Improving Efficiency in the Design Cycle David Costello, SSTL

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1 Improving Efficiency in the Design Cycle David Costello, SSTL Altair Technology Conference - September 10 th, 2013 Innovation Intelligence

2 Changing the economics of space SSTL - Improving efficiency in the Design Cycle

3 Contents Introduction to SSTL, what we do, and position in space industry Overview of Hypermesh v12 implementation at SSTL and experience so far Example: Automated approach to Modelling of spacecraft panels Hypermesh capabilities for Design Iteration and responding to design changes Overview and conclusions Potential future use of Hyperworks at SSTL Commercial in Confidence 2

4 Changing the Economics of Space This is achieved through: Rapid-response small-satellites built from advanced terrestrial technology

5 SSTL - the company UK-based satellite manufacturing company owned by EADS Astrium NV (99%) and the University of Surrey (1%) Formed in 1985, the Company now employs ~600 staff and occupies dedicated facilities in Surrey, Kent, Hampshire & Colorado

6 June 2011: New technical facility SSTL s new technical facility with hi-bay clean rooms, laboratories and testing facilities becomes operational SSTL Kepler Building

7 A history of success SSTL has delivered more than 40 satellites including 70 subsystems and complete avionics suites to international customers HERITAGE: RESULTS: Flight proven - low risk All projects fixed price, delivered on-time and on-budget SUCCESS: Very high mission success 100% mission success in last 10 CUSTOMERS: years proven equipment and full redundancy Variety of customers including many blue chip operators as well as 15 successful training programmes

8 Minimising mission costs Vertical integration reduces size of supply chain allows rapid schedules enhances flexibility use of COTS Target low-cost launch opportunities Low-cost (COTS based) ground systems & automated operations

9 SSTL capabilities Full mission capability from definition through to launch, commission, operations & exploitation Mission Definition and Design Sub Systems Design and Manufacturing Assembly & Integration Testing Environmental Testing Launch Mission Commission & Operations Image Processing & Application

10 Core satellite products: SSTL s products & services SSTL 100: Wide area imaging SSTL 150/300: High res imaging GMP: geostationary comms, navigation Ability to rapidly design and qualify custom platforms Sub-system products: Optical, RF Payloads Bus equipment SSTL offers training, launch services, ground systems, satellite operations using a global network of compatible ground stations

11 August 2011: Launch of NigeriaSat-2/X Launch: 17 August 2011 on Dnepr from Yasny 2.5m PAN, 20km swath 5m 4-band multispectral, 20km swath 32m 4-band multispectral 320km swath 7 year life Agile imaging modes 2 Terabit onboard storage 210 Mbps X-band downlink 150,000 sq.km per day For NASRDA (Nigeria) significantly enhancing Africa s ability to monitor its environment

12 Changing the economics of space SSTL - Improving efficiency in the Design Cycle Surrey Satellite Technology Ltd. Tycho House, 20 Stephenson Road, Surrey Research Park, Guildford, Surrey, GU27YE, United Kingdom Tel: +44(0) Fax:+44(0) info@sstl.co.uk Web:

13 Hypermesh v12 at SSTL The story so far Introduced in April 2013 as complement to other pre and post processing software packages Early training and regular workshops provided by Altair have helped rapid take up and familiarisation amongst analysts Currently been used across a number of SSTL GEO/LEO spacecraft missions in the design phase Primarily used Hypermesh and internal scripting for the automated Finite Element modelling of generic spacecraft structural panels, joints and equipment boxes Reduced the modelling time for spacecraft panels by 75% Commercial in Confidence 12

14 SSTL Aluminium Honeycomb Panels SSTL manufactures in-house panels for spacecraft missions Inserts Detailed view of internal layup of honeycomb and insert definition to be Joints modelled using Hypermesh Panel Edge Details Commercial in Confidence 13

