COMMUNICATION THROUGH DIGITAL ENGINEERING PROCESSES IN AN AIRCRAFT PROGRAM

International Journal of Advanced Information Technology (IJAIT) Vol. 3, No. 4, August 2013
DOI : 10.5121/ijait.2013.3403 19
COMMUNICATION THROUGH DIGITAL
ENGINEERING PROCESSES IN AN AIRCRAFT
PROGRAM
Bhanumathi K S1
and B Haridas2
National Civil Aircraft Development, CSIR-National Aerospace Laboratories
Old Airport Road, Kodihalli, Bangalore 560017, India
1
bhanumathi@nal.res.in
2
hari@nal.res.in
ABSTRACT
An aircraft is a complex, inherently multidisciplinary product that requires real time global collaboration
for Design, Manufacture and Service. Digital engineering processes play an intelligent role in product and
process design from concept to retirement, which is around 70 years. The entire engineering data is
hierarchically structured and traced throughout the lifecycle under strict Configuration Control (CC). This
requires an accurate, easily communicable Digital Mock-Up(DMU)as a Virtual 3D-static and dynamic
platform for, real-time concurrent engineering through wide collaboration, a sample of which is presented
herein. Holistically, this requires a networked Product Lifecycle Management (PLM) system as an
Integrated Digital Environment (IDE) for engineering (primary and continuous improvement) for life cycle
of the aircraft. The latest feature in PLM is the use of Model Based Engineering.
KEYWORDS
PLM, IDE, CC, DMU, collaborative design
1. INTRODUCTION
Since 1991, the year of launch of open market based economic reform, the Indian economy has
triggered an air traffic growth of about 7 to 8% per year both in PAX and cargo, international
growth rate of about 3 to 4% per year. This has led to forecast of civil transport aircraft
requirements of 100 to 200 per year to be added covering Long haul , Regional’s, general
aviation categories[1]. Also the industry today has aircraft and engines whose development
involves the use of dynamic maintenance packaging, diagnostics, prognostics, autonomic logistics
and total lifecycle asset management through advanced information technologies [2]. The
situation provides opportunity for design, development, manufacture and servicing of aircraft,
systems, and even engines. This opportunity beckons the engineering industry to create an
engineering eco system, comprising design, manufacturing engineering, tool engineering,
production facilities, servicing engineering facilities. The first requirement of such eco System is
an intelligent IT infrastructure using Integrated Digital Environment (IDE). Figure 1 shows the
global engineering collaboration using IDE.
1.1 Goals of IDE
Standards for data, IT infrastructure for life cycle product engineering

