Final Report Summary - WEMACS (WEights and MAnufacturing Costs)
Executive Summary:
The main objective of this project was the development of a software application - WEMACS - capable of obtaining detailed weights and manufacturing costs of various structural components of an aircraft, to support the Clean Sky Green Regional Aircraft development process in the preliminary design phase, and enable achieving the pollution and noise reduction targets for the regional aircraft entering the market in the coming decades.
Starting from a first level weight breakdown and based on conventional technologies given as input by the user along with other relevant data, the WEMACS software application provides a detailed weight breakdown for the fuselage, wing, horizontal and vertical stabilizing surfaces and pylons. The tool was designed to consider new materials, technologies and design solutions for the weight estimation, while estimating the cost for each of the components.
To promote flexibility and reusability in other projects as well as to allow future evolutions/expansion and updates, the WEMACS tool was designed and developed in a highly modular fashion. Each module is independent from others and with clearly defined, easily reconfigurable interfaces.
The modular approach and transparent interfaces also means that WEMACS architecture is easily integrated, as a whole or partially, into more complex aircraft design tools, namely in Multidisciplinary Design and Optimization (MDO) environments.
Figure 3 1: WEMACS software application architecture
The consortium is composed by GMV Portugal (GMV), acting as coordinator, and Spin.Works (SPW) from Portugal, KE-Works (KEW) and University of Delft (TUD) from Netherlands.
Project Context and Objectives:
From a technical perspective, the most relevant deliverables of this project are D2.1 – Software Requirements Document, D3.1 – Methodology Tool Design Document, D5.1 – Test Cases Document, D5.2 – Integration and Verification Report and two Software Packages, containing the WEMACS tool. Although not an official deliverable, the coordinator, responsible for the tool HMI, has prepared and submitted also a User Manual. The purpose of this document was to present the WEMACS application to the user and to provide the WEMACS user a comprehensive guide to the application’s features and describe the best way to use them. All deliverables were submitted to the Topic Technical Manager, which in this case is Alenia Aeronautica, and duly approved.
WEMACS software application, starting from a first level weight breakdown based on conventional technologies given as input by the user along with other relevant data (e.g. concerning geometries, design variables, etc.), is capable of obtaining a detailed weight for each structural item while also providing also detailed information about costs.
By default, a detailed weight breakdown is estimated based on conventional technologies. This detailed conventional weight breakdown may be then updated by the user through the tuning of weight technology coefficients in accordance with the following potential changes to the project (see Figure 3 2):
• New materials (i.e. change from Aluminium to CFRP; change from Aluminium to Aluminium-Lithium etc.);
• New technologies (i.e. new manufacturing processes);
• New design solutions (i.e. one piece frames, different frame and/or stringer spacing, one piece barrels, fuselage panels layout, wings with/without centre box etc.).
This design philosophy allows for quick and easy trade-off analyses.
Figure 3 2: WEMACS application – ‘Current Coeficients’ window
WEMACS software application also estimates the costs associated to the conventional and innovative solutions.
WEMACS users have yet the possibility to create new input files from within the application, reducing the time needed to explore changes in aircraft design and even novel aircraft configurations. Coupled with well defined interfaces and the ability to run in batch mode, WEMACS becomes a tool easily integrated into wider aircraft design frameworks.
The detail of the main structural items is provided with the following breakdown (as required in the tender):
• Fuselage:
o skins, stringers and doublers;
o frames;
o door surround structures;
o window frames and transparencies;
o keel beam;
o fuselage to wing integration;
o Sections joints;
o pressure bulkheads;
o landing gear bulkheads;
o doors and hatches;
o miscellaneous access doors;
o detailed floor structure;
o cargo floor structure;
o fairings;
o protection and external paint;
o other miscellaneous elements;
• Wing:
o wing box;
o fixed leading edge;
o fixed trailing edge;
o wingtip and winglet;
o movable surfaces;
o protection and external paint;
o other miscellaneous elements;
• Horizontal and Vertical Tail:
o the same level of breakdown as is performed for the wing;
• Pylons:
o structure, fairings, attachments, fittings;
Furthermore, for each of the items above, the specific installation weight is also estimated.
WEMACS software application is valid for projects within the following validity range defined in Table 3 1.
