Act1 - Scene 3 Helicopter Life Cycle Cost Reduction through Pre-Design Optimisation

Forum 2, The Hague, 24th - 26th October 2006

Dr. C. SEVIN (Eurocopter) & Ir. J.F. BOER (NLR)

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Use Case

Market Analysis for optimised helicopter design

Todays Market Analysis: Performed for: - only one definition; - many customers; - cost estimation made on the most critical mission. Needs: Market Analysis for: all customers; all missions. Economical impact estimation for all categories of customers. Goal: To optimize the technical definition of a helicopter for: - different customers; - different requirements; - opposite profiles.

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Scenario

- 1 - Define
the categories of customer

- 2 - Adapt the sizing

models of NLR and EC:
find a common list of technical parameters

- 3 - Develop
the cost model

- 4 - Perform sensitivity
analysis on a limited number of parameters

- 5 - Optimise helicopter
definition for LCC of 1 customer first.

- 7 - Optimise
helicopter definition for this composite criteria

- 6 - Define a criteria
to combine LCC of multiple customers & missions LCC = Life Cycle Cost

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Objective (1)

Helicopter Life Cycle Cost reduction through Pre-Design Optimisation

Current practice: pre-design driven by performance requirements Objective to find optimum helicopter design which: complies to all performance requirements satisfies the customer's requirements at lowest costs.

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Objective (2)

Criteria
Time to perform combined technical & market analysis

Today reference
1 2 weeks (Models not complete or not connected)

Objective
1 Day (models connected)

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Technical requirements

Service functions of the developed tool

Estimate the LCC of any technical definition for any customers profile

Optimise helicopter definition for LCC of 1 or multiple customers & missions

Perform sensitivity analysis

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Contributions

This scenario deploys

Multidisciplinary Design & Optimisation, MDO

Adapt the sizing tool for cost calculations Connect the sizing tool with the cost model

Perform the sensitivity analysis Define the multicriteria optimisation method

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LCC model (1)

Fleet Data
Number of H/C Number of FH per year and per HC Number of bases 5 [-] 600 [FH / year/HC] 1 [-]

Training data
Ground training hours/year/base Ground training cost per hour Flight training hours per year per crew Flight training cost Simulator training hours per year per crew Hour cost of simulator in $ 200 125 10 6303 h/year/base /h h/year/crew /h/HC 150 $/h 7564 $/h/HC 2000 $/h

Personnel and crew data

Number of pilot per aircraft MMH/FH Number of manager per base Number of crew per aircraft Annual cost for a Pilot Annual cost for a manager Annual cost for a technician 2 [-] 7.2 [H/FH] 2 1.5 83333 62500 41667 [-] [-] [/year] [/year] [/year]

15 h/year/base 1666.666667 /h

General data
100000 [$/year] 75000 [$/year] 50000 [$/year] Working hours / Day Working days / Year Insurance cost / Acquisition cost per year 8 [H / day] 200 [days / year] 7% [%/Year]

Nb GSE package per HC Maintenance data

Price for one GSE package Documentation cost / Purchase price Spare parts rate / Purchase price Software support cost / Avionics Purchase price/year Ratio for GSE maintenance per year Ratio for Documentation upgrade per year Infrastructure cost per year per HC Major retrofit at mid life in % of the purchase price Upgrade per year in % of the purchase price 1E+06 1.5% 12% 3% 2% 10% 14167 [] [%] [%] [%] [%/Year] [%/Year] [/Year] 1400000 [$] Nb of HC 1 2 5 10 20 50 Nb GSE package 1 1.5 2 4 7 12

17000 [$/Year]

10% [%] 0.50% [%]

Euro/Dollar exchange rate

Exchange rate (Dollar for 1 Euro)

1.2 [-]

Technical data
Pre-Project Breakdown Fuselage Landing gear Main rotor blades MGB Rotor hub Tail rotor transmission Electrical system Avionics Filght controls Hydraulics Engine Fuel system Furnishing & Miscellaneous Helicopter mass H/C usefull life ATA 52, 53, 55, 56 32 62-10 Value 1000 250 400 Cost driver 1 : RC Item mass (kg) Item mass (kg) Item mass (kg) Value 1 400 Cost driver 2 : DMC skid=0;wheel=1 Item mass (kg) TOP limit (kW) Fc (daN) * Thrust max (daN) Empty Weight (kg) Item mass (kg) Fc (daN) * Empty Weight (kg) TOP limit (kW) Empty Weight (kg) Value 15 1 1 2 4 2 1 2 1 Cost driver 3 % of composite skid=0;wheel=1 complexity for 1 to 3 Nb of accessory box Number of blade Fenestron (1) or classic (2) environment : critical (1); normal(2) Flight by wire (1) or hydraulic (2) Reduction (1) or not (2) Value Cost driver 4

63 3000 TOP limit (kW) 3000 62-20 150000 Fc (daN) * 150000 64, 65 1000 Thrust max (daN) 1000 24 350 Item mass (kg) 5000 22, 31, 34, 46 500 Item mass (kg) 500 67 150000 Fc (daN) * 150000 29 9300 MTOW (kg) 5000 71, 72, 76-77, 80 3000 TOP limit (kW) 3000 28 6 Nb of tank 5000 21, 25, 26, 30, 33 5000 Empty Weight (kg) 9300 [kg] 30 [years]

