MATRIX
II CASE-STUDY
13

FORM ALTERNATIVES FOR THE MAIN MECHANICAL FUNCTIONS
II CASE-STUDY
14

MULTIFUNCTIONAL INTEGRATED S/C LATERAL PANEL
AM
NOT AM
AM EMBEDDED AM PARTIALLY
EMBEDDED
STRUCTURE
INTEGRATED
STRUCTURE
SUPPORTED
FORM ALTERNATIVES FOR THE OTHER MAIN FUNCTIONS
II CASE-STUDY
15

OBJECTIVE:
to understand, apply
and assess the
methodology by
quickly arriving to a
manufacturable
product, even if not
completely
performance-optimized
CONSTRAINTS:
- development time
- AM machine size
SIMPLIFICATION:
by focusing on a more
simple and
manageable system
with reduced interfaces
and delivered
functions:
1. STRUCTURAL
2. THERMAL
3. HARNESS
ACCOMODATION
BIOMIMETIC
AM
EMBEDDED
STRUCTURE
INTEGRATED
FROM THE AM CDT
AM
NOT AM
AM EMBEDDED AM PARTIALLY
EMBEDDED
STRUCTURE
INTEGRATED
STRUCTURE
SUPPORTED
FORM ALTERNATIVES FOR THE OTHER MAIN FUNCTIONS
II CASE-STUDY
CONSIDERING ONE QUADRANT OF THE
MODULAR RADIATIVE PANEL SUPPORTING
AN ELECTRICAL EQUIPMENT
15

 NON-INTUITIVE SOLUTIONS HAVE BEEN OBTAINED
 SAVING DEVELOPMENT TIME (DESIGN & MANUFACTURING)
 IMPROVING THE DESIGN EFFECTIVENESS & PRODUCT PERFORMANCE
II CASE-STUDY
16

AM BIOMIMETIC
RADIATIVE-STRUCTURAL
MODULAR PANEL
QUANTITATIVE
STRUCTURAL
ANALYSIS
(TOPOLOGY
OPTIMIZATION)
QUANTITATIVE
THERMAL
ANALYSIS
EQUIPMENT DEFINITION
(TRADITIONAL HEAT PIPE)
CUSTOMIZED TOPOLOGY
CONFIGURATION
CONVERGENCE
VERSUS A HEAT PIPES
CUSTOMIZED
CONFIGURATION
(AS COMPROMISE OF BOTH
ANALYSIS, only minor
compromises were necessary))
heat pipe
crosssectionheat pipes
V-shape
boundary
connections
harness
accomodation
structural
grooves
DESIGN APPROACH
FINAL DESIGN
 NON-INTUITIVE SOLUTIONS HAVE BEEN OBTAINED
 SAVING DEVELOPMENT TIME (DESIGN & MANUFACTURING)
 IMPROVING THE DESIGN EFFECTIVENESS & PRODUCT PERFORMANCE
II CASE-STUDY
16

An opportunity for a SPACE 4.0 market requirement and trend
VERY LARGE CONSTELLATIONS
OF SMALL & LARGE SATELLITES
CUSTOMIZATION &
INTEGRATION
STANDARDIZATION &
MODULARIZATIONVS
Customer needs
(service point of
view)
System supplier
needs
(product
development
point of view)
 Integrated space mission architectures
(space-ground-launch)
 More challenging system requirements
 SoS approach
 High rate of technological innovation
 Products-Services more complex
 Increasing market volatility and
competitiveness
 Time-to-market reduction
 “Off-the-shelf” HW
CONCLUSIONS
17

An opportunity for a SPACE 4.0 market requirement and trend
VERY LARGE CONSTELLATIONS
OF SMALL & LARGE SATELLITES
OPTIMIZATION METHODOLOGIES
+
TICE©
CUSTOMIZATION &
INTEGRATION
STANDARDIZATION &
MODULARIZATIONVS
ADDITIVE MANUFACTURING
+
TICE©
ORGANIZATIONAL PROCESSES DESIGN & MAIT INNOVATIONS BEST PRACTICES
Customer needs
(service point of
view)
System supplier
needs
(product
development
point of view)
 Integrated space mission architectures
(space-ground-launch)
 More challenging system requirements
 SoS approach
 High rate of technological innovation
 Products-Services more complex
 Increasing market volatility and
competitiveness
 Time-to-market reduction
 “Off-the-shelf” HW
CONCLUSIONS
17

CONCLUSIONS
 The TICE© methodology, integrating systems & concurrent engineering and systems
architecting best practices with a whole life-cycle perspective, represents, with its
effectiveness, efficiency and flexibility, a very powerful design environment in which
to develop present and next-future large and complex space systems.
18

CONCLUSIONS
 Its value in reducing the design effort within the preliminary design phases of complex
systems and to responsively address very different missions, with optimal choices in
terms of system architectures and technological solutions has been for the first time
assessed through two very different case-studies, taking good decisions quickly.
 Its application to the optimization of the preliminary design of satellite constellations
and to the development of innovative additively manufactured spacecraft structures
has been shown.
18

CONCLUSIONS
 Its value in reducing the design effort within the preliminary design phases of complex
systems and to responsively address very different missions, with optimal choices in
terms of system architectures and technological solutions has been for the first time
assessed through two very different case-studies, taking good decisions quickly.
 Its application to the optimization of the preliminary design of satellite constellations
and to the development of innovative additively manufactured spacecraft structures
has been shown.
 Through the proposed methodology, it is possible to better explore the tradespace and
to comprehend the trade-offs, that have to be made when responding to different
needs or application contexts. Moreover it is possible to track the design choices and
to quickly eliminate the unfeasible or not optimal solutions and in some cases identify
some innovative, unexpected architectural solutions to be examined in more depth.
18

THANK YOU
QUESTIONS?

A Through-life, Integrated and Concurrent Engineering Methodology for the Responsive Development of Large and Complex Space Systems”

Recommended

Recommended

More Related Content

Similar to A Through-life, Integrated and Concurrent Engineering Methodology for the Responsive Development of Large and Complex Space Systems”

Similar to A Through-life, Integrated and Concurrent Engineering Methodology for the Responsive Development of Large and Complex Space Systems” (20)

More from Marco Lisi

More from Marco Lisi (20)

Recently uploaded

Recently uploaded (20)

A Through-life, Integrated and Concurrent Engineering Methodology for the Responsive Development of Large and Complex Space Systems”