Browse Topic: Total life cycle management
Despite advances in CFD, wind tunnel testing remains indispensable for aerodynamic validation, correlation, and homologation. Increasing configuration complexity, shortened development cycles, and stringent result robustness and documentation requirements demand a shift from isolated facilities to integrated, data-driven ecosystems within the overall development and company-wide test processes. We present a software-centric approach integrating wind tunnel operations into a strategic element of the Digital Thread. By orchestrating test planning, execution, data acquisition, and documentation within a unified framework, experimental data becomes reusable across projects and traceable for compliance and homologation. The interaction between CFD and physical testing is important. Such approach systematically improves simulation models with wind tunnel tests. And CFD results guide efficient test matrix definition. Extended measurement methodologies include automated actuation of active aerodynamic components in test sequences, while BEVs introduce further aerodynamic and thermal aspects for range and efficiency. Thus, extended and automated test definition down to the step-level of test sequences is introduced. Within such integrated environment, AI can be a supporting engineering tool to enhance testing. AI-based methods can assist in identifying relevant test points within complex parameter spaces and in correlating experimental and simulated results, assisting but not replacing established engineering judgment. Also, for the operating department, analyzing process data for maintenance predictions and efficiency optimizations can be assisted by AI-based methods and supporting AI-agents. The approach boosts efficiency by reducing test effort and tedious manual tasks, leading to shorter development cycles, supporting improved time-to-market. Structured workflows and standardized data handling enhance data quality, improve comparability of results, and ensure robust documentation for reliable audit trails. By combining physical testing, simulation, and intelligent processing, the wind tunnel becomes a reproducible, innovation-enabling element in modern product development, positioning software as the backbone of efficient, future-proof aerodynamic testing.
Aircraft verification and certification entail a variety of testing tasks and require coordination among numerous stakeholders across different disciplines to ensure alignment on requirements. Historically, certification strategies have relied on both physical testing and high-fidelity simulation. The integration of these complementary approaches is essential to address their respective blind spots and to support credible certification evidence. A key challenge lies in the rigorous correlation of simulation models with physical test data. Flutter verification, for instance, is a critical component in defining the aircraft’s flight envelope and plays a foundational role in certifying safe operational boundaries. In this work, the process of freedom from flutter verification is demonstrated. This work introduces a novel approach to combining simulation and test data with the aim to accelerate and streamline the verification process leading to more efficient and cost-effective aircraft development. In addition, it is shown how the flutter verification process can be deployed using a simulation process and data management (SPDM) tool from which tasks are assigned and results are collected allowing transparency about the status of the workflow and providing stakeholders access to the data they need when they need it. The workflow is demonstrated using ground vibration test measurement performed on a full-scale F16 aircraft. Throughout the process, simulation data, test results, requirements, and supporting documentation are systematically managed within the SPDM framework. This enables effective cross domain collaboration between simulation and test engineers while also maintaining a single source of truth for proof of compliance and progressively building a robust digital thread throughout the development lifecycle.
The UH-60 Black Hawk — manufactured by Sikorsky Aircraft Corporation — is a twin turbine engine, single rotor, semi-monocoque fuselage rotary wing helicopter used primarily for Utility (tactical transport of troops, supplies, and equipment) purposes. In August of 2024, an experimental effort known as Transformation in Contact was called for, where systems would be more simple, intuitive, low signature, and iterative. This effort, along with the implementation of MBSE, has become a critical component for evaluating and refining technologies that could be needed without delay. This paper will serve to provide the collective results of the digital thread being developed for the Black Hawk as well as explore the efforts and processes utilized for this design. In particular, how the application of a Modular Open Systems Approach (MOSA), integration of a digital backbone, and utilization of the Capability Program Executive (CPE) Aviation Enterprise Architecture Framework (EAF) has enabled a cohesive standard for the rapid technology insertions while reducing cost, increasing efficiency, and improving the overall maintenance and sustainment for the aircraft.
The integration of digital twins within a digital thread framework offers significant benefits for managing Army ground and surface water vehicles. This paper examines how digital twins can enhance lifecycle management, operational efficiency, and maintenance for mature and new military vehicle programs. Scalable and cost-effective implementation with layered capabilities allows organizations to start with a cost-effective foundational model and phase in additional layers of capability over time. This phased approach allows you to expand your digital twin capabilities as program budgets permit, ensuring that you can adapt to evolving requirements without overwhelming upfront investment. For established programs, digital twins enable real-time monitoring, predictive analytics, and data-driven decisions, improving resource allocation and cutting costs. For new programs, they speed up prototyping, integrate modern technologies, and enhance training capabilities. Case studies demonstrate that digital twins can simulate vehicle performance, support proactive maintenance, and improve resource management. Despite challenges like data integration and cybersecurity, our findings highlight the potential of digital twins to boost the resilience and readiness of military fleets, ultimately aiding mission success. This research provides a roadmap for military stakeholders to modernize vehicle management using advanced digital technologies.
