an engineering consultancy for advanced systems. We support technology development in the fields of Energy, Defense, Space, Military and Commercial Aviation. AIRWORKS // Company Profile
cultures, AIR is seen as a universal power or a pure substance. According to ancient Greek philosophy AIR is the element in relationship with imagination and thought, focusing on ideas which have not materialized yet. WORKS Our Facts. Cosmo-Skymed 2, PK-4, Compact SAR, eROSITA, EUVL Collector, SAMSS, A340, A350, A330F, A380, A380F, Learjet 85, MRJ, Mirach 200, B787, Falco, Falco EVO, DT-93-2000, DT-82-2000 & more AIRWORKS // ENGINEERING ADVANCED SYSTEMS 2 OUR SYMBOL
8 SYSTEM ENGINEERING (MECHANICAL) Josef Eder Broad skills and a comprehensive experience are the foundation for the development of sophisticated designs such as space instruments. The supervision of our designs is assigned to Josef Eder, a specialist with over 30 years of experience in the management and execution of projects for Space. Please check: www.e-der.de System Engineering (Mech.)
11 SATELLITE DESIGN Satellite Design Since start, AIRWORKS has served Space Integrators by supporting the development of the satellite mechanical and structural designs Cosmo - Skymed 2nd Generation Thales Alenia Space (2011-12) Mechanical Design Design and manufacturing optimization of the Frame (primary structure) – Design and manufacturing optimization of the MacroTiles (secondary structure) – Design of the brackets of the Fixed Hold and Release Mechanisms (FHRM) – Design of the Radiating Board assy including the FRP chassis – Harmonization of the 3D structural models with the Harness/Piping requests – 2D drawings and Interface Control Drawings (ICD) – Mechanical Analysis Generation of FE models – Structural and thermo-elastic sizings – Sine analysis in the frequency domain (accelerations, forces, stress) – Notching masks – Random analysis in the frequency domain – Dynamic analysis vs. structural tests correlation –
12 SATELLITE GROUND & TEST SUPPORT Ground & Test Support AIRWORKS deliveries a complete set of solutions for Satellite & Instrument management on ground & during tests, including designed / manufactured MGSEs, jigs, tools, storage systems, test set-ups, handling procedures. eROSITA MPE / 2010 -12 Design of thermal insulation – Test set-up design – Design of MGSE – Handling & test procedures –
13 ISS EXPERIMENTS ISS Experiments & Instruments AIRWORKS provides comprehensive design, analysis or turn-key development services up to prototypes for ISS experiments, at system or sub-system level. The PK4 Experiment Kayser-Threde GmbH (2012) AIRWORKS Tasks: Review of the existing analysis documentation – Consolidation of the applicable mech. requirements – Upgrade PK4 facility FE models to latest designs – Thermo structural calculations (ground / on orbit) – Justification of the facility: intact & failsafe launch set up – Modal analysis – Random analysis – Shock response analysis – Test correlation analysis – FE model tuning to measured dynamic response – Burst– pressure strength check – Containment analysis – De - / Repressurization analysis – Joint check including fatigue – Structural analysis reports for CDR with ESA –
14 OPTOMECHANICS Optomechanics MAIN CHALLENGES: High dimensional stability (10μm) under extreme thermal impact (10kW). High accuracy manufacturing, assembly and co-alignment of mirrors Since year 2010, AIRWORKS has been supporting the development of new optical systems for different industrial applications. EUVL Grazing Incidence Collectors Media Lario Technologies (2010-12) Support to Opto-Mechanical Design Mechanical design and configuration control of the Collectors – Development of the mirror cooling system – Materials compatibility with plasma, EUV light, vacuum – Design of permanent and demountable joints – Design of the Heat Exchangers – Design of adjustable supports systems for mirrors – Design of jigs and tools – Analytical and Experimental Development 1D Simulations of the cooling system – Experimental fluidynamics, Measurements. 1D model calibration –