20
Timely and accurate configuration control of the product
Digital Mock-Up based life-cycle engineering
Model-Based Engineering (Structure & Systems)
Workflow-enabled processes in virtual/digital environment though PLM tool
Community Collaboration through inter-operable systems
In-place security processes and procedures
Figure 1.Global engineering collaboration scenario
2. Characteristics of Digital Engineering Processes
The practice of loft and physical mock-up based aircraft design is to be replaced by the more
efficient Digital Mock-up (DMU) based engineering, where all design engineers will add their
portion of the product design on a visual DMU in Virtual reality, under Configuration Control. It
is necessary to build a digital engineering processes that enable innovation, reduce time to market
and re-engineering through concurrency and collaborative actions between myriad R & D and
engineering agencies, instead of the past successive actions in vertically integrated set ups, which
were resulting in excessive re-engineering, effort and cost. In the aircraft industry, lack of
effective communication between the functions of design, manufacturing and assembly causes
delays and setbacks whereby production capabilities are unable to realize design intent in high-
complexity product models [3].It provides a safe-net against challenges arising from continuous
innovations, global collaborations and at the same time, making product and process data
accessible to everyone [4]. Collaborative models reduce delays and eliminate errors. In such an
environment, legacy paper-based and manual data exchange/synchronization processes are no
longer required [5].This intelligent communication is provided by an open PLM
business/engineering process that features a proven Service Oriented Architecture (SOA). SOA
introduced in an attempt to allow for breakdown and re-assembly of business models and
processes into services, built on layers of open standards and is capable of handling changes
through each of the stages and across the life span of the elements. It is a well-defined, self-
contained ‘service’ function that does not depend on the context or state of other services. It plays
a crucial role in dealing with the challenge of a heterogeneous environment containing integrated
systems, making sure that work flows with flexibility and robustness. Promotes re-use of
components, reduces development and deployment costs[6].Online /Real Time engineering
collaboration, through Web in different Modes (immersed or synchronous or asynchronous) AND
/OR Online /Real Time engineering collaboration, through Cloud Computing using Software as
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a Service (SaaS), Platform as a Service (PaaS) and Infrastructure as a Service (IaaS).The
engineering communication process is an open architecture and high Computer Aided Design
(CAD)/Computer Aided Engineering (CAE)/Computer Integrated Manufacturing (CIM)
interoperability and covers the engineering processes in the following engineering domains from
concept to retirement in geographically separated centres in an IDE for collaborative concurrent
design.
 Product Design (Functions, Materials, Systems Geometrics, Design For Manufacturing
and Assembly (DFMA),Design For Reliability and maintenance using CAD/CAE/ MBE , DMU,
Simulation, Testing and Validation
 Process design (Digital manufacturing/assembly Simulation, Tool Design and virtual
dynamic validation,
 System engineering on basis of Model Based System engineering
 Flight test engineering and execution process
 Airworthiness engineering processes
 Manufacturing execution system
 Maintenance Repair Overall(MRO)/Service Data Management (SDM)system
 Computerized Maintenance Management System (CAMMS)
 Life Cycle maintenance upgrade engineering support system
 Seamless Interfacing with Enterprise Resource Planning (ERP)/Supply Chain
Management (SCM)
All of these work under governance of the PLM backbone and tail no based Configuration
control.
3. DIGITAL ENGINEERING PROCESSES
Aircraft industry has recognized that to stem the competition and survive in business [7], it is
necessary to speedily absorb results of continuing R& D, into the product or service. This
requires an IDE based PLM. An IDE provides hardware, software, visualization platform to all
the engineering players in an aircraft program throughout its life, to carry out their innovation
functions through CAD, CAE, CIM, CAM software and have the execution carried out by ERP
systems duly interfaced. In creating such a system CAx tools (Computer Aided, where x stay for
Design, Styling, Manufacturing, Engineering, Process Planning, etc.), PLM tools, and smart
technologies like cloud computing have revolutionized modelling techniques, virtual prototyping,
digital mock up and created intelligent factory networks that encourage effective collaboration
[8],[9]. For high interoperability, a light weight CAD neutral format providing high accuracy
visualization and manipulation platform called DMU to all engineers.. All Engineers can see
assemblies as they are evolving with the components designed into the DMU by different
engineers globally. Assembly analysis tests are carried out for some components intersecting on
assembly (Design error), kinematic simulation of the functioning of the product and testing of
dynamic stresses and finite element analysis. In short, all the stages of the life cycle are simulated
in VR and aircraft is preassembled on computer [10]. The fields covered for enveloping by an
IDE /PLM are given in Figure 2 [11].