PARAMETER VALIDITY RANGE
Maximum Take-Off Weight 15.000 – 70.000 (kg)
Number of Passengers 40 – 150 pax
Range 900 – 3000 (nm)
Mach Number 0.45 – 0.83
Maximum Flight Altitude 20000 – 40000 (ft)
Table 3 1: WEMACS software application validity range
Figure 3 3: WEMACS – example of the application reports
Project Results:
WP5 of the WEMACS project was dedicated to the verification and validation of the software application that was developed in the previous work-package. Several system verification tests (focused on functionality, interfaces, resource and performance) were performed. In this section, more focus on the system validation test and results will be given.
The main purpose of the system validation test is to validate the detailed weight breakdown as estimated by the Fuselage Weight estimation Module (FWM) and the Wings, tail and pylons Weight estimation Module (WWM) when running WEMACS with the inputs referring to the Boeing 737-200. One can only validate the detailed weight estimations, by comparison, given that the available data (retrieved from literature) is limited in scope for the purpose of performing a detailed validation of the costs breakdown estimations as provided by WEMACS.
3.3.1. VALIDATION RESULTS
This section aims at presenting the system validation tests that were performed in the WEMACS software application. The objective was to use the available (Boeing 737-200) aircraft data to feed-in and run the application, to compare it with the WEMACS application output reports, while establishing that reasonable deviations in the results were obtained.
The test presented below is part of the Integration and Validation Report (D5.2) of the WEMACS project.
3.3.1.1. WEMACS Tool Validation Test
This validation test is referenced as WEMACS-IVR-TC500 in the Integration and Validation Report. To perform this test, the user is required to run the WEMACS application in HMI mode with correct inputs and to verify the output produced.
3.3.1.1.1 Description
The user shall run the WEMACS application with the HMI inputs specified in Table 3 2 and compare the application output reports with the expected output data as specified in Table 3 3; and then establish a mean deviation between the application results and the data from literature for an intermediate aircraft structural breakdown (i.e for fuselage, wings and horizontal and vertical tail). The test will be considered successful if the procedure is concluded without any error message, while returning the complete breakdown for the detailed weight estimations as specified in Table 6-2, Table 6-4 and Table 6-6 defined in [RD.3] and result deviations are shown to be reasonable.
Table 3 2 presents the inputs list that is required to start the WEMACS application in order to execute the test WEMACS-IVR-TC500 presented above. The data refers to Boeing 737-200 and was collected from [RD.6] and [RD.7] and compiled in InputFile737200.xml (shown for completeness in Appendix A.1) according to the application schema as defined in [RD.4].
BOEING 737-200
TYPE PARAMETER VALUE UNIT REFERENCE
value MTOW 52390 [kg] [RD.6] and [RD.7]
value MLW 46720 [kg] [RD.6] and [RD.7]
value MZFW 43091 [kg] [RD.6] and [RD.7]
value Max Mach number 0.83 [-] [RD.6] and [RD.7]
value Dive Mach number 0.90 [-] estimated
value Manoeuvre Speed 100.0 [m/s] estimated
value Max Flight Altitude 35000 [ft] [RD.6] and [RD.7]
file Input file Appendix A.1
N.A. -
Table 3 2: WEMACS inputs (Boeing 737-200) used in WEMACS-IVR-TC500
Table 3 3 presents the weight breakdown that was found in the literature. The data refers to Boeing 737-200 and was collected from [RD.8]
TYPE PARAMETER VALUE UNIT REFERENCE
Weight Wing 4814 [kg] [RD.8]
Weight Horizontal and Vertical tail 1233 [kg] [RD.8]
Weight Fuselage 5503 [kg] [RD.8]
Table 3 3: Boeing 737-200 Weight breakdown
3.3.1.1.2 Test Case Procedure
Table 2 4 presents the procedure for the test execution, step-by-step, as well as the verifications to be made.
STEP DESCRIPTION TEST VERIFICATION
Launch wemacs.exe Check that the WEMACS HMI launches.
Fill out the HMI inputs with the data presented in Table 5 1 and select:
• ‘Create conventional solution’ for the solution type. N.A.
Click the “Generate Report” button. Check that the tool begins to perform the calculations to generate the report.
Confirm that the tool notifies the user that the report has been successfully generated.
Click the “View Reports” button. Check that the reports dialog box appears.
