ASEE International Forum 2013, Atlanta, GA, June 22, 2013
Jean Koster,
University of Colorado Boulder
Students from around...
ASEE 2013
• Opportunities made available by software and internet
• 3D CAD software, Product Lifecycle Management (PLM)
• ...
ASEE 2013
Hierarchies Become Networks
-Purpose-
“The corporation as we know it is unlikely to survive
the next 25 years. L...
ASEE 2013
Benefits of Collaboration
-Purpose-
Need: A better understanding of the process of
collaborating and the skills ...
ASEE 2013
Aircraft Market Diversity is Increasing
-Purpose-
Source: Boeing Commercial Airplanes, 2012 CMO
5
ASEE 2013
Boeing 787 Global Work Breakdown Structure
-Purpose-
• Manufacturing dispersed in
many countries
– For Boeing’s ...
ASEE 2013
Huge Organizational Challenges
-Purpose-
Young Engineers need to learn to
choreograph
delocalized design and man...
ASEE 2013
1. Critical thinking and problem solving
2. Collaboration across networks and leading by influence
3. Agility an...
ASEE 2013
“If you have an apple and I have an apple and we exchange apples
then you and I will still each have an apple.
B...
ASEE 2013
NASA’s ERA Goals
Reduce:
Aircraft fuel consumption
Emissions
Noise
…Simultaneously!
10
Motivation: Green Avia...
ASEE 2013 11
Global Team
- Follow The Sun -
Engineering students need to develop skills in
orchestrating (delegating) and ...
ASEE 2013 12
System Configuration: HYPERION
- Hyperion -
Hyperion 2012-13
Hybrid-Electric
Engine
BWB Carbon
Fiber / Compos...
ASEE 2013 13
Schedule
-Global Collaboration-
PDR CDRStart
Flight
Testing
𝑪 𝑳 𝒎𝒂𝒙
~1
𝑳/𝑫 𝒎𝒂𝒙 ~18
𝑽 𝒔𝒕𝒂𝒍𝒍 13.2 m/s (29.5 mph)
𝑽 𝑻𝑶 15.8 m/s (35.4 mph)
𝑽 𝑪𝑹 30 m/s (67 mph)
𝑺 1.693 m2 (18.22 ft2)
𝒃 ...
15
Wind Tunnel Tests
Hyperion 2012-13
 Goal: Find out if takeoff pitch-flip behavior is systematic, or a ½
scale proto ma...
ASEE 2013 16
Aerodynamics & Structures
-Technology Overview-
½ Scale Wind Tunnel Model Internal Structure Center Body/Inte...
ASEE 2013 17
Global Integration Manufacturing
IDT (Interface Dimension
Template)
• Device used to ensure
German center bod...
ASEE 2013 18
Global Integration
-Global Collaboration-
“Flat Sat” Approach (Simulation and Test-bed)
- Used while center b...
ASEE 2013
FTS Example
-Global Collaboration-
Colorado Team
• Changes structure component
• Does it meet Requirements?
• Wh...
ASEE 2013 20
Lessons Learned
-Global Collaboration-
Language and Cultural Barriers
Although everyone speaks Englineerish…....
ASEE 2013 21
Lessons Learned
-Global Collaboration-
Follow-the-Sun (FTS):
• Great for CAD design work
• Ideas across borde...
ASEE 2013
• Project needs managerial infrastructure
– Needs strong Project Manager (Choreographer)
– MBA candidate on team...
ASEE 2013
Student Global Team
-Team-
Michaela Cui
Tyler Drake
Arthur Kreuter
Gavin Kutil
Brett Miller
Corey Packard
Marcus...
ASEE 2013 24
Acknowledgements
-Acknowledgements-
A special thanks to…
Mike Kisska of Boeing
Frank Doerner of Boeing
Blaine...
Questions?
Contact: jean.koster@colorado.edu
ASEE 2013 26
Project Papers
- Papers -
Hyperion 2012-13
The Hyperion 2.1 Green Aircraft Project, AIAA-2013-0817 (Best Pape...
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Students from around the world design, build, and fly an aircraft

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Presentation on the need for global student projects given at the ASEE International Forum in Atlanta, GA on June 22, 2013.