22
Figure 2.Fields covered for enveloping by an IDE
4. DIGITAL MOCK UP UNIT UNDER CONFIGURATION CONTROL
The DMU is created in a CAD CAE CIM neutral, light weight format to enable diverse
engineering groups to work and build the aircraft in virtual environment, - static, MBD and
dynamic analysis, with Motions virtualized, test virtually and thus reduce reengineering,
development time and cost. This Digital Mock Up of an aircraft created under configuration
control using CAD neutral format replaces the old method of using costly Physical Mock Up
[12]. The availability of the DMU especially in CAD neutral format of light nature enables,
concurrent engineering based collaboration between various design groups of the aircraft
regardless of their physical location or the type of CAD/CAE/CAM software they may be using
clash/tolerance/interference/variance analysis along with assembly path planning is made possible
in concurrent mode leading to parallel processing and optimal layouts. Further it aids the
functions of design for manufacturing and design for Reliability Availability Maintainability
(RAM) to be built in early in the design life. DMU makes all of the above possible. Parts and the
product structure continually populate the DMU, evolving the e BOM. The lightweight format
should be capable of seamless absorption of data from heterogeneous CAD/CAE systems
[13].The lightweight CAD neutral DMU visualization process in PLM software allows
visualizing a particular configuration or a product structure for all use processes under strict CC
and change management control vital in aircraft design/manufacture/support procedures. It allows
non-CAD users to gain access to the 3D model with an ease of use and without any training, for
purposes of incorporation in documentation, promotional literature training [13].
According to EAI-649A standards, Configuration Management is defined as "A process that
establishes and maintains consistency of a product's attributes with its requirements and product
configuration information throughout the product's life cycle”. This will apply to Product and
Process. Applicability (called effectivity) with regard to tail number of the aircraft and state of the
aircraft will be assigned. The engineering process- typically will start from the case-working
engineer obtaining a PLM task with tentative product structure number assigned by PLM on the
DMU as a unique e-BOM. The design sequence of modelling/checking for geometry
produceability /maintainability/reliability /layout on DMU, mass, balance/ analysis will be tasked
by PLM and carried out by concerned. Every change will be by a process. The system will feature
a dynamic but controlled change management process under governance by a configuration
control board at high level for major changes and a chief designer controlled local technical
committee for minor changes. During the various stages in development, manufacture and use,
there are bound to be changes and as such the configuration is controlled in several progressive
AS –XXXX conditions as in Figure 3. The As-XXXX engineering state of the aircraft and the
respective engineering activity is described in Table1. Any change to any Product or process
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23
documentation shall be scripted into the BOM only by the case working engineer in the design or
methods group with the hierarchy of checking engineers having access and annotating facility
only.
Figure 3. End to End engineering activity map of an aircraft PLM
Table1. Progression of the engineering state of the aircraft (Concept to Retirement)
PDM SDM
23
only.
PDM SDM
23
only.
PDM SDM

24
5. MODEL BASED DESIGN (MBD)
Conventionally, products were being designed in 2D drawings with 3rd
angle projection calling
for very high visualization skills to understand and take up process design. The advent of 3D
representation eased out the visualization part of the complexity. However, the attributes of the
part or assembly such as dimensions, tolerances, special indicators of quality, material and
surface conditions had to be furnished in separate documents enlarging the complexity of
configuration control and traceability. Engineering drawings are subjected to a document
lifecycle which includes data preservation, storage, destruction, security and transportation. They
represent intellectual property, and are valued as evidence and as legal information [14]. The
MBD file will contain all information, including those in the conventional 2D engineering
drawings [15]. Using MBD files and DMU, the PLM software and infrastructure will govern
under configuration control, a change process, the editing and manipulation of
CAD/CAE/CAM/CIM data created in any heterogeneous system, including revisioning, check-
in/check-out, attributes, synchronization, automatically and bilaterally between native CAD and
the Lightweight DMU. This is possible by use of Neutral CAD, Lightweight format for DMU.
There is one or two PLM OEM light weight CAD Neutral software tools that support MBD,
PLM-centric automation and lends itself to parallel and distributed processing [16]. The
engineering process enable model based system engineering in system design with100% model
based design of objects and assemblies of the product.
Boeing B-777is reported to be one of the first in the aircraft industry to claim a 100% digital
definition. Digital data were used to drive the manufacturing processes whenever possible. The
entire aircraft assembly was simulated using digital techniques[17].With the advent of light
weight CAD format in which the software can been stored and tweaked as and when required, a
single file MBD is expected to provide all information governed by the light weight CAD
neutral DMU and configuration control. This will enable collaboration and concurrency between
various system design groups, avoid clash in layout and consequent reengineering, allow accurate
mass and balance control and layout and contribute to innovation across the product lifecycle.
6. MODEL BASED SYSTEM ENGINEERING
Model Based system Engineering is a holistic, multidisciplinary and collaborative approach for
designing and maintaining complex systems [18]. The “V” Diagram shown in the figure 4 covers
all domains and approach that is followed [18].Data is generated once and handed down and used
by customers along the data stream. Models form the pillars in model based engineering and are
reused to drive all aspects of the product lifecycle [19]. When a model is initiated and
developed from the initial stages of the project, it will be easier to carry out verification
and validation of the safety critical software and its interfaces [20].