Verify generated report. Confirm that the weights and costs from the report are displayed according to the breakdown specified in Tables 6-2, 6-4 and 6-6 in [RD.3].
Analyse the estimated total weight for the Wing. Check that the estimated weight deviation from the literature value is reasonable.
Analyse the estimated total weight for the Horizontal and Vertical tail. Check that the estimated weight deviation from the literature value is reasonable.
Analyse the estimated total weight for the Fuselage. Check that the estimated weight deviation from the literature value is reasonable.
Table 3 4: WEMACS-TCD-TC500 Test Case Procedure [RD.5]
3.3.1.1.3 Test Results
The application was successfully subject to the test described in WEMACS-TCD-TC500 [RD.5].
The following table describes the outcome of each of the steps of the test procedure.
STEP DESCRIPTION wemacs.exe was launched.
TEST VERIFICATION Check that the WEMACS HMI launches.
TEST RESULT
Figure 3 4: Validation test: WEMACS HMI
CONCLUSION WEMACS HMI was successfully presented to the user.
STEP DESCRIPTION The HMI inputs were filled in accordingly and report generation was demanded.
TEST VERIFICATION Check that the tool begins to perform the calculations to generate the report. Confirm that the tool notifies the user that the report has been successfully generated.
TEST RESULT
Figure 3 5: Validation test: WEMACS generating a report
Figure 3 6: Validation test: WEMACS notification of sucessful report generation
CONCLUSION WEMACS began to perform the required calculations after user request displaying a progress bar, given the valid inputs. WEMACS notified the user after generating the requested report.
STEP DESCRIPTION “View Reports” button was clicked.
TEST VERIFICATION Check that reports dialog box appears.
TEST RESULT
Figure 3 7: Validation test: WEMACS reports dialog box
CONCLUSION WEMACS displayed the required reports dialog box, presenting the report in a separator with a corresponding number.
STEP DESCRIPTION The generated report was verified.
TEST VERIFICATION Confirm that the weights and costs from the report are displayed according to the breakdown specified in Tables: 6-2, 6-4 and 6-6 in [RD.3].
TEST RESULT
Figure 3 8: Validation test: WEMACS report breakdown
CONCLUSION WEMACS report was presented according to the specified breakdown, also displaying HMI inputs and whether default coefficients were changed.
STEP DESCRIPTION The estimated total weight for the Wing was analyzed.
TEST VERIFICATION Check that the estimated weight deviation from the literature value is reasonable.
TEST RESULT Wing weight as estimated by WEMACS: 4926.54 kg
Wing weight according to [RD.8]: 4814 kg
WEMACS estimation error: +2.34%
CONCLUSION The estimation error presented by WEMACS in the estimation of the Wing for 737-200 is acceptable.
STEP DESCRIPTION The estimated total weight for the Tail group was analyzed.
TEST VERIFICATION Check that the estimated weight deviation from the literature value is reasonable.
TEST RESULT Tail group weight as estimated by WEMACS: 1351.68 kg
Tail group weight according to [RD.8]: 1233 kg
WEMACS estimation error: +9.63%
CONCLUSION The estimation error presented by WEMACS in the estimation of the Tail group for 737-200 is acceptable.
STEP DESCRIPTION The estimated total weight for the Fuselage was analyzed.
TEST VERIFICATION Check that the estimated weight deviation from the literature value is reasonable.
TEST RESULT Fuselage weight as estimated by WEMACS: 5490.55 kg
Fuselage weight according to [RD.8]: 5503 kg
WEMACS estimation error: -0.02%
CONCLUSION The estimation error presented by WEMACS in the estimation of the Fuselage for 737-200 is acceptable.
Table 3 5: WEMACS-IVR-TC500 Test Case Results
Potential Impact:
The WEMACS Consortium has developed several dissemination activities under the scope of the WP7 (Dissemination and Exploitation). The main objectives of such activities are: to ensure a systematic dissemination of the project outcomes among the aeronautical community (public dissemination) and to facilitate the collaboration and information exchange between partners (internal dissemination).
The dissemination activities are under the responsibility of each consortium member and therefore, each partner reports on the activities they carried out for the dissemination of the WEMACS project results, activities that are compatible with the any protection of intellectual property rights, confidentiality obligations and legitimate interests of the owner(s) of the foreground.