Rapid advances in high fidelity modeling and high performance computing capabilities have enabled their routine utilization in support of aircraft design. Analysts are able to generate orders of magnitude more data that must then be turned into actionable intelligence to guide design. Enabling effective application of advanced analysis to design requires a robust end-to-end digital transformation to make the simulation processes reusable, repeatable, traceable, scalable and minimize setup errors. This is achieved through the development of a Computational Fluid Dynamic (CFD) modeling framework where streamlining and automation are inserted within the current CFD workflow that involves model setup, simulation and post processing. Workflow automation techniques have been implemented in simulation pre and post processing that reduce the overall process time or enhance the fidelity of the simulation. To conduct CFD evaluations through flight envelope efficiently, space filling methods that take into account uncertainties of complex systems are needed and have driven updates to the boundary condition and design of experiments (DOE) generation within the workflow. Vehicle sub-system design can be highly iterative, performed by a large number of participants in multidisciplinary groups. To ensure traceability across the digital thread, a provenance and metadata storage methodology has been implemented to capture information about CFD simulations and construct a query able database while a model-based systems engineering (MBSE) framework provides a structured and integrated approach to managing information throughout the product lifecycle. The SIM-FIX-SIM approach enabled with a robust analysis framework for digital flight assessment prior to first flight will contribute to the overall goal of reducing development timelines and achieving cost reduction goals for cutting-edge rotorcraft development programs.
Electric Vertical Takeoff and Landing (eVTOL) designers and manufacturers operate in a dynamic and rapidly developing industry where innovation and regulatory compliance are continuously evolving. For most manufacturers, a "Digital Thread" of software solutions can not only help them build better products and increase operational efficiency, but also be one of the most crucial aspects towards their success.
The Software Production Factory (SPF) is a cyber physical construct of computers, hardware and software integrated together to serve as an ideation and rapid prototyping environment. SPF is a virtual dynamic environment to analyze requirements, architecture, and design, assess trade-offs, test Ground Vehicle development artifacts such as structural and behavioral features, and deploy system artifacts and operational qualifications. SPF is utilized during the product development as well as during system operations and support. The white paper describes the components of the SPF to build relevant Ground Vehicle Rapid Prototyping (GVRP) models in accordance with the model-centric digital engineering process guidelines. The factory and the processes together ensure that the artifacts are produced as specified. The processes are centered around building, maintaining, and tracing single source of information from source all the way to final atomic element of the built system.
ABSTRACT As technology continues to improve at a rapid pace, many organizations are attempting to define their place within this modern age and the Department of Defense (DoD) is no exception. The DoD’s primary focus on modernization ensures that its design, development, and sustainment of systems demonstrate unparalleled strength that outpaces our adversaries and continue to solidify our position quickly and efficiently as the world’s mightiest through fundamental change. Digital Engineering (DE) is the foundation of that fundamental change. Speed-to-Warfighter, reliability, maintainability, resiliency, and performance are all improved through DE techniques. Accelerating technical integration by connecting once isolated data to a digital thread encompassing all domains, and further facilitating the evolution of the traditional approach/processes into an effective DE strategy. DE’s goal supports a reduction of inefficient process/procedures/communications that traditionally can yield slow iteration, inconsistent resource management, limited participation, and more while promoting mitigating efficiencies. This document explores a DE approach that allows for stakeholder/user collaboration daily using a model centric environment connected through the digital thread and supports the DoD’s 2018 DE strategy implementation. It provides easy and efficient information sharing with one input informing and directly impacting the inputs/outputs of the connected model; creating one authoritative source of truth. Demonstrations and support can readily be provided using existing tools and enabling the ability to complete iterations in minutes or hours instead of weeks or months. It also supports early collaboration, evaluations, and reviews using immersive and XR (augmented/virtual/mixed reality) technologies utilizing both concepts of augmented reality to virtual reality to improve overall efficiency and decision making throughout the product lifecycle. Additionally, the utilization of XR provides many other benefits that allow for a variety of more in-depth applications involving human in the loop practices promoting efficiency, consistency, validation, verification, and facilitates performance and knowledge boost of processes, procedures, and end-user applications. Through the use of XR immersive technologies the technological landscape is quickly shifting and evolving in how data is consumed in many areas including industry, government, commercial, and academics. This document demonstrates actual proofs of concept of this evolutionary change in conjunction with DE practices to demonstrate military adoption and processes that support collaboration, evaluation, and opportunities for quicker project completion or stage progression with XR. Citation: A. D., Granville, “Accelerating the Delivery of Technology to the Warfighter Using Collaborative Immersive XR Technology Environments & Tools,” In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium (GVSETS), NDIA, Novi, MI, Aug. 15-17, 2023.
