Der virtuelle Entwurfsprozess (Virtual Spacecraft Design VSD) Joachim Fuchs (joachim.fuchs@esa.int) Modelling and Simulation Section (TEC-SWM), Software and Technology Dept. Technical Directorate, ESA
Context Design and development process of complex system Complex setup of customer and provider Two handovers between design authorities in the life-cycle (feasibility, design and development, operations) Complex industrial setup Prime and subcontractors Geographically wide distribution We are flying prototypes Higher degree of iteration and parallelism in process Desire to improve the interaction of all players and increase the capture of problems in early (cheaper) phases Presentation DLR - 12 June 2007 2
Underlying Ideas of New Approach For the design phases Define a design definition process based on an approach based on a virtual representation of the spacecraft / system For the verification phases Assess the changes that a Virtual Spacecraft Design philosophy would bring to the process in general and to the AIT process in particular To do this Develop a digital or virtual model of the spacecraft already in early phases to support the specification and definition activities, and to evolve it to support design, AIV and operations phases. Presentation DLR - 12 June 2007 3
Virtual Model The virtual model has to be an integral part of the specification, design and verification process (part of model philosophy). Improvements are expected in the following areas: Requirements management and verification Design trade-offs at system level of system operability issues Assessment of engineering margins Coherence between analysis and testing Preparation and execution of AIV Transition from AIV to operations Model-Based data sharing Presentation DLR - 12 June 2007 4
The Engineering Lifecycle Design Validation by Simulation AIT on EQM and Simulation Mission/ Spec & design MPS SCS FES Functional Validation Testbench Spacecraft AIT Simulator Qualification Qualification- AIV Simulator + EQM ESA GNC,MVM, FDIR Spec & design SVF Avionics Integration FVT Prime Equipment Supplier Software Spec & design (prototyping) Software Production Functional / electrical Software V&V -Incremental releases SVF Software test -unit/module level -SDE - Legend: Iterative system development process Transfer of facilities to contractor Test procedures and Results Presentation DLR - 12 June 2007 5
Mapping on Standard Lifecycle Steps Pre-Phase A Phase A Phase B Phase C Phase D Phase E Phase F Feasibility and Performance /Trade-Offs Concurrent Design Activities Requirements Specification Concurrent Design Activities & Mission Design Interfaces and End-to-End Design Tradeoff Interfaces and End-to-End Design tradeoffs Subsystem & Payload V&V Interfaces and End-to-End AIV OBSW AIV OBSW Spacecraft Qual. and Acceptance Ground Segment Qual. and Acceptance Qual. and Acceptance Training & Operations Virtual AIV MCS Testing AIV SVTs Operations Procedure Validation SVTs AIV SVTs Mission Control Team Training Maintenance (e.g. S/W) On-Going Mission Control Team Training OBSW Patch and Ops Procedure Validation Anomaly investigation and resolution Investigation of Disposal options Presentation DLR - 12 June 2007 6
Focus on cross-domain aspects Mechanical Functional Electrical Operational SSRM of Functional Architecture of Topological Architecture of Physical Architecture & AIT Requiring: Common process definition Common data repository for all domains Interoperability between domain tools Presentation DLR - 12 June 2007 7
Functional Architecture The diagram shows the top-level functionality required in order to realize the in order to support the overall system design, manufacturing, verification and operation process. VSEE S/C Design and Modelling Design Browsing Engineering Data Storage Design Data Transformation Virtual Factory Assembly Proc Execution S/C Operation Control G/S Simulation Domain Domain Tool Tool Link to simulation for e.g. control algorithm detail wrt to ops / fmeca, fdir aoc thermal Assembly Simulation Payload Simulation S/C S/C Visualisation Simulator GSE Logistics Data required (schedule, availability, ) GSE Simulation Facility Simulation Factory Visualisation <<Data>> Logistics Presentation DLR - 12 June 2007 8
Envisaged VSEE Architecture VSEE Modelling Requirements Operational Design Harness Definition Tool Physical Design AIT Definition Design Resource Center Functional Design Architectural Design TM/TC Design Concurrent Engineering Bus Operation Activity Tool Management Database Procurement Collaboration Bus ESATAN / ESARAD A... Domain Matlab / Simulink Ansys Patran / Nastran Operation Space Reference DB Simulator Virtual Spacecraft Communication Bus Visualization Design Browser V(M)-AIT Execution CCS Domain 4 Patran / Nastran ESATAN / ESARAD... Presentation DLR - 12 June 2007 9