15 Hypermesh at SSTL Panel Automation Example of efficiencies in the modelling of spacecraft panels Starting point for analysis is design output from CAD software (2D generated IGES files based on 2D mid-plane geometry) CAD data is directly imported into Hypermesh Panel edge definitions Module equipment mounting points Insert definitions Commercial in Confidence 14

16 Hypermesh at SSTL Panel Automation Using automated Hypermesh scripting, and Hypermesh functionality, to edit geometry and create surfaces suitable for meshing rapidly SSTL toolbox created to implement internal process using easy to use Hypermesh GUI interfaces Commercial in Confidence 15

17 Hypermesh at SSTL Panel Automation Used Hypermesh automesh panel functionality to quickly optimise mesh density, size and element quality as required Commercial in Confidence 16

18 Hypermesh at SSTL Panel Automation Used Hypermesh scripting to automate modelling of generic equipment boxes which was previously a difficult and slow process Can quickly define equipment box in 5 steps. Combination of RBE2, cbush and CONM2 elements has been defined as standard modelling approach. 1. Create node at C of G location 2. Enter the equipment mass 3. Click on the C of G node 4. Click on the attachment nodes 5. Use card edit functionality to directly enter element properties Commercial in Confidence 17

19 Hypermesh at SSTL Panel Automation Used Hypermesh scripting to automate modelling of generic joints between panels which was previously a time consuming task Can quickly define Joints in 3 steps. Combination of RBE2 and cbush elements has been defined as standard modelling approach. 1. Select attachment nodes on panel 1 2. Select attachment nodes on panel 2 3. Use card edit functionality to directly enter element properties Commercial in Confidence 18

20 Hypermesh at SSTL Design Iterations Used Hypermesh mesh edit panel and imprint or Hypermorph functionality to quickly reflect design changes in FE modelling and carry out large or small design iterations. Example of using the imprint function to quickly update panel meshes improving speed of design cycle Commercial in Confidence 19

21 Hypermesh Time Savings FE Modelling Task Typical Panel meshing Equipment Boxes Structural Joints Design Iterations Approximate Time Spent Previously Approximate Time using Hypermesh SSTL Benefits hours 2-3 hours Last minute changes to manufacturing drawings before panel 1.5 hours 10 minutes 1 hours < 5 minutes Not possible within time constraints < 30 minutes pressing (flexibility) Divert resources onto more complex engineering challenges Rapid response to new design changes to achieve mission level objectives On a typical SSTL design cycle we will complete on average 1. 6 to 17 panels to be meshed in detail 2. > 60 joints per spacecraft 3. > 10 equipment boxes (GEO missions can be >300) Commercial in Confidence 20

22 Hypermesh at SSTL Conclusions Early training and regular workshops has helped with early adoption by SSTL analysts Internal Wiki page used for hints and tips to share knowledge of methods and processes. Modelling effort for generic spacecraft structural panels has been reduced by 75% through automation Reduces project cost and resource requirements Allows resource to be diverted to more complex modelling tasks Allows design iterations to be assessed by analysis which was not previously an option within project time constraints Early success after 5 months of use - efficiencies will only improve after further familiarisation and development of automation of SSTL standard processes, with the aim of further reducing time spent in the design cycle phase Commercial in Confidence 21

23 Hyperworks Potential Future Uses Investigate the use of OptiStruct optimisation tools and how this can be incorporated into the SSTL design cycle to achieve: Minimum number of design cycle iterations Evaluate and Solve design problems quickly Efficient strength and stiffness optimised structures Develop light weight structural solutions whilst still achieving low cost manufacturability Investigate the use of alliance partner software across SSTL business to spread efficiencies to other engineering departments Propulsion system modelling Motor and magnetic design Composite design and analysis Material databases Commercial in Confidence 22

24 Changing the economics of space Thank You for Listening Surrey Satellite Technology Ltd. Tycho House, 20 Stephenson Road, Surrey Research Park, Guildford, Surrey, GU27YE, United Kingdom Tel: +44(0) Fax:+44(0) Web:

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