ABSTRACT Traditionally, the life cycle management of military vehicle fleets is a lengthy and costly process involving maintenance crews completing numerous and oftentimes unnecessary inspections and diagnostics tests. Recent technological advances have allowed for the automation of life cycle management processes of complex systems. In this paper, we present our process for applying artificial intelligence (AI) and machine learning (ML) in the life cycle management of military vehicle fleets, using a Ground Vehicle fleet. We outline the data processing and data mapping methodologies needed for generating AI/ML model training data. We then use AI and ML methods to refine our training sets and labels. Finally, we outline a Random Forest classification model for identifying system failures and associated root causes. Our evaluation of the Random Forest model results show that our approach can predict system failures and associated root causes with 96% accuracy.
The making of a quilt is an interesting process. Historically, a quilt is a canvas of work made from old pieces of cloth cut into squares or whatever shape that make a nice connected pattern and then stitched together. The quilt could be random pieces that is not related to each other. In most recent years and more common cases, a quilt is made of different pieces of patches that are connected and laid out in a special way to tell a story. Not only does it portray a story that is put together in a certain sequence, but it also stiches the pieces of the quilt into a nice and complete narrative. A story that one can understand just by looking at the quilt spread and unfolded. Much like the making of a quilt that has a story to tell, a Product Digital Quilt will tell the story of a product. The Digital Product Quilt replaces the conventional way of telling a product story. The traditional product story is a method that is serially connecting multiple product life cycle silos together. This process is usually error prone, difficult to understand and hard to maintain. The Digital Product Quilt is made up of multiple pieces of the puzzle that makes a product story and the source of truth. At the center of the Product Digital Quilt is the Digital Model which represent the source of truth for the product. The first core band of the Product Digital Quilt, surrounding the Digital Model, are Requirements, Engineering, Analysis, Manufacturing, Integration and Fielding the product to the end user which includes Sustainability and Maintenance. The different pieces of the Product Digital Quilt are stitched with many different digital threads such as the System, Software, hardware and quality threads.
Traditional solutions developed for the aerospace industry must overcome challenges posed for automation systems like design, requalification, large manual content, restricted access, and tight tolerances. At the same time, automated systems should avoid the use of dedicated equipment so they can be shared between jigs; moved between floor levels and access either side of the workpiece. This article describes the development of a robotic system for drilling and inspection for small aerostructure manufacturing specifically designed to tackle these requirements. The system comprises three work packages: connection within the digital thread (from concept through to operational metrics including Statistical Process Control), innovative lightweight / low energy drill, and auto tool-change with in-process metrology. The validation tests demonstrating Technology Readiness Level 6 are presented and results are shown and discussed.
ABSTRACT The DoD Digital Engineering Strategy [1] released in June 2018 outlined the DoD’s strategic goals which “promote the use of digital artifacts as a technical means of communication across a diverse set of stakeholders” In addition to build, test, field and sustainment of defense systems, emphasis was placed on the acquisition and procurement of systems and the importance of digital engineering. This was further reinforced in the Feb 2022 release of the Engineering of Defense Systems Guidebook [2] which contains Digital Engineering sections in each chapter. The norm for Systems Engineering has become Model-Based Systems Engineering (MBSE) in which models are used at all phases of development. To complete the digital thread from concept to disposal, models will be required for the acquisition phase. This paper will describe Model-Based Acquisition (MBAcq), and how it can be used to increase clarity compliance and understanding in Capability Systems and Software Acquisition for ground vehicles. Citation: M. Hause, L. Hart “Model-Based Acquisition: Increasing Clarity, Compliance and Understanding In Product Acquisition” In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium (GVSETS), NDIA, Novi, MI, Aug. 16-18, 2022.