15 OPTOMECHANICS Optomechanics AIRWORKS has been the selected partner by MEDIA LARIO TECHNOLOGIES to support the development & optimization of the Single Aperture Multispectral Sensors System. Unveiled in April 2012, the sensors outperform most of current available systems in the market. SAMSS (2010 -12) AIRWORKS Tasks: Conceptual module mechanical design – Technology feasibility – Mathematical optimization of the mechanical design – Maximize stability of the optical response in operation – Compliance with assembly and alignment requirements – Compliance with maximum weight requirements – Thermo-structural strength – Design of flight and lab modules – Design of tools – Design and manufacturing documents – Capabilities of the Multispectral Modules: Suited for Airborne, UAV, Security and Space – Compatibility with MIL-STD-810G – Compatibility with cooled and uncooled detectors – Optical design for a dual detectors scheme – Available cold stop position – Available beam splitter position –
(2009-11) Design and Analysis of Cargo Doors Mechanisms (from definition to CDR) LATCHING MECHANISM AIRBUS A330-800F Analysis of the Latching mechanism of the MD Cargo Doors. Certification Reports. Mechanisms SPECIALISTS IN AEROSPACE MECHANISMS Our company takes complete responsibility design and analysis of mechanisms. In developing these systems, AIRWORKS works via a long standing partnership with the company QFP (Mr. A. Zuccari). QFP is specialized in design and stress of airframes and mechanisms, tooling design, reverse engineering and inspection. BOEING 747-400 Cargo Door Mechanism 3D modelling Tooling Design Test and Rigging Procedures Assembly Management. AEROSPACE MECHANISMS AIRWORKS // ENGINEERING ADVANCED SYSTEMS 16
G2F, G2A, G2, G2C, G3C, G4F, G4L, G4R, G6, G44 AIRBUS A380 GALLEYS G1F, GM28, GM36, GU23, GU26, GU27, GU95 Interiors (1/2) SOUND KNOWLEDGE IN GALLEYS AIRWORKS takes complete responsibility of the stress analysis of Cabin Galleys. Our engineers also provide support during the test preparation and execution. MAIN COMPETENCES & EXPERTISE: FE model generation & management Linear & non-linear static analysis for: I/F Load Stress Deformation Post processing Certification Reports Test plan Test support AIRBUS A319/A320/A321 GALLEYS G1, G5, G12, G44 INTERIORS // GALLEYS AIRWORKS // ENGINEERING ADVANCED SYSTEMS 17
of Refueling operator console EADS-CASA C295 VIP VERSION VIP interior refurbishing feasibility study Interiors (2/2) PRODUCT KNOWLEDGE Our engineers took part to other EADS/CASA programmes, such as Complete Design of Operator consoles, Galleys, Racks, Equipment supports and Interiors Refurbishing. EADS-CASA P3 ORION Refurbishing Design of Sonobuoy Rack, Galley, Equipment support and Lining. INTERIORS // OTHERS AIRWORKS // ENGINEERING ADVANCED SYSTEMS 18 EADS-CASA A330-200FSTA MOC CONSOLE Design of Refueling operator console
20 FATIGUE & CRACK PROPAGATION Fatigue and Crack Propagation AVAILABLE MODULES Spectrum Manager (to filter-modify-count time histories of loads/stresses, count sequence, show exceedance plots) Fatigue Crack Initiation Life calculator for uniaxial or multi-axial cases with strain based approach (Neuber or Strain Energy Density and mean stress effect correction with Smith-Watson-Topper, Morrow, Manson-Halford correction) Multi-axiality assessment plots Other computational modules in the roadmap (e.g. multi-axial fatigue Brown- Miller critical plane) S-N curves based Fatigue calculator Crack growth calculator with user defined SIFs StructLife is a modular tool for calculating fatigue crack initiation life in metallic structures subjected to variable amplitude sequence of loads, uniaxial or multi-axial. It includes a FEM post processor (NASTRAN interface implemented, other interfaces in the roadmap). Fatigue life is calculated for the entire FEM or, optionally, in a user defined set of elements.