Process Structure & Content VSD Top Level Process Architecture n-1 Process Models Requirements Functional Operational Until Requirements Review (SRR) Until Preliminary Design Review (PDR) Until Critical Design Review (CDR) Until Qualification Review (QR) Until Acceptance Review (AR) Until Flight Acceptance Review (FAR) ECSS-E-10 1B Process Tasks and/or Industry specific Process Tasks Physical Architecture AIT Control Output of Review Phase E Preparation & Support (Simulation of Mission and Operations) Phase C/D Preparation, Suppport and Execution Virtual system Mission Simulation (ESOC) SVF RTB STB STM QM or PFM FM Real system ECSS-E-10 2B Purpose Definition and/or Industry specific Process Tasks ECSS-E-10 3A Definitions Presentation DLR - 12 June 2007 11
Results on Iteration of VSD process VSD Top Level Process Architecture Physical Architecture n-1 Process Models Requirements Functional Operational Until Requirements Review (SRR) Define Satellite Design Specification (SDS) Define Functions and transfer missing requirements into SDS. Define Operational Concept (Commandability, Observability, Mission /Goal) Define baseline Architecture Establish Budgets Define Physical Design Until Preliminary Design Review Detail SDS based on Design Detail Functions and transfer into next lower level specs. Detail Operational Concept, Define of Mission Timeline Detail baseline Architecture Detail Budgets Detail Physical Design & perform Structural/Thermal/Dynamics Until Critical Design Review Control & revise SDS based on Detailed Design Control & revise Functions and transfer into next lower level specs. Prepare User Manual, TM/TC and Flight Dynamics DB and Flight Procedures. Control & revise baseline Architecture Control & revise Budgets Control & revise Physical Until Qualification Review Until Acceptance Review Until Flight Acceptance Review Assess of Non-Conformance issues Assess of Non-Conformance issues Assess of Non-Conformance issues Assess impact of functional nonconformance Prepare & validate User Manual, TM/TC and Flight Dynamics DB and Flight Procedures. on Architecture & budgets Design & perform Structural/Thermal/ on Physical Architecture (e.g. Dynamics mounting, CoG, MoI) Assessment on impact of functional non-conformance Validate User Manual, TM/TC and Flight Dynamics DB and Flight Procedures. on Architecture & budgets on Physical Architecture (e.g. mounting, CoG, MoI) Assess impact of functional nonconformance Validate User Manual, TM/TC and Flight Dynamics DB and Flight Procedures. on Architecture & budgets on Physical Architecture (e.g. mounting, CoG, MoI) AIT Define preliminary AIT approach. Identify Tests Detail AIT approach. Detail Tests Prepare E-AIT and M-AIT activities for RTB/STB and STM). Define Test Specs, Integration and Test Procedures for RTB, STB and STM. Prepare E-AIT and M-AIT activities for QM/PFM). Define Test Specs, Integration and Test Procedures for QM/PFM. Prepare E-AIT and M-AIT activities for FM. Define Test Specs, Integration and Test Procedures for FM. Verify AIT activities Control Output of Review Phase E Preparation & Support (Simulation of Mission and Operations) Phase C/D Preparation, Suppport and Execution Execute & visualize simulation of mission and operations & analyse Execute & visualize simulation of mission and operations & analyse Execute & visualize simulation of mission and operations & analyse Functional & Operational Architecture Functional & Operational Architecture Functional & Operational Architecture Mission Simulation (ESOC) SVF RTB Prepare and Execute AIT based on model Detail and Execute AIT based on model for PFM & FM Execute Software Integration & Testing on SVF for Software Execute H/W & S/W Integration on RTB Perform Testing on RTB for H/W S/W Compatibility Integrate & test STB (e.g. by H/W EMs or PFMs). Detail and Execute AIT based on model for PFM & FM Perform IST's (e.g. FDIR, OBCP's and FOP) Prepare Validation Tests (SVT's) Analyse alternative AIT approach based on late arrival of next lower level system Perform IST's (e.g. FDIR, OBCP's and FOP) Prepare Operator Training, Use to verify Software Patches Analyse alternative AIT approach based on late arrival of next lower level system Perform IST's (e.g. FDIR, OBCP's and FOP) Prepare Operator Training, Use to verify Software Patches Analyse alternative AIT approach based on late arrival of next lower level