25
Figure 4. Model Based System Engineering Approach
7. DIGITAL MANUFACTURING ENGINEERING IN IDE/PLM
With digital manufacturing software built into PLM Process designs will get refined for
produceability, processes will get optimized early in design, and a single philosophy of high
quality process tuneable to rated production can be decided early in the design cycle leading to
economic production and low time to market.The processes of concurrency between design and
methods including Design For Manufacturing and Assembly (DFMA) is described in in the V
diagram as shown in the figure 5.
DESIGN CONCEPT PRODUCTION CONCEPT
PROCESS AND TOOL DEISGN
FACTORY AUTOMATION
TOPLEVEL DESIGN
FEASIBILITY /SPECIFICATION PRODUCTION& MAINTENANCE
TOOL PHILOSOPHY
CONCURRENT SYSTEMS DESIGN
DEATAIL STRUCTURE
DESIGN
DIGITAL PROCESS DEIGN/TOOL
DESIGN INCONTESXT
DIGITAL DYNAMIC VR
SIMULATION VALIDATION
DMU
CAD NEUTRAL
LIGHT WEIGHT &
MBD
HIGH INTEGRITY
Any CAD/CAE
CIM-DIGITAL PROCESS
DESIGN ON
DMS/VR/SIMULATION
PLM BACKBONE
VIRTUAL AIRCRAFT
CONGFIGURATION CONTROLLED
NCAD
PLM CORE
DIGITAL FACTORY
ERP SHOPSO delivery
Figure 5.Concurrent product and process design engineering V diagram
25
FACTORY AUTOMATION
TOPLEVEL DESIGN
TOOL PHILOSOPHY
DEATAIL STRUCTURE
DESIGN
DESIGN INCONTESXT
DIGITAL DYNAMIC VR
DMU
CAD NEUTRAL
LIGHT WEIGHT &
MBD
HIGH INTEGRITY
Any CAD/CAE
CIM-DIGITAL PROCESS
DESIGN ON
DMS/VR/SIMULATION
PLM BACKBONE
VIRTUAL AIRCRAFT
NCAD
PLM CORE
DIGITAL FACTORY
ERP SHOPSO delivery
25
FACTORY AUTOMATION
TOPLEVEL DESIGN
TOOL PHILOSOPHY
DEATAIL STRUCTURE
DESIGN
DESIGN INCONTESXT
DIGITAL DYNAMIC VR
DMU
CAD NEUTRAL
LIGHT WEIGHT &
MBD
HIGH INTEGRITY
Any CAD/CAE
CIM-DIGITAL PROCESS
DESIGN ON
DMS/VR/SIMULATION
PLM BACKBONE
VIRTUAL AIRCRAFT
NCAD
PLM CORE
DIGITAL FACTORY
ERP SHOPSO delivery

