Periodic Reporting for period 2 - MASCOT (Modular multilevel cost Analysis Software for COmposite smarT fuselage)
Berichtszeitraum: 2020-10-01 bis 2021-09-30
PROBLEM/ISSUE BEING ADDRESSED
The aim of this project is to develop an open source software (SW) to allow full cycle cost analysis for innovative composite manufacturing of fuselage barrels. The cost estimation SW is to be included in a more general optimization procedure aimed at designing the best composite fuselage. Three established cost estimation methods are to be implemented, and they have to be linked with Computer Aided Design (CAD), Abaqus (FEM) and Structural Health Monitoring (SHM). The estimation has to involve production and assemblying steps, statistical features and aintenance/ repair activities. The subcomponents of the fuselage to be cost-estimated are depicted in Figure 1.
KEY IMPROVEMENTS FOR SOCIETY
MASCOT can certainly contribute to Airframe ITD WP B-4.3.6 of the SHERLOC development activities. The project allows the inclusion of the manufacturing, maintenance and repair costs in the design phase, thus providing an economic comparison of different solutions during the design step.
The project also improves innovation capacity and integration of new knowledge. Embedded SHM apparatus and novel monitoring/predicting procedures are the frontier line of the aeronautics nowadays, but their influence on the final cost for the industries is still vague. The MASCOT SW provides an essential tool to measure such an influence and, hence, to boost the industries in investing in new technologies. MASCOT SW will help in benefitting the society from safer airplanes at lower cost.
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OVERALL OBJECTIVES
MASCOT was organized in 8 WPs. WP1 is project management.
Main objective of MASCOT was to implement the cost estimation procedure in Python (the main flowchart is depicted in Figure 2). Such a goal was fulfilled by accomplishing the cost estimation by 1) Analogous method (WP3), by 2) Parametric method (WP4), and by 3) Bottom-Up (WP5).
A preliminar multilevel structure (flowchart in Figure 3, its implementation in the SW in Figure 4) is set up. Each level is associated to a different type of component, being 0 for raw material, 1 for assembled component from raw materials, and upper levels for more complex assemblying parts. Figure 5 provides a schematic sketch of the main structure of the SW and Figure 6 details the structure between Level 0 and Level 1 (similar links can be established at the upper levels).
Further objective of the project was to allow the MASCOT SW to be interface with CAD, Abaqus and Isight (WP6) and to include the SHM equipment (WP7) in the cost estimation. The SHM affects both the production cost and the maintenance/repair cost. The last issue may be improved by a Bayesian-based Dynamic Data Driven System BDDAS (WP8).
The aim of this project is to develop an open source software (SW) to allow full cycle cost analysis for innovative composite manufacturing of fuselage barrels. The cost estimation SW is to be included in a more general optimization procedure aimed at designing the best composite fuselage. Three established cost estimation methods are to be implemented, and they have to be linked with Computer Aided Design (CAD), Abaqus (FEM) and Structural Health Monitoring (SHM). The estimation has to involve production and assemblying steps, statistical features and aintenance/ repair activities. The subcomponents of the fuselage to be cost-estimated are depicted in Figure 1.
KEY IMPROVEMENTS FOR SOCIETY
MASCOT can certainly contribute to Airframe ITD WP B-4.3.6 of the SHERLOC development activities. The project allows the inclusion of the manufacturing, maintenance and repair costs in the design phase, thus providing an economic comparison of different solutions during the design step.
The project also improves innovation capacity and integration of new knowledge. Embedded SHM apparatus and novel monitoring/predicting procedures are the frontier line of the aeronautics nowadays, but their influence on the final cost for the industries is still vague. The MASCOT SW provides an essential tool to measure such an influence and, hence, to boost the industries in investing in new technologies. MASCOT SW will help in benefitting the society from safer airplanes at lower cost.
.
OVERALL OBJECTIVES
MASCOT was organized in 8 WPs. WP1 is project management.
Main objective of MASCOT was to implement the cost estimation procedure in Python (the main flowchart is depicted in Figure 2). Such a goal was fulfilled by accomplishing the cost estimation by 1) Analogous method (WP3), by 2) Parametric method (WP4), and by 3) Bottom-Up (WP5).