Integration of advanced technologies in the casting commodity through digital transformation efforts is essential to future success of rotorcraft transmission castings. This paper reviews the advanced technologies that have been integrated into the casting process for transmission housings. The transformation in casting designs, solidification modeling, mold fabrication, casting techniques, thermal and mechanical post processing, inspection, and quality management are all impacted by new technologies and driven by the continued digital thread in the manufacturing process. The casting manufacturing process is 6000 years old, but the complexity of aircraft requirements and part designs has outpaced capability of standardized casting processes. Digital transformation driven technologies create repeatable processes that reduce production scrap and development lead times.
Aerospace industry OEMs and suppliers are progressing their engineering processes and performance to the next maturity level gearing to digital thread solutions. Current challenges like continuous engineering, virtual certification, distributed development, consolidated virtual proving grounds, homologation, digital twin and operational applications, require well informed decision making in a comprehensive, reliable, traceable and customizable environment. In particular, in aerospace domain, with widespread tight collaborative ecosystems between integrators and suppliers, the capability of tracing each decision and its underlying artifacts becomes a key value of an engineering platform. This paper will outline a middleware approach to reuse generated artifacts and their relationships in a federated engineering environment supporting a "best tool for the job" approach by introducing a layer providing unification and consistency throughout all managed artifacts. Based on an exemplary eVTOL setup, the benefits of integrated data and workflows from specification to virtual design verification are highlighted to motivate their value towards realisation of MBSE methodologies.
Vehicles consume energy and release harmful emissions throughout their life period from the manufacturing stage of raw materials to the vehicle scrapyard. The current Green-House Gas (GHG) emissions from diesel and petrol vehicles are reported to be 164 g CO2/km and 156 g CO2/km respectively. Thus, enormous research studies are been carried out for low-carbon alternative fuel-powered vehicles to reduce the overall GHG emissions. Numerous research on hydrogen as a transportation fuel has demonstrated the potential of reduced vehicular emissions compared to conventional fuels. Life cycle assessment (LCA) is a comprehensive methodology used for estimating the overall environmental impact of vehicles. In this present work, a comparative LCA is conducted between Compressed Natural gas (CNG) powered vehicles and H-CNG powered vehicles. The effect of the two alternative vehicles is assessed from various points in their lifetime using the GREET model software. The analysis is done in two stages namely, well to pump and pump to the wheel. The obtained results of the analysis reveal that the H-CNG fuel exhibits a favorable reduction in CO emissions by 3% and CO2 emissions by 5%. It is also found that there is no significant reduction in NOX emissions. The H-CNG refueling sites are equipped with on-board small scale reformers for producing hydrogen, which is blended with CNG and then pressurized on-site for vehicle fueling. The proposed H-CNG production process is cheaper than the conventional physical blending process and thus paving way for the potential usage of H-CNG fuel.
The traditional acquisition and development cycles of a weapon system by government agencies goes through multiple stages throughout the life cycle of the product. Over the last few decades, many of the United States military equipment had experienced acquisition cost growth. Many studies by the Department of Defense indicates that the cost growth is a result of multiple factors including the development and manufacturing stages of the product. Organizations with multiple operation sites that goes across multiple states or even countries and continents are finding it increasingly difficult to share informational databases to ensure the corporate synergy between multiple sites or divisions. For such organizations, there exist the need to synchronize the operations and have standard and common database where everything is stored and equally accessed by different sites. Digital transformation sounds real exotic and futuristic and promise to reduce operation costs of big organizations. Digital Transformation promises that it would improve the quality control and the quality of a product. While exotic, Digital Transformation remains a challenging proposition that would require some initial investment to setup the infrastructure for such system to operate successfully. Along with the initial setup cost of the system, there needs to be a change in the culture of running the business in each individual site to have that much needed synergy across the multiple divisions or sites. In this paper, we will examine the effect of the Digital transformation in general and utilizing the Digital Thread specifically to improve the quality and quality control of a product as well as to mitigate the risk of the cost growth of military programs.
The U.S. Army monitors the structural integrity of its rotary-wing aircraft fleet through annual evaluations and reporting via the Airframe Condition Evaluation (ACE) program. ACE evaluations capture the location and character of structural defects for each aircraft, which are then available for trending and detailed analysis by engineers with the U.S. Army Combat Capabilities Development Command Aviation & Missile Center (CCDC AvMC). As analytic methods are increasingly advanced through the digital thread, CCDC AvMC has sought to improve available trending, modeling, and analysis tools beyond status quo to provide higher fidelity visuals to both aid communication with decision makers, and also to reveal structural defect trends which may not otherwise be evident. This paper will detail the development and utility of the ACE Color Mapping Application within the ACE Mapping Module and its impact on product support of U.S. Army aircraft with regard to airframe structural integrity.
