1、Reference Structure Design Principles the basis for A350XWB design June 2014 CFK-Valley Stade Convention 2014 Presented by Dr. Ulrich Bieling Head of A350 NSDW Structure Design AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 P
2、age 2 Contents Why do we need Design Principles? Introduction Requirement cascade Design Principles Focus of the Presentation and Definition of “Design Principles” Summary and Conclusion AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention J
3、une 2014 Page 3 Introduction Requirement cascade Aircraft level Section level Transverse Activities Major component level Design Principle RSDP/SIDP TLAR TLStrRD StRD/SRD AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 4
4、Starting with the customer needs, Top Level Aircraft Requirements (TLAR) are formulated, e.g. Number of passengers/seats Weight payload range, etc. These requirements are broken down into requirements for Major Components of the A/C, Top Level Structure Requirements Dossier(TLSrRD) e.g. for: Fuselag
5、e Wing Empennage Systems Section Level requirements (StRD) for structural components e.g. for Skins Stringers Floor Structure Design Principles (Reference Structure Design Principles and System Installation Design Principles) Requirements Introduction AIRBUS Operations GmbH. All rights reserved. Con
6、fidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 5 Introduction Focus of the Presentation Reference Structure Design Principles System Installatio n Design Principles Detailed Design System Installation Design Principles Specific Design Work teams at Airbus and at Risk
7、Share Partners Non-Specific Design Work Team at Airbus Core Engineering A n SIDP is a set of DPs that guide the systems design engineer when designing the aircraft systems A n RSDP is a set of DPs that guide the structures design engineer when designing the structure of the airframe AIRBUS Operation
8、s GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 6 Contents Why and when do we need Design Principles? Introduction Design Principles Design Process Goals and Approach Schedule overview Summary and Conclusion AIRBUS Operations GmbH. All r
9、ights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 7 Why and when do we need Design Principles? Goals and Approach Avoid the “Harlequin Aircraft” Ensure a good design, taking into account robustness, inspection, repair. AIRBUS Operations GmbH. All right
10、s reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 8 The following aspects have to be taken into account when designing an aircraft: avoid the “Harlequin Aircraft” guarantee Consistency across the aircraft secure Interfaces standardize Solutions Goals and A
11、pproach This is even more important since the introduction of extended enterprise i.e working with Risk Share Partners Consequences: homogeneous section approach even if more than one design solution will work, it is not Airbus intention to implement different solutions for one and the same applicat
12、ion in the aircraft Why and when do we need Design Principles? AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 9 Design Process NSDW SDW Why and when do we need Design Principles? AIRBUS Operations GmbH. All rights reserv
13、ed. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 10 Schedule Overview Why and when do we need Design Principles? RSDPs availability for A350-900 Mat A Mat B Mat C RSDPs availability: Mat A in mid 2008 Mat B in mid 2009, since MG5/Mat B the RSDP is mandatory for A
14、350 design Mat C in mid 2010, further updates issued under a strictly controlled change process AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 11 Contents Why do we need Design Principles? Design Principle Documents Intr
15、oduction Design Principles RSDP content Summary and Conclusion AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 12 Design Principles Documents Experience from previous aircraft programmes Latest technology progress derived
16、 from tests and R&T programmes Significant design optimization Recent in-service and manufacturing experience Reference Structure Design Principles sources RSDPs must not outline any rational, why the DPs are as they are! Content of RSDP is generated from various sources: AIRBUS Operations GmbH. All
17、 rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 13 Design Principle Documents RSDP: Description & Content Generic Design Principles General design principles (volume 1) Composite design principles (volume 2) Metallic design principles (volume 3) Co
18、mponent Specific Design Principles Fuselage (volume 4) Wing (volume 5) Empennage (volume 6) AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 14 RSDP distribution restriction outside Airbus Applicable Restrictions for Exter
19、nal Distribution Export rules towards A350XWB Risk Sharing Partners (RSPs) are as follows: Volume 0 (Introduction): available for all RSPs Volumes 1, 2 & 3 (Generic): available for all RSPs Volume 4 (Fuselage): available for Fuselage section RSPs only Volume 5 (Wing): available for Wing RSPs only Vo
20、lume 6 (Rear Fuselage and Empennage): available for Empennage RSPs only RSDP: Description & Content AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 15 Design Principles RSDP: Vol 1 - Generic Design Principles Mechanically
21、 Fastened Joints in composite, metal, hybrid structures Specific Design Rules for Damage Prone Areas Shimming Sealing Principles Assembly Surface Protection DP Lightning Strike Protection Design for Erosion Protection Protection Installation DP for A-Brackets Bushing Installation Lubrication, Draina
22、ge Design for Accessibility and Inspectability Others AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 16 RSDP Vol. 1 Generic Design Principles - example mechanical joints AIRBUS Operations GmbH. All rights reserved. Confi
23、dential and proprietary document. CFK-Valley Stade Convention June 2014 Page 17 RSDP Vol. 1 Generic Design Principles - example surface protection Environmental categories definition Surface protection schemes depending on environmental categories AIRBUS Operations GmbH. All rights reserved. Confide
24、ntial and proprietary document. CFK-Valley Stade Convention June 2014 Page 18 RSDP Vol. 1 Generic Design Principles - example for brackets locations Allowed and forbidden locations on the structure for system installation brackets Allowed area for bracket Installation on frames AIRBUS Operations Gmb
25、H. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 19 Design Principles RSDP: Vol 2 - Composite Design Principles Rules for Laminate Design Stacking/staggering rules Manufacturing rules Design Principles for sandwich components Bonded Joints Co-
26、curing/ Co-bonding / Secondary Bonding Structural Analysis Categories Structural Critical Classification Composite classification for primary/secondary structure AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 20 Interlea
27、ved plies RSDP Vol. 2 Composite Design Principles - example laminate rules Ply drop-off Ramp ratios in load direction and perpendicular AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 21 RSDP Vol. 2 Composite Design Princ
28、iples - example manufacturing constraints Minimum strip length for AFP and ATL Processes to be considered in ply boundaries Lap and gap limits Automated Fibre Placement/ Automated Tape Laying process AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade
29、 Convention June 2014 Page 22 RSDP Vol. 2 Composite Design Principles - example rules for sandwich components Ply location, chamfer angle For sandwich component design Extension of potting/filler materials in sandwich components around attachment elements AIRBUS Operations GmbH. All rights reserved.