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Students from around the world design, build, and fly an aircraft

  1. 1. ASEE International Forum 2013, Atlanta, GA, June 22, 2013 Jean Koster, University of Colorado Boulder Students from around the World Design, Manufacture, and Fly an Aircraft
  2. 2. ASEE 2013 • Opportunities made available by software and internet • 3D CAD software, Product Lifecycle Management (PLM) • Common digital environment • Global companies operate Design Bureaus around the world. – Opportunities to expedite design work on new systems – Opportunities to harvest bright minds – Leveraging expertise and talent – Limit or eliminate duplication of efforts • Focus on technological Innovation and diverse approaches to find solutions – Leverage diverse critical thinking 2 Why a Global Collaborative Project? -Purpose-
  3. 3. ASEE 2013 Hierarchies Become Networks -Purpose- “The corporation as we know it is unlikely to survive the next 25 years. Legally and financially, yes. But not structurally and economically.” Peter Drucker, 2000 Daly, James (22 August 2000), “Sage Advice: An Exclusive Interview with Peter Drucker,“ Business 2.0. 3
  4. 4. ASEE 2013 Benefits of Collaboration -Purpose- Need: A better understanding of the process of collaborating and the skills it takes to realize its benefits are required. Shuman, Jeffrey and Janice Twombly with David Rottenberg (2001), Collaborative Communities: Partnering for Profit in the Networked Economy, Dearborn Trade, Chicago, IL. 4
  5. 5. ASEE 2013 Aircraft Market Diversity is Increasing -Purpose- Source: Boeing Commercial Airplanes, 2012 CMO 5
  6. 6. ASEE 2013 Boeing 787 Global Work Breakdown Structure -Purpose- • Manufacturing dispersed in many countries – For Boeing’s Dreamliner, 28 suppliers are located outside USA, e.g. • Wings produced in Japan • Ailerons produced in Australia • Fairings produced in Canada • Doors produced in France and Sweden • Final assembly in USA • Preassembled parts delivered allow for a vastly reduced final assembly crew. • Faster assembly: 3 days 6
  7. 7. ASEE 2013 Huge Organizational Challenges -Purpose- Young Engineers need to learn to choreograph delocalized design and manufacturing • Constraint: Global project is high risk! • Risk management skills is a most important qualification requirement to industry employers • Goal: Global project significantly strengthens the risk management skills of students 7
  8. 8. ASEE 2013 1. Critical thinking and problem solving 2. Collaboration across networks and leading by influence 3. Agility and adaptability 4. Initiative and entrepreneurship 5. Accessing and analyzing information 6. Effective oral and written communication 7. Curiosity and imagination 8. Capacity to add value through innovation Skills to be Developed Purpose Tony Wagner, Harvard 8
  9. 9. ASEE 2013 “If you have an apple and I have an apple and we exchange apples then you and I will still each have an apple. But if you have an idea and I have an idea and we exchange these ideas, then each of us will have two ideas.” Why Global Collaboration? -Purpose- Performance: • Decreasing the learning curve • Responding rapidly to customer needs and inquiries • Preventing “reinvention of the wheel” • Spawning new ideas for products and services • Fast and lean time to (new) market(s) G.B. Shaw 9
  10. 10. ASEE 2013 NASA’s ERA Goals Reduce: Aircraft fuel consumption Emissions Noise …Simultaneously! 10 Motivation: Green Aviation -Motivation- Image credit: NASA “In 2009, … [the] United States flew 704 million passengers, a number forecast to reach 1.21 billion by 2030.” – NASA Facts [1]
  11. 11. ASEE 2013 11 Global Team - Follow The Sun - Engineering students need to develop skills in orchestrating (delegating) and coordinating multi‐site teams, not just acquire deep technical knowledge. Follow-The-Sun
  12. 12. ASEE 2013 12 System Configuration: HYPERION - Hyperion - Hyperion 2012-13 Hybrid-Electric Engine BWB Carbon Fiber / Composite Structure Integrated Control System
  13. 13. ASEE 2013 13 Schedule -Global Collaboration- PDR CDRStart Flight Testing
  14. 14. 𝑪 𝑳 𝒎𝒂𝒙 ~1 𝑳/𝑫 𝒎𝒂𝒙 ~18 𝑽 𝒔𝒕𝒂𝒍𝒍 13.2 m/s (29.5 mph) 𝑽 𝑻𝑶 15.8 m/s (35.4 mph) 𝑽 𝑪𝑹 30 m/s (67 mph) 𝑺 1.693 m2 (18.22 ft2) 𝒃 3.2 m (10.5 ft.) 𝑾 16 kg (35 lb) 𝑾/𝑺 9.45 kg/m2 ΛLE 35° Aerodynamics 14Hyperion 2012-13 Lift Distribution of Hyperion 2.1. Solid Line represents the lift per unit span. Dashed Line represents local lift coefficient CL. Design demonstrates the key characteristics of a blended wing body in its lift distribution S-5010 airfoils for the wings S-5016 airfoil for center body
  15. 15. 15 Wind Tunnel Tests Hyperion 2012-13  Goal: Find out if takeoff pitch-flip behavior is systematic, or a ½ scale proto manufacturing flaw  Compare: CFD models and experiments  Method: 3D print scaled model wind tunnel tests 10” wingspan