The main objective of this project was the development of a software application - WEMACS - capable of obtaining detailed weights and manufacturing costs of various structural components of an aircraft, to support the Clean Sky Green Regional Aircraft development process in the preliminary design phase, and enable achieving the pollution and noise reduction targets for the regional aircraft entering the market in the coming decades.
Starting from a first level weight breakdown and based on conventional technologies given as input by the user along with other relevant data, the WEMACS software application provides a detailed weight breakdown for the fuselage, wing, horizontal and vertical stabilizing surfaces and pylons. The tool was designed to consider new materials, technologies and design solutions for the weight estimation, while estimating the cost for each of the components.
To promote flexibility and reusability in other projects as well as to allow future evolutions/expansion and updates, the WEMACS tool was designed and developed in a highly modular fashion. Each module is independent from others and with clearly defined, easily reconfigurable interfaces.
The modular approach and transparent interfaces also means that WEMACS architecture is easily integrated, as a whole or partially, into more complex aircraft design tools, namely in Multidisciplinary Design and Optimization (MDO) environments.
Figure 3 1: WEMACS software application architecture
The consortium is composed by GMV Portugal (GMV), acting as coordinator, and Spin.Works (SPW) from Portugal, KE-Works (KEW) and University of Delft (TUD) from Netherlands.
Project Context and Objectives:
From a technical perspective, the most relevant deliverables of this project are D2.1 – Software Requirements Document, D3.1 – Methodology Tool Design Document, D5.1 – Test Cases Document, D5.2 – Integration and Verification Report and two Software Packages, containing the WEMACS tool. Although not an official deliverable, the coordinator, responsible for the tool HMI, has prepared and submitted also a User Manual. The purpose of this document was to present the WEMACS application to the user and to provide the WEMACS user a comprehensive guide to the application’s features and describe the best way to use them. All deliverables were submitted to the Topic Technical Manager, which in this case is Alenia Aeronautica, and duly approved.
WEMACS software application, starting from a first level weight breakdown based on conventional technologies given as input by the user along with other relevant data (e.g. concerning geometries, design variables, etc.), is capable of obtaining a detailed weight for each structural item while also providing also detailed information about costs.
By default, a detailed weight breakdown is estimated based on conventional technologies. This detailed conventional weight breakdown may be then updated by the user through the tuning of weight technology coefficients in accordance with the following potential changes to the project (see Figure 3 2):
• New materials (i.e. change from Aluminium to CFRP; change from Aluminium to Aluminium-Lithium etc.);
• New technologies (i.e. new manufacturing processes);
• New design solutions (i.e. one piece frames, different frame and/or stringer spacing, one piece barrels, fuselage panels layout, wings with/without centre box etc.).
This design philosophy allows for quick and easy trade-off analyses.
Figure 3 2: WEMACS application – ‘Current Coeficients’ window
WEMACS software application also estimates the costs associated to the conventional and innovative solutions.
WEMACS users have yet the possibility to create new input files from within the application, reducing the time needed to explore changes in aircraft design and even novel aircraft configurations. Coupled with well defined interfaces and the ability to run in batch mode, WEMACS becomes a tool easily integrated into wider aircraft design frameworks.
The detail of the main structural items is provided with the following breakdown (as required in the tender):
• Fuselage:
o skins, stringers and doublers;
o frames;
o door surround structures;
o window frames and transparencies;
o keel beam;
o fuselage to wing integration;
o Sections joints;
o pressure bulkheads;
o landing gear bulkheads;
o doors and hatches;
o miscellaneous access doors;
o detailed floor structure;
o cargo floor structure;
o fairings;
o protection and external paint;
o other miscellaneous elements;
• Wing:
o wing box;
o fixed leading edge;
o fixed trailing edge;
o wingtip and winglet;
o movable surfaces;
o protection and external paint;
o other miscellaneous elements;
• Horizontal and Vertical Tail:
o the same level of breakdown as is performed for the wing;
• Pylons:
o structure, fairings, attachments, fittings;
Furthermore, for each of the items above, the specific installation weight is also estimated.
WEMACS software application is valid for projects within the following validity range defined in Table 3 1.
