Presentation to the Defense Science Board Task Force on “Improving Fuel Efficiency of Weapons Platforms”

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Information about Presentation to the Defense Science Board Task Force on “Improving Fuel...

Published on November 13, 2008

Author: lightspeed65

Source: slideshare.net

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I was invited to present to the Defense Science Board Task Force on Improving Fuel Efficiency of Weapons Platforms on September 20, 2000.

Presentation to the Defense Science Board Task Force on “Improving Fuel Efficiency of Weapons Platforms” September 20, 2000 David F. Taggart Hypercar, Inc. [email_address] +44 7974 920 441 Riding a Bike (with the emphasis on “riding”)

Development of Weapon Platforms: Current Status Our ability to design and field energy efficient weapons platforms depends directly on our ability to design energy efficient weapons platforms No new fundamental technologies are required to see dramatic near term efficiency improvements. What is required is that we be creative in our application of existing technology The required actions may be viewed as intangible and difficult to get our arms around, but logical, disciplined actions can be defined and implemented in the near term to significantly improve our capabilities Must reinvent requirements definition, force structure, and product development environment Must build, test, produce, and LEARN Must nurture growth and support productivity of the individual Must never forget: garbage in  garbage out Government must be prepared to do what it takes, not do what is palatable, before we see significant improvement

Our ability to design and field energy efficient weapons platforms depends directly on our ability to design energy efficient weapons platforms

No new fundamental technologies are required to see dramatic near term efficiency improvements. What is required is that we be creative in our application of existing technology

The required actions may be viewed as intangible and difficult to get our arms around, but logical, disciplined actions can be defined and implemented in the near term to significantly improve our capabilities

Must reinvent requirements definition, force structure, and product development environment

Must build, test, produce, and LEARN

Must nurture growth and support productivity of the individual

Must never forget: garbage in  garbage out

Government must be prepared to do what it takes, not do what is palatable, before we see significant improvement

Development of Weapon Platforms: Considerations Cost: time (development, validation, fielding), competitiveness, risk and setbacks, and ultimately procurement and LCC Weight: fuel efficiency, mission effectiveness, cost Efficiency: energy blueprint, systems level product development vs sub-systems level, design freedom, platform AND weapons, do more with less # of vehicles: design freedom, experience and capabilities Development environment and strategy: makes the difference to success or failure, usefulness or folly, revolution or evolution, focus on desirable end point Product requirements: focused vs do-all, platform economics vs multi-role performance Who integrates the advanced technologies? People, not tools!

Cost: time (development, validation, fielding), competitiveness, risk and setbacks, and ultimately procurement and LCC

Weight: fuel efficiency, mission effectiveness, cost

Efficiency: energy blueprint, systems level product development vs sub-systems level, design freedom, platform AND weapons, do more with less

# of vehicles: design freedom, experience and capabilities

Development environment and strategy: makes the difference to success or failure, usefulness or folly, revolution or evolution, focus on desirable end point

Product requirements: focused vs do-all, platform economics vs multi-role performance

Who integrates the advanced technologies? People, not tools!

Design as a Process If we are to achieve results never before accomplished, we must employ methods never before attempted. - Sir Francis Bacon, Philosopher The process is as important as the people. - David Taggart, Engineer

If we are to achieve results never before accomplished, we must employ methods never before attempted. - Sir Francis Bacon, Philosopher

The process is as important as the people.

- David Taggart, Engineer

Design as a Process Design is a dynamic process, not a specific discipline, that begins with an intimate understanding of the product’s functional requirements, and the materials, technologies and processes used in the construction of the components comprising the product The overall efficiency (cost, weight…) of a product is a first order function of the design of that product, and the technologies and resources available to manufacture that product Design is the process of creation, and occurs in peoples minds The environment must be conducive to invention for invention to occur

Design is a dynamic process, not a specific discipline, that begins with an intimate understanding of the product’s functional requirements, and the materials, technologies and processes used in the construction of the components comprising the product

The overall efficiency (cost, weight…) of a product is a first order function of the design of that product, and the technologies and resources available to manufacture that product

Design is the process of creation, and occurs in peoples minds

The environment must be conducive to invention for invention to occur

Advanced Composites: Technology Trend A gap exists between the potential of advanced composites and our ability to effectively utilize them (weight and cost) Composites Maturity Metals Maturity Effective Utilization of Composites 1940 1960 1980 2000 Production Year Effective Utilization of Metals 1940 1960 1980 2000 Production Year Utilization Gap