A primary factor for the development of military avionics systems is the requirement for a Modular Open System Architecture (MOSA). The US Department of Defense (DoD) is driving MOSA-compliant systems to achieve benefits in cost and flexibility within their procurements. MOSA definitions are examined in light of advances in computing disciplines that open the interfaces necessary for the aircraft operator to update and manage their fleet's Health Awareness Systems (HAS). Opening the relevant HAS interfaces via software configuration toolsets and MOSA building blocks avoids contracting for costly software changes and gives control of the update to the operator. Two business related factors are presented for consideration in developing the best way forward while using MOSA principles to guide development. These factors are (1) Intellectual Property (IP) and (2) the underlying investments companies make to develop IP. The need to routinely update the HAS to incorporate fleet lessons learned is inherent in the system's support. Updates may also reflect new methodologies that deliver the desired system control to the operator. The paper demonstrates a MOSA-compliant architecture via an example. Within the example, efficiencies are driven by an end-to-end Digital Thread that minimizes errors and rework while reducing the overall cost of change for the full platform lifecycle. The approach enables organic operator support, lowering the overall cost of aircraft operations. The design and support of the platform’s Health Awareness System benefits from the application of linked-automation.
Researchers have developed artificial intelligence (AI) software for powder bed 3D printers that assesses the quality of parts in real time without the need for expensive characterization equipment. The software, named Peregrine, supports the advanced manufacturing “digital thread” that collects and analyzes data through every step of the manufacturing process, from design and feedstock selection, to print build and material testing.
The Structures Division at the Naval Air Systems Command (NAVAIR) continues to support capital investment in enabling technologies for sustainment of our aircraft which will lower total life cycle costs, ensure safety, and increase operational readiness. This paper presents a general overview of the major improvements which have been made in the area of Structural Health and Usage Management (SHUM), including: usage severity monitoring via regime recognition (RR), gross weight and center of gravity (GW/CG) estimation, local/global damage detection, environmental effects monitoring, damage alleviation, prognostication, and individual asset/component tracking (IAT). Advances in structural analyses have been made in the accuracy of predicted rotorcraft loads using coupled rotor and fuselage interactions. Innovative approaches to fatigue testing at both the component and full scale airframe levels will allow for more accurate introduction of vibratory loading content from operation, reveal failure modes, and improve fatigue life predictions. Additive manufacturing (AM) of fly-away aircraft parts and the standardization of cold spray repair applications present unique qualification challenges and benefits to the warfighter.
ABSTRACT Systems change over time. Sometimes this is planned as in the normal maintenance, planned upgrades, refits and modifications to keep a system fit for purpose and ready to deploy. There may also be multiple allowable configurations of a system providing flexibility to meet different operational needs. Sometimes the changes are not planned. This can be due to complete system failure, component failure, accidental or deliberate damage, as well as unforeseen operational needs. Whatever the reason for the change, the “To-Be” configuration of the system needs to be captured, analyzed and evaluated to ensure it will meet the projected operational need. Systems engineering and trade-off analysis also need to be performed to ensure that the best configuration of the system has been specified regarding time, cost, system effectiveness, as well as a host of other criteria. Additionally, it is not sufficient to simply model the system configurations. It is necessary to show how a configuration will evolve over time, how the variations will differ, common components, additional and emergent behavior, how a systems behavior and capabilities change over time, etc. For military vehicles, there is the additional dimension of the configuration of a manufactured set of vehicles. They are traditionally manufactured in this way in order to take advantage of economies of scale, as well as other factors. Over the typical course of a system lifecycle, they are regularly serviced and reconfigured to address operational needs as well as take advantage of technological developments. Mission and usage parameters continually evolve and the vehicle must adapt to suit. These need to be planned in advance, and the multiple configurations of each vehicle or set of vehicles need to be tracked and managed. No two vehicles are the same and arguably no two systems of systems are the same. This paper will show how these configurations can be modeled, managed and analyzed in an effective way.
ABSTRACT This paper will discuss the systematic operations of utilizing the BOXARR platform as the ‘Digital Thread’ to overcome the inherent and hidden complexities in massive-scale interdependent systems; with particular emphasis on future applications in Military Ground Vehicles (MGVs). It will discuss how BOXARR can enable significantly improved capabilities in requirements-capture, optimized risk management, enhanced collaborative relationships between engineering and project/program management teams, operational analysis, trade studies, capability analysis, adaptability, resilience, and overall architecture design; all within a unified framework of BOXARR’s customizable modeling, visualization and analysis applications.
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