PARAMETER VALIDITY RANGE
Maximum Take-Off Weight 15.000 – 70.000 (kg)
Number of Passengers 40 – 150 pax
Range 900 – 3000 (nm)
Mach Number 0.45 – 0.83
Maximum Flight Altitude 20000 – 40000 (ft)
Table 3 1: WEMACS software application validity range
Figure 3 3: WEMACS – example of the application reports
Project Results:
WP5 of the WEMACS project was dedicated to the verification and validation of the software application that was developed in the previous work-package. Several system verification tests (focused on functionality, interfaces, resource and performance) were performed. In this section, more focus on the system validation test and results will be given.
The main purpose of the system validation test is to validate the detailed weight breakdown as estimated by the Fuselage Weight estimation Module (FWM) and the Wings, tail and pylons Weight estimation Module (WWM) when running WEMACS with the inputs referring to the Boeing 737-200. One can only validate the detailed weight estimations, by comparison, given that the available data (retrieved from literature) is limited in scope for the purpose of performing a detailed validation of the costs breakdown estimations as provided by WEMACS.
3.3.1. VALIDATION RESULTS
This section aims at presenting the system validation tests that were performed in the WEMACS software application. The objective was to use the available (Boeing 737-200) aircraft data to feed-in and run the application, to compare it with the WEMACS application output reports, while establishing that reasonable deviations in the results were obtained.
The test presented below is part of the Integration and Validation Report (D5.2) of the WEMACS project.
3.3.1.1. WEMACS Tool Validation Test
This validation test is referenced as WEMACS-IVR-TC500 in the Integration and Validation Report. To perform this test, the user is required to run the WEMACS application in HMI mode with correct inputs and to verify the output produced.
3.3.1.1.1 Description
The user shall run the WEMACS application with the HMI inputs specified in Table 3 2 and compare the application output reports with the expected output data as specified in Table 3 3; and then establish a mean deviation between the application results and the data from literature for an intermediate aircraft structural breakdown (i.e for fuselage, wings and horizontal and vertical tail). The test will be considered successful if the procedure is concluded without any error message, while returning the complete breakdown for the detailed weight estimations as specified in Table 6-2, Table 6-4 and Table 6-6 defined in [RD.3] and result deviations are shown to be reasonable.
Table 3 2 presents the inputs list that is required to start the WEMACS application in order to execute the test WEMACS-IVR-TC500 presented above. The data refers to Boeing 737-200 and was collected from [RD.6] and [RD.7] and compiled in InputFile737200.xml (shown for completeness in Appendix A.1) according to the application schema as defined in [RD.4].
BOEING 737-200
TYPE PARAMETER VALUE UNIT REFERENCE
value MTOW 52390 [kg] [RD.6] and [RD.7]
value MLW 46720 [kg] [RD.6] and [RD.7]
value MZFW 43091 [kg] [RD.6] and [RD.7]
value Max Mach number 0.83 [-] [RD.6] and [RD.7]
value Dive Mach number 0.90 [-] estimated
value Manoeuvre Speed 100.0 [m/s] estimated
value Max Flight Altitude 35000 [ft] [RD.6] and [RD.7]
file Input file Appendix A.1
N.A. -
Table 3 2: WEMACS inputs (Boeing 737-200) used in WEMACS-IVR-TC500
Table 3 3 presents the weight breakdown that was found in the literature. The data refers to Boeing 737-200 and was collected from [RD.8]
TYPE PARAMETER VALUE UNIT REFERENCE
Weight Wing 4814 [kg] [RD.8]
Weight Horizontal and Vertical tail 1233 [kg] [RD.8]
Weight Fuselage 5503 [kg] [RD.8]
Table 3 3: Boeing 737-200 Weight breakdown
3.3.1.1.2 Test Case Procedure
Table 2 4 presents the procedure for the test execution, step-by-step, as well as the verifications to be made.
STEP DESCRIPTION TEST VERIFICATION
Launch wemacs.exe Check that the WEMACS HMI launches.
Fill out the HMI inputs with the data presented in Table 5 1 and select:
• ‘Create conventional solution’ for the solution type. N.A.
Click the “Generate Report” button. Check that the tool begins to perform the calculations to generate the report.
Confirm that the tool notifies the user that the report has been successfully generated.
Click the “View Reports” button. Check that the reports dialog box appears.