30、 Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 23 Design Principles RSDP: Vol 3 - Metallic Design Principles Manufacturing Technologies Forming, machining, Description & constraints Design rules Welded joints Process Design recommendations Design for Static, Fatig
31、ue & DT Guidelines AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 24 Design Principles Examples of Vol. 3 content: Metallic Materials specific items Aluminum, Ti, Steel, new alloys description of specific features to be
32、considered e.g. bend radii and machining radii, thickness steps Environment Friendly Design Substances not allowed/banned materials Surface protection code management RSDP: Vol 3 - Metallic Design Principles AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Vall
33、ey Stade Convention June 2014 Page 25 Design Principles RSDP: Vol 4 Fuselage Design Principles Fuselage Design Fuselage component DPs Fuselage joints DPs Skins and stringers F r a m e s Frame to skin connection clips Cabin window frames Door surround structure PAX floor Bilge area Design Principles
34、Longitudinal joints Orbital joints Nodes of orbital/longitudinal joints Lightning strike protection Electric Structure Network Design for repairability/damage prone ares Miscellaneous AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June
35、 2014 Page 26 RSDP Vol. 4 Fuselage Design Principles - example orbital joints AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 27 RSDP Vol. 4 Fuselage Design Principles - clip to frame attachment F Positioning of the faste
36、ners Definition of distances Clip Frame Skin Stringer AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 28 RSDP Vol. 4 Fuselage Design Principles - example ramps under Omega- stringers AIRBUS Operations GmbH. All rights res
37、erved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 29 RSDP Vol. 4 Fuselage Design Principles - example lightning strike protection at longitudinal joints AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convent
38、ion June 2014 Page 30 Design Principles RSDP: Vol. 5 - Wing/Pylon Design Principles Wing Design Wing component DPs Fastener systems Wing covers Wing spars Wing ribs Leading&Trailing edge attachment Man-hole cut-outs and doors Root joint Lightning strike protection AIRBUS Operations GmbH. All rights
39、reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 31 RSDP Vol. 5 Wing Design Principles- example fastener systems Fastener types Assembly details spar to wing cover Surface protection /LSP AIRBUS Operations GmbH. All rights reserved. Confidential and proprie
40、tary document. CFK-Valley Stade Convention June 2014 Page 32 RSDP Vol. 5 Wing Design Principle - example T-stringer geometry and ply build-up T-stringer geometry and build-up Ply run-out in radius AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Co
41、nvention June 2014 Page 33 RSDP Vol. 5 Wing Design Principles- example of a wing stringer run-out configuration Double angle configuration of stringer run-out (one out of several Options) AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention
42、June 2014 Page 34 RSDP Vol. 5 Wing Design Principle - example root joint Root joint general view Design details AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 35 Design Principles RSDP: Vol. 6 Empennage Design Principles
43、 HTP/VTP/Sect. 19 Design Empennage component DPs HTP/VTP overview Covers Spars R i b s Leading edge protection HTP root joint VTP attachment Surface protection Drainage Rudder&elevator Fuselage rear end AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley St
44、ade Convention June 2014 Page 36 Summary and Conclusion RSDP aims at achievement of a proof design, in compliance with best practices, applicable regulations, weight & cost optimization, manufacturing processes economical/environmental constraints. RSDPs are mandatory and must be followed by design
45、offices! In case of significant deviation from these Design Principles the originator must justify his solution by test or analysis Deviation must be authorized by Airbus RSDPs are needed to ensure a proof design taking into account robustness, inspection, repairability, etc a good way to avoid the
46、“harlequin aircraft” and secure a harmonized design AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-Valley Stade Convention June 2014 Page 37 Thank you for your attention AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. CFK-V
47、alley Stade Convention June 2014 Page 38 AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS Operations GmbH. No intellectual property rights are granted by the delivery of this document
48、 or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS Operations GmbH. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein d
49、o not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS Operations GmbH will be pleased to explain the basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.
