Ergonomic Simulation for Rotorcraft Manufacturing

Sikorsky has recently installed sophisticated three-dimensional ergonomic simulation software. This software tool allows ergonomic manufacturability design studies to be carried out during the initial design phase using Computer Aided Design (CAD) data when design changes can be made more easily for lower cost. Additionally, by using the three-dimensional solid model data in a virtual three-dimensional space, a more accurate assessment of the manufacturability of any given design will be reached in comparison with the old method of laying up two-dimensional line drawings. This paper describes the tools and methodology used in the ergonomic simulation process at Sikorsky Aircraft. All aspects of the process will be covered, from the translation of CAD data to the various output formats available. Methods of integrating simulations into shop floor work instructions will also be described in detail. Examples of simulations carried out at Sikorsky will be described to illustrate the potential benefits of this process. Areas to be covered include fabrication of detail parts involving heavy machinery (e.g. multi-axis milling machines), fixtured assembly of parts, assembly of non-fixtured parts, and maintainability studies. The ergonomic simulation efforts at Sikorsky Aircraft are supported by the Rotary Wing Structures Technology Demonstration (RWSTD) Program, a U.S. Army Aviation Applied Technology Directorate (AATD) contract.