system Perform IST's (e.g. FDIR, OBCP's and FOP) Perform IST's (e.g.obc IST) Perform IST's (e.g.obc IST) Perform IST's (e.g.obc IST) Perform IST's (e.g.obc IST) Perform IST's (e.g. instrument IST's, Perform IST's (e.g. instrument IST's, STB PCDU IST) PCDU IST) STM Prepare Integration of STM Integrate & test STM QM or Integrate QM/PFM & execute Qual Refurbished to FM PFM program FM Baseline Design, Baseline Design Baseline set of Requirements Baseline lower level Specs Baseline next lower level system defined in SDS. Preliminary Design of next lower level design system Equipment Qualification Programs Integrate FM & execute Acceptance program Qualification & of Acceptance of Ship to Launch Site & integrate to Launcher Launch Readiness of Presentation DLR - 12 June 2007 12
Illustration: Existing situation Interdisciplinary system model is limited to product tree for document access Model is documented in Design Description (mainly office products) no validation on Consistency Completeness Integrated Domain Process from analysis to verification only little interdisciplinary I/F Many manual tasks to ensure consistency Presentation DLR - 12 June 2007 13
Background Every Discipline has its own Perspective on the represented by discipline-specific Diagrams, Tables or Tool Files. Examples: Thermal: Component Temperature Range Table Heater Circuit Overview Diagram Structure: Catia Model FEM Result Sheets Electrical : Electrical Architecture Schematic AOCS: AOCS Functional Breakdown Mode Transition Diagram Propulsion: RCS Flow Diagram Thruster Accommodation Schematic Communication Subsystem Schematic Link Budget Table Power EPS Block Diagram Component Power Dissipation / Mode Little or no automated link between Discipline Views -> High Effort to reach/maintain consistent Design. No continuous Design Evolution over S/C Life Cycle with traceability towards earlier Phases, Loss of Design information due to changing design environments with separated data repositories Presentation DLR - 12 June 2007 14
Modelling benefits Envisaged Objectives Demonstration of integrated Model-Based Engineering process (MBSE) Demonstration of integration of domain specific analysis and verification (by analysis) activities and system engineering Demonstrate Model as communication platform for collaboration and concurrent engineering Demonstration of Model Refinement Process throughout the Project Phases -> Design Continuity over S/C Life Cycle Demonstrate Integration to DRC Presentation DLR - 12 June 2007 15
Mapping to VSD process VSD Top Level Process Architecture Physical Architecture n-1 Process Models Requirements Functional Operational Until Requirements Review (SRR) Define Satellite Design Specification (SDS) Define Functions and transfer missing requirements into SDS. Define Operational Concept (Commandability, Observability, Mission /Goal) Define baseline Architecture Establish Budgets Define Physical Design Until Preliminary Design Review Detail SDS based on Design Detail Functions and transfer into next lower level specs. Detail Operational Concept, Define of Mission Timeline Detail baseline Architecture Detail Budgets Detail Physical Design & perform Structural/Thermal/Dynamics Until Critical Design Review Control & revise SDS based on Detailed Design Control & revise Functions and transfer into next lower level specs. Prepare User Manual, TM/TC and Flight Dynamics DB and Flight Procedures. Control & revise baseline Architecture Control & revise Budgets Control & revise Physical Until Qualification Review Until Acceptance Review Until Flight Acceptance Review Assess of Non-Conformance issues Assess of Non-Conformance issues Assess of Non-Conformance issues Assess impact of functional nonconformance Prepare & validate User Manual, TM/TC and Flight Dynamics DB and Flight Procedures. on Architecture & budgets Design & perform Structural/Thermal/ on Physical Architecture (e.g. Dynamics mounting, CoG, MoI) Assessment on impact of functional non-conformance Validate User Manual, TM/TC and Flight Dynamics DB and Flight Procedures. on Architecture & budgets on Physical Architecture (e.g. mounting, CoG, MoI) Assess impact of functional nonconformance Validate User Manual, TM/TC and Flight Dynamics DB and Flight Procedures. on Architecture & budgets on Physical Architecture (e.g. mounting, CoG, MoI) AIT Define preliminary AIT approach. Identify Tests Detail AIT approach. Detail Tests Prepare E-AIT and M-AIT activities for RTB/STB and STM). Define Test Specs, Integration and Test Procedures for RTB, STB and STM. Prepare E-AIT and M-AIT activities for QM/PFM). Define