26
8. MAINTENANCE REPAIR OVERALL ENGINEERING IN IDE/PLM
The Aircraft has to be designed for Minimum maintenance with respect Scheduled maintenance,
low failure rates, high wear life of parts, and maximized mean time of failures, and considerations
in design have to run parallel with various stages of design and development. It requires
coordinated work thought the life cycle of aircraft between Design/Manufacturing, Operating and
Maintaining engineers. At present the maintenance Planning is commenced very late in the cycle
probably starting only when the Prototype No 1 has taken to flights and gets into snags (that is
about 3to 5 years from the Conceptualization of the aircraft The PLM approach with DMUs
MBD and DMS ensures concurrent engineering. The concurrency is demonstrated in the V
DESIGN CONCEPT MAINTENANCE CONCEPT
VALIDATE/ANIMATE AND
PREPARE DIGITAL PRO SHEET
TOPLEVEL DESIGN
TOP LEVEL PUBLICATIONS TO ATA
SD 1000D STANDARDS
FEASIBILITY
/SPECIFICATIONMAINTENANC
E PHILOSOPHY
MAINTENANCE PHILOSOPHY
CHECKSA/B/C/D
TESING AND MAINTENANCE
PROCEDURES CREATION FOR LRUS
DEATAIL STRUCTURE DESIGN
CHECK A/B/C/D DETAILING
INSTAL AND REMOVAL STUDIES
ANIMATION & DIGITAL PRO
SHEET GENERATION FOR PUB
TETSCHEDULES/RIG DESIGN
DIGITAL DYNAMIC VR
DMU
CAD NEUTRAL
LIGHT WEIGHT &
MBD
HIGH INTEGRITY
Any CAD/CAE
CIM-DIGITAL PROCESS
DESIGN ON
DMS/VR/SIMULATION
PLM BACKBONE
VIRTUAL AIRCRAFT
NCAD
PLM CORE
DIGITAL FACTORY CHECK C/D
DIGITAL CREATION VALIDATION
ERP
MRO
SHOPSSO delivery
IETP GENERATION & SUPPORT
TECHNICAL SERVICE
Figure 6. Maintenance Repair Overall (MRO) engineering process on PLM
9. COLLABORATIVE DESIGN AND DESIGN IN CONTEXT
An exercise carried out to establish collaborative design and design in context processes under
configuration control between structural designer, hydraulics designer and electrical designer of
an aircraft under design using a neutral CAD lightweight DMU and several native CAD systems
is presented. Configuration Control will commence on PLM with the ideation of the aircraft and
creation of texts, graphics, etc of a Top Level Aircraft Requirement (TLAR) document. A PLM
controlled unique numbering system will govern this document and all other child documents
shall fall under the parent number, with a change process and number change as may be needed
downstream of the concept right up to aircraft retirement. Typically, the PLM will govern the
process for start of design as in the figure 7 below.

27
CONCEPT DOCUMENT MBD
Program Requirements
TLAR
Regulatory Requirements
Manufacturing Requirements
Service Requirements
Figure 7. Requirement-BOM in PLM, with top level requirement, work break-down structure, Regulatory,
Manufacturing and Service Requirements
Product Structure is defined by Chief Designer/Design quality cum Configuration
Controller/ATA standards and Configuration standards such as EIA 636/849A from the TLAR as
above and makes for TRACEABILITY to TLAR. The process for configuration controlled top
level design schemes and top level DMU is shown in the figure 8 below.
Top Level Assembly
3View
Surface Model
Structures
Electrical Systems
Hydraulic Systems
Figure 8. Product structure definitions with numbering system
Unique
Nu
mb
er
Revision
Part
Na
me

28
ThederivationofcollaborationcapableDMUofStructureisshowninthefigure9.
Figure 9. Derivation of Structure DMU in lightweight CAD neutral with e BOM
The Steps in Collaborated Design in Context of Electrical Installation DFM/DFMRO/release
Figure 10. Wiring Schematic Logical data in any CAD
Figure11 DMU Devices are located in the DMU and synched with the schematics layout

29
Figure12. Creation of Centre-line Routing
Figure13. Routing between connections along centre-line
Figure14. Auto Routing at Pin Level

30
Figure15. Validation of Design rule (radius etc.)
The Collaborative engineering on light weight CAD neutral DMU in respect of a Hydraulic
system is demonstrated below.
Figure 16. Screen shots of Automatic Form-board creation and different options for layout