A gap exists between the potential of advanced composites and our ability to effectively utilize them (weight and cost)

Performance Potential IM7/8552 Properties

Integrated Technology for Affordability (IATA) DARPA funded effort (1994-96) The challenge: Airframes must provide ever increasing performance affordably What was needed: A Breakthrough cost reduction compared to current airframe technology Proposed solution: Design- create a new paradigm Lockheed Martin Skunk Works, Alliant Techsystems, Dow-UTC, AECL Focus: JSF                                      

DARPA funded effort (1994-96)

The challenge: Airframes must provide ever increasing performance affordably

What was needed: A Breakthrough cost reduction compared to current airframe technology

Proposed solution: Design- create a new paradigm

Lockheed Martin Skunk Works, Alliant Techsystems, Dow-UTC, AECL

Focus: JSF

Backbone Concept Over/Under Concept Preferred System Concept Preliminary Intermediate Final Decision Points vs Level of Detail Integrated Airframe Design Paradigm Dwg. 0020-003 Dwg. 0020-009

IATA Preferred System Concept JAST / ASTOVL Config. 140: Conventional Structure 90 Composite Parts, 21 Metallic Parts 95% Composites, Bonded Assembly Large Integrated Components Continuous, Tailored Load Paths Process/Assy Tailored Component Design Detoleranced, Self-Fixturing Bonded Assembly Functionality Attributes

90 Composite Parts, 21 Metallic Parts

95% Composites, Bonded Assembly

Large Integrated Components

Continuous, Tailored Load Paths

Process/Assy Tailored Component Design

Detoleranced, Self-Fixturing

Bonded Assembly

Functionality Attributes

PRELIMINARY DESIGN PSC Component Design Integral Spar/Bulkhead

Low Tolerance Bonded Assembly Fastenerless Assembly of Multiple Components Tolerance Relief in 2 of 3 Dimensions Direct Reinforcement of Classic Failure Modes Co-Processed, Sandwich, or Solid Laminate All interfaces to external surface are co-cured Allows sub-system installation prior to closeout Minimal fuel cell penetrations

Fastenerless Assembly of Multiple Components

Tolerance Relief in 2 of 3 Dimensions

Direct Reinforcement of Classic Failure Modes

Co-Processed, Sandwich, or Solid Laminate

All interfaces to external surface are co-cured

Allows sub-system installation prior to closeout

Minimal fuel cell penetrations

PSC Component Design Upper Skin PRELIMINARY DESIGN

PRELIMINARY DESIGN PSC Component Design Left/Right Vertical Tail Assembly

PSC Assembly Flow PRELIMINARY DESIGN Design Detail for Each Component Includes: Structural Sizing: Failure Mode and Load Tooling Approach Fabrication Approach, Materials, and Process Assembly Sequence and Flow Bottoms Up Production Cost and Airframe Weight

PSC Assembly Flow Fore / Aft Body Mate PRELIMINARY DESIGN

Fiber Placed Upper/Lower Skins E-beam Cured: Cationic Resin Co-Cured Large Cell Core Alliant TechSystems VARTM Keelson E-beam Cured: Cationic B/C Skunk Works / AECL RTM Spar/Bulkheads Tailored Load Paths PR500 Epoxy DOW-UT Hand Lay-up Ribs Thermoset Materials Alliant TechSystems Bonded Assembly Detoleranced Self-Fixturing Full Scale: 5 ft x 5 ft x ft section Envisioned Production Processes Most complex, highly loaded section Process Demonstration Assembly

Fiber Placed Upper/Lower Skins

E-beam Cured: Cationic Resin

Co-Cured Large Cell Core

Alliant TechSystems

VARTM Keelson

E-beam Cured: Cationic B/C

Skunk Works / AECL

RTM Spar/Bulkheads

Tailored Load Paths

PR500 Epoxy

DOW-UT

Hand Lay-up Ribs

Thermoset Materials

Alliant TechSystems

Bonded Assembly

Detoleranced

Self-Fixturing

Full Scale: 5 ft x 5 ft x ft section

Envisioned Production Processes

Most complex, highly loaded section

Critical Technology Areas Fastenerless Assembly Skin Stabilization Approaches Integral Hard Points Battle Damage Survivability High Temperature Structure Integral, Fully Bonded Fuel Cells (and Structure) R, M, & S Culture / Issues E-Beam Technology