5 3

Nb of reduction step Type of rotor hub

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LCC model (2)

Life Cycle Cost
Costs per HC in for the all life long Costs per HC in /FH 1 115 1 000 100 15 650 400 250 2 222 119 116 3 2 115 1 500 20 000 000 6 000 000 1 000 000 6 150 000 150 000 4 000 000 2 000 000 400 000 3 500 000 600 000 900 000 2 000 000 1 025 000 425 000 600 000 6 000 000 100 30 30 200 100 100 20 50 100 9 000 000 6 000 000 3 000 000 30 000 000 500 50 300 100 2 000 000 19000000 3 000 000 6 000 000 10 000 000 2 000 400 50 23 750 000 750 000 20 000 000 3 000 000 135 000 000 100 000 000 30 000 000 5 000 000 Total Costs for the all fleet and for the all HC life long 86 75 10 1 500 000 000 500 000 000 000 000 xxx

Initial Purchase cost

Purchase cost (P. Cost) Initial Spare procurement & renewal Documentation

17 300 000 15 000 000 2 000 000 300 000 11 000 000 7 500 000 3500000 40 000 000 2 141 603 2 087 603 54 000 38 075 000 27 000 000

Direct result Calculation xxx Sub total

Mission personnel
Pilots salaries Specific maintenance personnel

55 000 000 37 500 000 17 500 000 200 000 000 10 708 017 10 438 017 270 000 188 750 000

XXX

Global result

Insurance Unit level consumption

Fuel consumption Other

Maintenance and operation

Direct Maintenance Cost (DMC) Basic HC Mission equipment Consummable Training Ground training Flight training Simulator training GSE Sustaining Support Support Equipment Replacement Substaining documentation replacement Software Maintenance Support Indirect Support Infrastructure Admistration & management

Modification & upgrade LI F E CYCLE COST

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Generic Mission Profiles

Business Aviation Crew of 2, 6 pax, max cr. speed at 5000ft, full fuel ISA conditions Offshore missions Crew of 2, 10/12 pax transport, JAR OPS fuel reserve, ISA/ISA+20C conditions SAR mission Crew of 4, Cruising at 3000ft, 30mn fuel 5 rescuees hoisting at 100nm radius ISA/ISA+20C conditions
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Pre-Design Sizing Tool (1)

SPEAR
SPEcification Analysis of Rotorcraft Specification analysis and pre-design sizing tool Contains large amount of empirical information Potential for Life Cycle Cost optimisation and trade-off studies
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Pre-Design Sizing Tool (2)

SPEAR capabilities
Determines gross mass, main dimensions, installed engine power, fuel capacity, and the mass breakdown for main components Consequences of operational requirements Trade-off studies Effects of technological developments on optimal rotorcraft mass and size
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Pre-Design Sizing Tool (3)

SPEAR specification of requirements

Rotorcraft configuration (lay-out + efficiency parameters) Flight performance
flight condition atmospheric condition engine settings

Mission performance
mission segments payload
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Pre-Design Sizing Tool (4)

SPEAR methodology
Configuration data Initial sizing Operational requirements DL trend
N Y

Flight performance requirements evaluation Engine size

Mission

Optimise

Empty mass Mission requirements evaluation Gross mass & fuel capacity

Range

Optimum
Y

Optimum mass
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DL = Disk Loading
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Pre-Design Sizing Tool (5)

SPEAR functionality (1)

Basic analysis
sizing based on disk loading, blade loading and tip speed engine selection (scaled or from database)

Parametric analysis
variation of 7 main rotor parameters effect analysis

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Pre-Design Sizing Tool (6)

SPEAR functionality (2)

Graphical analysis
Design chart
power required or gross mass vs. disk loading

Parameter analysis chart

mass or power required vs. one of the 7 main rotor parameters

Carpet plot
mass or power required vs. two of the 7 main rotor parameters

Power curve
power required vs. airspeed for given values of gross mass, altitude and temperature
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Calculation results (1)

Design optimisation

Sensitivity analysis of flight performance requirements to optimise helicopter design

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Calculation results (2)

Design optimisation

Helicopter optimisation for lowest mass or lowest Life Cycle Cost for different missions
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LCC Optimisation Demo

MDO with integrated Sizing and LCC models

Helicopter optimisation
Lowest mass Lowest cost

DMC = Direct Maintenance Costs MGB = Main Gear Box SPC = Sale Price Costs

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Conclusions

Heli MDO results

Integrated sizing and cost tool:
Helicopter pre-design sizing based on multiple flight and mission performance requirements Life Cycle Cost calculation Manual optimisation achieved
More details: see 32nd ERF 2006 paper: Helicopter Life Cycle Cost reduction through pre-design optimisation by J.F. Boer and J.M.G.F. Stevens
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Next iteration

Heli MDO next iteration

Identification of the cost driving parameters and sensitivity analysis Development of a multidisciplinary design optimisation methodology to obtain minimum LCC Optimisation to multiple mission performance requirements 1-day automatic design-to-cost optimisation
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Benefits

VIVACE expected benefits for H/C companies

Pre-design studies will be more adapted to the market LCC will be taken into account earlier in the design process, allowing the company to be more reactive

Competitiveness Improvement Customer satisfaction

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Questions?

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