31
Figure 17.The Automatic Form-board drawing with connection list, pin list, length of wire and mass
properties
Figure 18. The equipments in context of assembly, in this case frame design (CAD Type 1) is being
collaboratively performed by Structures
Figure 19. The Piping done interactively between equipments
Extract 3D CAD Models in Neutral CAD from DMU of each Pipeline
with Fittings for CAM on Pipe Benders and
Assembly/inspection on Jigs for manufacture Design in
Context
31
properties
Context
31
properties
Context

32
10. CONCLUSIONS
The engineering activities of an aircraft life cycle have transformed from vertically integrated
organizations into highly distributed and collaborative mode involving subcontracting of various
product and process design packages into tier 1, Tier 2 and tier 3 entities all over the worlds.
These sources tend to operate with different CAD/CAE/CIM systems presenting heterogeneous
software scenario. Concurrent engineering demands the creation of a virtual and 3D static,
dynamic digital product platform and environment. Open standards and high interoperability,
between software are needed. The use of MBD, MBSE and CAD neutral light weight DMU base
engineering, all under configuration control in a PLM system will help achieve faster time to
market and speedy continuous improvements in the life cycle. In the Indian context, most of the
sub contracted engineering work requires Small and Medium Enterprise (SME) (Tier 3) level
participants /partners by the aircraft prime. The SMEs or Universities, or Free lance specialists
will not have the necessary techno economics to invest in high end infrastructure as they may not
have enough orders to ensure maximum utilization and recover the investments. In such case, the
CLOUD method and related infrastructure appears to be the right win-win investment decision.
Collaboration through cloud computing has to be implemented. All R& D organisations,
manufacturing engineering groups, should be networked by appropriate IDE/PLM.
ACKNOWLEDGEMENTS
The authors would like to thank Mr. Shyam Chetty, Director, CSIR-NAL for conducting this
study, Dr. Sathish Chandra, Project Director-NCAD and HOD STTD-NAL for guidance.
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AUTHORS
Short Biography
Bhanumathi K. S. received her M.S. Degree in Software Systems from BITS, Pilani,
and M.Sc. M.Phil., Degrees in Mathematics from Bangalore University. She has
worked as a Scientist at Defence Research and Development Organisation (DRDO) for
28 years, during which she has been actively involved in the Design and Development
of Avionics and Weapon systems software for Light Combat Aircraft(LCA) project,
Mission Computer software for Cockpit Environment Facility (CEF) of LCA project,
Lead Angle Computation of Air to Air gun, Vendor Projects of ADA, Product Life
Cycle Management solution for LCA project across Aeronautical Development
Agency (ADA), Aircraft Research and Development Centre (ARDC) of Hindustan Aerospace Limited and
Limited Series Production (LSP) at Aircraft Division of Hindustan Aerospace Limited. She has shown the
way and been a team leader in many of these projects. Currently she is working for National Civil Aircraft
Development (NCAD) Project under Council of Scientific & Industrial Research (CSIR)-National
Aerospace Laboratories (NAL). Bhanumathi’s interest are in the realm of Model Based Design
(MBD),Model Based Systems Engineering (MBSE) and the use of open standards to establish global
collaboration using light weight neutral CAD,CAM,CAE for end to end product and systems lifecycle
management (PLM/SLM) system in the aerospace industry.
B Haridas, majored in the Mechanical Engineering from Mysore University and holds
a masters in Manufacturing Engineering from I. I. Sc. Served department of atomic
energy in the areas of reactor equipment Design, Manufacture, as a manufacture
engineer including sounding rockets. Moved to aeronautical industry and served
Hindustan Aeronautics Ltd. Finished at the position of director corporate Planning.
After retirement continued to serve Light Combat Aircraft for its productionisation and
followed up similar activity in manufacturing. design assistance to NCAD, during all
these he has involved in implementation of ERP and PLM solutions

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