A preliminar multilevel structure (flowchart in Figure 3, its implementation in the SW in Figure 4) is set up. Each level is associated to a different type of component, being 0 for raw material, 1 for assembled component from raw materials, and upper levels for more complex assemblying parts. Figure 5 provides a schematic sketch of the main structure of the SW and Figure 6 details the structure between Level 0 and Level 1 (similar links can be established at the upper levels).
Further objective of the project was to allow the MASCOT SW to be interface with CAD, Abaqus and Isight (WP6) and to include the SHM equipment (WP7) in the cost estimation. The SHM affects both the production cost and the maintenance/repair cost. The last issue may be improved by a Bayesian-based Dynamic Data Driven System BDDAS (WP8).
OVERVIEW OF THE RESULTS
Main result of the projects was the issue of the MASCOT software (SW), that is:
- open source, modular, multi-layer and with attractive GUIs;
- capable to calculate the cost of aircraft components by Analogous and Parametric approaches, both supported by a SQL database;
- capable to calculate the exact cost by Bottom-Up equipped with a rich list of materials and activities.
- capable to be interfaced with CAD, Abaqus and Isight in simple and fashion way.
- Including a specific module for the SHM equipment.
DISSEMINATION AND EXPLOITATION
Due to Covid pandemy, communication and dissemination activities were limited to the web. Web page, on-line events and workshops, social activity by Linkedin were the tool through which the progress of Mascot was communicated and disseminated.
The exploitation activity has been mainly based on the investigation of proposing the possible strategies to Aircraft Industries of components or fuselages:
Development of personalized interfaces of the SW to the customer;
Development of new features to comply with special requests by the Company (for instance introduction of new activities or new materials in Bottom-Up, linking the confidential database of the company with the SW, etc.)
WORK PERFORMED FROM THE BEGINNING
In WP1 the management of the project along its complete duration was successful in dealing with all the communication problems related to Covid pandemy and to the review process with the TM. All the essential goals were accomplished.
In WP2 the general structure of the SW was first set up accordingly with the TM, then, at the end, the final cost software was issued.
In WP3 the SW was developed in its Analogous module (Figure 7). During the review phase, the module was then improved in some output utilities.
WP4 focused on the extension of the SW to the Parametric module (Figure 8), improved further with new probabilistic features (heteroskedasticity, log data, etc.) and appealing graphical output utilities. The supporting database was designed in the SQL format in order to guarantee the highest capability.
In WP5 the SW was extended to the Bottom-up module (Figure 9), allowing the exact estimation of the cost of materials, machines and manufacturing activities. Analogous, Parametric and Bottom-up can be combined in the same component. A wide range of materials and activites was developed at no extra cost but with a higher amount of months-person.
With W6 the SW was equipped with a powerful interface (Figure 10) to input geometrical and mechanical data directly from CAD and Abaqus. Furthermore, a special interface (Figure 11) with Isight was developed in order to allow MASCOT to be included in any general optimization process. Finally, the cost of any maintenance/repair activity can be estimated by a specially designed window inside MASCOT.
WP7 was focused on the inclusion of the SHM equipment (Figure 12). A wide range of SHM components and manufacturing activities were implemented; the effect of the extra weight on the cost was also kept into account allowing a reliable estimation of the influence of the SHM on the total cost. The incidence of the SHM system on the maintenance cost is still under progress in collaboration with the TM and it will be completed at no extra cost very shortly.
WP8 was not deemed essential by the TM and has not been developed so far in MASCOT. Nevertheless, it will be possibly developed in MASCOT once the the essential BDDAS module will be provided by the TM.
Main result of the projects was the issue of the MASCOT software (SW), that is:
- open source, modular, multi-layer and with attractive GUIs;
- capable to calculate the cost of aircraft components by Analogous and Parametric approaches, both supported by a SQL database;
- capable to calculate the exact cost by Bottom-Up equipped with a rich list of materials and activities.
- capable to be interfaced with CAD, Abaqus and Isight in simple and fashion way.
- Including a specific module for the SHM equipment.