  16. 16. ASEE 2013 16 Aerodynamics & Structures -Technology Overview- ½ Scale Wind Tunnel Model Internal Structure Center Body/Integration Aerodynamic Validation CFD Validation Wing Integration/Assembly
  17. 17. ASEE 2013 17 Global Integration Manufacturing IDT (Interface Dimension Template) • Device used to ensure German center body matches USA wings Similar ideas used for wing manufacturing Winglet  Wing -Integration- Delocalized manufacturing increases integration risk! Risk Mitigation
  18. 18. ASEE 2013 18 Global Integration -Global Collaboration- “Flat Sat” Approach (Simulation and Test-bed) - Used while center body is in Germany - • Full Scale Mockup of Center Body • Wire Length and placement • Hardware placement platform • Full system testing for electronics Need: Electronics integration into plane Problem: Plane center body in Germany! Solution Image credit: NASA Cubesat Broken Down Flat Layout Electronics
  19. 19. ASEE 2013 FTS Example -Global Collaboration- Colorado Team • Changes structure component • Does it meet Requirements? • What does this mean for manufacturing and aerodynamics? Sydney Team • Evaluates Structural Implications on Aerodynamic Design • Proposes design changes • Provides aerodynamic feedback Stuttgart Team • Evaluates Manufacturing implications on aerodynamic and structural designs • Proposes design changes • Provides manufacturing feedback 8 Hours 8 Hours 8 Hours 19
  20. 20. ASEE 2013 20 Lessons Learned -Global Collaboration- Language and Cultural Barriers Although everyone speaks Englineerish…. Encodes/Writes Message Decodes/Misinterprets Message Cloud Noise Filter Can Cause: -Loss of Tone -Loss of Intent -Misinterpretation Encodes Counter Productive Feedback Message Decodes Message
  21. 21. ASEE 2013 21 Lessons Learned -Global Collaboration- Follow-the-Sun (FTS): • Great for CAD design work • Ideas across border • Dynamic positive synergy • Benefit of diversity in critical thinking • Helps mitigate risk through smaller team delegation • Difficult in academic environment due to schedules Follow-The-Week (FTW) • Suited for concept designs • Specialized tasks assignments to small local teams • Finished tasks reviewed by global team • Weekly global team meetings.
  22. 22. ASEE 2013 • Project needs managerial infrastructure – Needs strong Project Manager (Choreographer) – MBA candidate on team – Economics student on team • Understand international shipping requirements – International Traffic in Arms Regulations (ITAR) – Understand international trade and regulations • Collaboration on “trust” and “respect” – Limited control over non-local teams’ efforts – Understand skills and capabilities of partners – Free sharing of information leads to IP issues • Planning – Extend the planning process significantly! – Better understand skills and capabilities of partners – Each partner should have own funding 22 Lessons Learned - Global Collaboration-
  23. 23. ASEE 2013 Student Global Team -Team- Michaela Cui Tyler Drake Arthur Kreuter Gavin Kutil Brett Miller Corey Packard Marcus Rahimpour Gauravdev Soin Martin Arenz Holger Kurz David Pfeiffer Matthias Seitz Baris Tunali Jonas Schwengler Pascal Weihing Benjamin Arnold Kai Lehmkuehler Matthew Anderson Joshua Barnes Byron Wilson Andrew McCloskey Julie Price Eric Serani Tom Wiley Richard Zhao Kristen Brenner Corrina Gibson Nathan Jastram Michael Johnson Eric Kenney 23 Jeremy Klammer Lydia Mcdowell Boris Papazov Taylor Petersen Robert Whitehill Ben Benjamin Andrew Haynes Andrew Gilbert Greg Nelson Pierce Martin Zach Dischner Vibin Mahdev Kristin Uhmeyer Adil Ali Wes Willits Alex North Lucas Miller Sean Ortiz
  24. 24. ASEE 2013 24 Acknowledgements -Acknowledgements- A special thanks to… Mike Kisska of Boeing Frank Doerner of Boeing Blaine Rawdon of Boeing Tom Hagen of Boeing Dr. Robert Liebeck of Boeing/USC Steven Yahata of Boeing Norman Princen of Boeing Diane Dimeff of eSpace Brian Taylor of NASA Joseph Tanner of CU Trent Yang of RASEI Dr. Donna Gerren of CU Prof. Eric Frew of CU Matt Rhode of CU Trudy Schwartz of CU Prof. Claus-Dieter Munz of Stuttgart Prof. Ewald Kraemer of Stuttgart Dr. KC Wong of Sydney Dr. Dries Verstraete of Sydney Skip Miller of Skip Miller Models James Mack of RECUV (Pilot) Raytheon IDS (student support)
  25. 25. Questions? Contact: jean.koster@colorado.edu
  26. 26. ASEE 2013 26 Project Papers - Papers - Hyperion 2012-13 The Hyperion 2.1 Green Aircraft Project, AIAA-2013-0817 (Best Paper AIAA-DETC) The HYPERION 2 Green Aircraft Project, AIAA-2012-0878 (Best Paper DETC) HYPERION UAV: An International Collaboration, AIAA-2012-1223 Design of a Hybrid Propulsion System for Aircraft. AIAA-2011-1011 (Best Paper DETC) Design of a Blended Wing Body UAS with Hybrid Propulsion, ASME-IMECE2011-62126 Work Force Development for Global Aircraft Design, ASME-IMECE2011-62273 SOLSTICE, AIAA-2012-0147 -1st Place at AIAA Region V Student Competition 2011 http://www.youtube.com/watch?v=OM825EZGhS0 http://www.youtube.com/watch?v=u2qjvbLs_t0

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