Verify generated report. Confirm that the weights and costs from the report are displayed according to the breakdown specified in Tables 6-2, 6-4 and 6-6 in [RD.3].
Analyse the estimated total weight for the Wing. Check that the estimated weight deviation from the literature value is reasonable.
Analyse the estimated total weight for the Horizontal and Vertical tail. Check that the estimated weight deviation from the literature value is reasonable.
Analyse the estimated total weight for the Fuselage. Check that the estimated weight deviation from the literature value is reasonable.
Table 3 4: WEMACS-TCD-TC500 Test Case Procedure [RD.5]
3.3.1.1.3 Test Results
The application was successfully subject to the test described in WEMACS-TCD-TC500 [RD.5].
The following table describes the outcome of each of the steps of the test procedure.
STEP DESCRIPTION wemacs.exe was launched.
TEST VERIFICATION Check that the WEMACS HMI launches.
TEST RESULT
Figure 3 4: Validation test: WEMACS HMI
CONCLUSION WEMACS HMI was successfully presented to the user.
STEP DESCRIPTION The HMI inputs were filled in accordingly and report generation was demanded.
TEST VERIFICATION Check that the tool begins to perform the calculations to generate the report. Confirm that the tool notifies the user that the report has been successfully generated.
TEST RESULT
Figure 3 5: Validation test: WEMACS generating a report
Figure 3 6: Validation test: WEMACS notification of sucessful report generation
CONCLUSION WEMACS began to perform the required calculations after user request displaying a progress bar, given the valid inputs. WEMACS notified the user after generating the requested report.
STEP DESCRIPTION “View Reports” button was clicked.
TEST VERIFICATION Check that reports dialog box appears.
TEST RESULT
Figure 3 7: Validation test: WEMACS reports dialog box
CONCLUSION WEMACS displayed the required reports dialog box, presenting the report in a separator with a corresponding number.
STEP DESCRIPTION The generated report was verified.
TEST VERIFICATION Confirm that the weights and costs from the report are displayed according to the breakdown specified in Tables: 6-2, 6-4 and 6-6 in [RD.3].
TEST RESULT
Figure 3 8: Validation test: WEMACS report breakdown
CONCLUSION WEMACS report was presented according to the specified breakdown, also displaying HMI inputs and whether default coefficients were changed.
STEP DESCRIPTION The estimated total weight for the Wing was analyzed.
TEST VERIFICATION Check that the estimated weight deviation from the literature value is reasonable.
TEST RESULT Wing weight as estimated by WEMACS: 4926.54 kg
Wing weight according to [RD.8]: 4814 kg
WEMACS estimation error: +2.34%
CONCLUSION The estimation error presented by WEMACS in the estimation of the Wing for 737-200 is acceptable.
STEP DESCRIPTION The estimated total weight for the Tail group was analyzed.
TEST VERIFICATION Check that the estimated weight deviation from the literature value is reasonable.
TEST RESULT Tail group weight as estimated by WEMACS: 1351.68 kg
Tail group weight according to [RD.8]: 1233 kg
WEMACS estimation error: +9.63%
CONCLUSION The estimation error presented by WEMACS in the estimation of the Tail group for 737-200 is acceptable.
STEP DESCRIPTION The estimated total weight for the Fuselage was analyzed.
TEST VERIFICATION Check that the estimated weight deviation from the literature value is reasonable.
TEST RESULT Fuselage weight as estimated by WEMACS: 5490.55 kg
Fuselage weight according to [RD.8]: 5503 kg
WEMACS estimation error: -0.02%
CONCLUSION The estimation error presented by WEMACS in the estimation of the Fuselage for 737-200 is acceptable.
Table 3 5: WEMACS-IVR-TC500 Test Case Results
Potential Impact:
The WEMACS Consortium has developed several dissemination activities under the scope of the WP7 (Dissemination and Exploitation). The main objectives of such activities are: to ensure a systematic dissemination of the project outcomes among the aeronautical community (public dissemination) and to facilitate the collaboration and information exchange between partners (internal dissemination).
The dissemination activities are under the responsibility of each consortium member and therefore, each partner reports on the activities they carried out for the dissemination of the WEMACS project results, activities that are compatible with the any protection of intellectual property rights, confidentiality obligations and legitimate interests of the owner(s) of the foreground.