Test Specs, Integration and Test Procedures for QM/PFM. Prepare E-AIT and M-AIT activities for FM. Define Test Specs, Integration and Test Procedures for FM. Verify AIT activities Control Output of Review Phase E Preparation & Support (Simulation of Mission and Operations) Phase C/D Preparation, Suppport and Execution Execute & visualize simulation of mission and operations & analyse Execute & visualize simulation of mission and operations & analyse Execute & visualize simulation of mission and operations & analyse Functional & Operational Architecture Functional & Operational Architecture Functional & Operational Architecture Mission Simulation (ESOC) SVF RTB Prepare and Execute AIT based on model Detail and Execute AIT based on model for PFM & FM Execute Software Integration & Testing on SVF for Software Execute H/W & S/W Integration on RTB Perform Testing on RTB for H/W S/W Compatibility Integrate & test STB (e.g. by H/W EMs or PFMs). Detail and Execute AIT based on model for PFM & FM Perform IST's (e.g. FDIR, OBCP's and FOP) Prepare Validation Tests (SVT's) Analyse alternative AIT approach based on late arrival of next lower level system Perform IST's (e.g. FDIR, OBCP's and FOP) Prepare Operator Training, Use to verify Software Patches Analyse alternative AIT approach based on late arrival of next lower level system Perform IST's (e.g. FDIR, OBCP's and FOP) Prepare Operator Training, Use to verify Software Patches Analyse alternative AIT approach based on late arrival of next lower level system Perform IST's (e.g. FDIR, OBCP's and FOP) Perform IST's (e.g.obc IST) Perform IST's (e.g.obc IST) Perform IST's (e.g.obc IST) Perform IST's (e.g.obc IST) Perform IST's (e.g. instrument IST's, Perform IST's (e.g. instrument IST's, STB PCDU IST) PCDU IST) STM Prepare Integration of STM Integrate & test STM QM or Integrate QM/PFM & execute Qual Refurbished to FM PFM program FM Baseline Design, Baseline Design Baseline set of Requirements Baseline lower level Specs Baseline next lower level system defined in SDS. Preliminary Design of next lower level design system Equipment Qualification Programs Integrate FM & execute Acceptance program Qualification & of Acceptance of Ship to Launch Site & integrate to Launcher Launch Readiness of Presentation DLR - 12 June 2007 16
Architectural Elements addressed VSEE Modelling Requirements Operational Design Harness Definition Tool Physical Design AIT Definition Design Resource Center Functional Design Architectural Design TM/TC Design Concurrent Engineering Bus Operation Activity Definition Management Database Procurement Collaboration Bus ESATAN / ESARAD A... Domain Matlab / Simulink Ansys Patran / Nastran Operation Space Reference DB Simulator Virtual Spacecraft Communication Bus Visualization Design Browser V(M)-AIT Execution CCS Domain 4 Patran / Nastran ESATAN / ESARAD... Presentation DLR - 12 June 2007 17
ESA Activities related to the VSD approach VSEE VSD Requirements Operational Design Modelling Harness Definition Tool Physical Design AIT Definition Design Resource Center Functional Design Architectural Design SSRM TM/TC Design Concurrent Engineering Bus Operation Activity Tool Management Database Procurement ESATAN / ESARAD A... Domain Matlab / Simulink Ansys ECSS E40-07 Patran / Nastran SMP ETM 10-21 M&S for SE Modelling tools Operation Space Reference DB Simulator Collaboration Bus Virtual Spacecraft Communication Bus ETM 10-23 Engineering Database Visualization Design Browser V(M)-AIT Execution CCS Domain 4 Patran / Nastran ESATAN / ESARAD... Presentation DLR - 12 June 2007 18
Related Activities (I) Ongoing / planned activities Virtual Spacecraft Design (VSD) Define Process, tool environment and demonstrate / validate by prototyping Space Reference Model (SSRM) Validate the approach chosen to formalise and standardise an engineering database (standardisation activity ECSS ETM 10-23) in an industrial context Architecture design editor (ADE) Validate engineering database metamodel by providing an editor for automatic DB generation Support activities for Simulation Model Portability Demonstrator Modelling Environments Reference Architecture Presentation DLR - 12 June 2007 19
Related Activities (II) Proposed Future Activities Model-Based Engineering Environment Operational implementation of elements (such as database, architecture editor, process management ) Integration to get a deployable environment Deployment in industrial context Demonstration on a pilot project Possibly development of an Open Source Design Success depends on adaptation by all stakeholders Presentation DLR - 12 June 2007 20