Fastenerless Assembly

Skin Stabilization Approaches

Integral Hard Points

Battle Damage Survivability

High Temperature Structure

Integral, Fully Bonded Fuel Cells (and Structure)

R, M, & S Culture / Issues

E-Beam Technology

Detailed Component Information PSC Specific FE Component Loads Component Sizing Summary Solid Geometry Database Weight Summary Detailed Fabrication Drawing Accompanying Assembly Drawing PD4 Lessons Learned PD4 Stereolith Model

PSC Specific FE Component Loads

Component Sizing Summary

Solid Geometry Database

Weight Summary

Detailed Fabrication Drawing

Accompanying Assembly Drawing

PD4 Lessons Learned

PD4 Stereolith Model

Components, Weight Non-Recurring Tooling, Planning Recurring Fabrication Fabrication Summary Recurring Assembly Production Summary IATA PSC JAST/ASTOVL 140 Labor, QA, Tooling, Eng., Materials Labor, QA, Tooling, Eng., Materials Fab, Assy, Procurement Benchmark Comparison to Baseline IATA Production Costs: Bottoms-Up NR, Recurring QA, Matls, Fab, Assy, and Weight Baseline Production Costs: Parametric Historical Database Based on Weight Assumptions: 4 AC/month, 100-1000 Total AC over 10 years Assume Development Program Completed, Facilities Exist Same Rates Applied to IATA and 140 Manhours IATA Subs Estimated Fab, Skunk Works Estimated Assy

IATA Production Costs: Bottoms-Up NR, Recurring QA, Matls, Fab, Assy, and Weight

Baseline Production Costs: Parametric Historical Database Based on Weight

Assumptions:

4 AC/month, 100-1000 Total AC over 10 years

Assume Development Program Completed, Facilities Exist

Same Rates Applied to IATA and 140 Manhours

IATA Subs Estimated Fab, Skunk Works Estimated Assy

90 Composite Components, 21 Metallic 65% Reduction in T100 Rec. Production Costs ($3.68M savings) 48% Reduction in Non-Recurring Production Costs ($30.2M savings) 33% Reduction in Weight (1621 lbs savings) 95% Composites (vs 30% in Baseline) Orders of magnitude part count reduction Conservative PSC Estimates: 6% “Intangible” Cost and Weight Added to PSC Full Recurring Engineering Added to PSC Full Extent of E-beam Cost Advantage Not Included No Credit for Material Forms to Enhance Producibility Commensurate Reductions in LCC Anticipated Benchmark Comparison to Baseline

90 Composite Components, 21 Metallic

65% Reduction in T100 Rec. Production Costs ($3.68M savings)

48% Reduction in Non-Recurring Production Costs ($30.2M savings)

33% Reduction in Weight (1621 lbs savings)

95% Composites (vs 30% in Baseline)

Orders of magnitude part count reduction

Conservative PSC Estimates:

6% “Intangible” Cost and Weight Added to PSC

Full Recurring Engineering Added to PSC

Full Extent of E-beam Cost Advantage Not Included

No Credit for Material Forms to Enhance Producibility

Commensurate Reductions in LCC Anticipated

Back to Riding the Bike You don’t really get how to do it until you get on it. The difference is the distinction “balance” The difference for energy efficient platforms is the distinction “effective design development” and that requires experience: in systems level development, the intimate understanding of relevant advanced technologies, hardware build and test, lessons learned, nurturing growth… …then decisions can be made.                                        

You don’t really get how to do it until you get on it. The difference is the distinction “balance”

The difference for energy efficient platforms is the distinction “effective design development” and that requires experience: in systems level development, the intimate understanding of relevant advanced technologies, hardware build and test, lessons learned, nurturing growth… …then decisions can be made.

 

Applicability? Land Vehicles Survivability Endurance Mobility Naval Vessels Embedded EMS Fast Attack OPV’s Air vehicles Prototypes UAV’s

Land Vehicles

Survivability

Endurance

Mobility

Naval Vessels

Embedded EMS

Fast Attack

OPV’s

Air vehicles

Prototypes

UAV’s

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