DISSEMINATION AND EXPLOITATION
Due to Covid pandemy, communication and dissemination activities were limited to the web. Web page, on-line events and workshops, social activity by Linkedin were the tool through which the progress of Mascot was communicated and disseminated.
The exploitation activity has been mainly based on the investigation of proposing the possible strategies to Aircraft Industries of components or fuselages:
Development of personalized interfaces of the SW to the customer;
Development of new features to comply with special requests by the Company (for instance introduction of new activities or new materials in Bottom-Up, linking the confidential database of the company with the SW, etc.)
WORK PERFORMED FROM THE BEGINNING
In WP1 the management of the project along its complete duration was successful in dealing with all the communication problems related to Covid pandemy and to the review process with the TM. All the essential goals were accomplished.
In WP2 the general structure of the SW was first set up accordingly with the TM, then, at the end, the final cost software was issued.
In WP3 the SW was developed in its Analogous module (Figure 7). During the review phase, the module was then improved in some output utilities.
WP4 focused on the extension of the SW to the Parametric module (Figure 8), improved further with new probabilistic features (heteroskedasticity, log data, etc.) and appealing graphical output utilities. The supporting database was designed in the SQL format in order to guarantee the highest capability.
In WP5 the SW was extended to the Bottom-up module (Figure 9), allowing the exact estimation of the cost of materials, machines and manufacturing activities. Analogous, Parametric and Bottom-up can be combined in the same component. A wide range of materials and activites was developed at no extra cost but with a higher amount of months-person.
With W6 the SW was equipped with a powerful interface (Figure 10) to input geometrical and mechanical data directly from CAD and Abaqus. Furthermore, a special interface (Figure 11) with Isight was developed in order to allow MASCOT to be included in any general optimization process. Finally, the cost of any maintenance/repair activity can be estimated by a specially designed window inside MASCOT.
WP7 was focused on the inclusion of the SHM equipment (Figure 12). A wide range of SHM components and manufacturing activities were implemented; the effect of the extra weight on the cost was also kept into account allowing a reliable estimation of the influence of the SHM on the total cost. The incidence of the SHM system on the maintenance cost is still under progress in collaboration with the TM and it will be completed at no extra cost very shortly.
WP8 was not deemed essential by the TM and has not been developed so far in MASCOT. Nevertheless, it will be possibly developed in MASCOT once the the essential BDDAS module will be provided by the TM.
PROGRESS BEYOND THE STATE OF THE ART AND RESULTS
A study of the literature and of the commercial market shows that there are many examples of software providing a cost estimation of aeronautic items. Most of them are specifically designed as cost models and they are not linked to other utilities such as SHM, FEM, CAD. Furthermore, their structure does not allow a versatile modularity.
The results of MASCOT stand:
- in the way the software is conceived, that is, multilevel, open source, modular, communicating with CAD, FEM, SHM, Isight, supported by a dynamic database;
- in its novel integration with SHM.
POTENTIAL IMPACTS
The marketing of new technologies is often hampered by economic issues in the industries’ world. MASCOT SW is a powerful tool to foster industries to invest in the production of more advanced aeronautic fuselages. The SW allows the investors to properly balance passengers’ safety, cost and profit. Furthermore, the inclusion of novel SHM equipment and prediction utilities promotes the launch of new hi-tech SMEs.
A study of the literature and of the commercial market shows that there are many examples of software providing a cost estimation of aeronautic items. Most of them are specifically designed as cost models and they are not linked to other utilities such as SHM, FEM, CAD. Furthermore, their structure does not allow a versatile modularity.
The results of MASCOT stand:
- in the way the software is conceived, that is, multilevel, open source, modular, communicating with CAD, FEM, SHM, Isight, supported by a dynamic database;
- in its novel integration with SHM.
POTENTIAL IMPACTS
The marketing of new technologies is often hampered by economic issues in the industries’ world. MASCOT SW is a powerful tool to foster industries to invest in the production of more advanced aeronautic fuselages. The SW allows the investors to properly balance passengers’ safety, cost and profit. Furthermore, the inclusion of novel SHM equipment and prediction utilities promotes the launch of new hi-tech SMEs.