21 DAMAGE TOLERANCE ANALYSIS Damage Tolerance Analysis AFGROW is a Damage Tolerance Analysis (DTA) framework that allows users to analyze crack initiation, fatigue crack growth, and fracture to predict the life of metallic structures. The classic stress intensity factor library provides solutions for over 30 different crack geometries. In addition, an advanced, multiple crack capability allows AFGROW to analyze two independent cracks in a plate (including hole effects), non-symmetric corner cracked holes, and a continuing damage solution. Finite Element (FE) based solutions are available for two, non-symmetric corner cracks at holes as well as cracks growing toward holes. This capability allows AFGROW to handle cases with more than one crack growing from a row of fastener holes. AFGROW implements five different material models (Forman Equation, Walker Equation, Tabular lookup, Harter-T Method and NASGRO Equation) to determine crack growth per applied loading cycle. Other AFGROW user options include five load interaction (retardation) models (Closure, FASTRAN, Hsu, Wheeler, and Generalized Willenborg), a strain-life based fatigue crack initiation model, and the ability to perform a crack growth analysis for structures with a bonded repair.
22 MECHANICAL DESIGN Mechanical Design AVAILABLE MODULES Bolt Design according to VDI2230 Shaft Design according to DIN 743 Bolted joints and flanges Compression springs Load distribution in gear, drive train design, Vessel and Valve design MDESIGN as an e-engineering platform which provides advanced knowledge on calculations, design procedures and technical rules is being used in all sectors of automotive industry and machine manufacturing
23 DEFENSE UAS systems AIRWORKS is a selected supplier of SELEX GALILEO unmanned technology department to support the development of drones. The cooperation extends through engineering & certification process. SELEX GALILEO MIRACH 200 (2010) Thermal analysis (Avionics), Static structural analysis of the UAS body, load application, FEA , Certification Reports. SELEX GALILEO FALCO EVO (2011-12) Development of the new empennage FE model, Sizings, Static structural justification of the empennages and boom Falco UAS (2011-12) AIRWORKS Tasks: Upgrade UAS platform to new materials – Consolidation of existing global FE models – Modeling of the applicable loads – Static analysis. Stability – Strength check of FRP & metallic structures – Check of primary interfaces – Bonded and fastened joints’ check – Preparation of structural analysis reports for UAS certification –
24 BUSINESS AIRCRAFTS Business Aircrafts PRODUCT CONCEPTION Since the very project start, AIRWORKS has been feeding structural conceptual design of Learjet 85, an all composite Business Jet. For this program our operations extended to Germany and Canada, at Bombardier Product Development Center. BOMBARDIER LEARJET 85 – All Composite Business Jet Global FE model management (Wing, Center & Aft Fus) Conceptual stress analysis Trade studies on wing planform Compliance of the wingbox (stiffness, weight, fuel volume) Wing CFRP optimization with respect to: loads, stiffness, fuel Studies on MLG attachment Studies on engine mounts and pylons Studies on Center & AFT Fuselage
25 WIND POWER Wind Power SERVICE RANGE Contractor for complete rotor design Contractor for Research & Development projects Aerodynamic design of rotor blades Structural blade design Mould design Sizing and Certification of rotor blades according to GL, DNV Design of systems & components (Nacelle, Tower, Hub) Turbine load calculations Performance optimization on existing turbines Implementation of composite materials Manufacturing support BLADE SYSTEMS Since 2010, AIRWORKS is developing technologies to support Wind Power turbine manufacturers in the segment of large rotor blades.
26 WIND POWER From Scratch to Certification through Manufacturing (1/2) DONGTAI (XEMC) 45.0m – 1.5MW Blade In 2011, AirWorks (via his shareholded company A2Wind) developed a 45.0m – 1.5MW glass fiber blade from the scratch book to the manufacturing drawings. Our team was involved in all the phases of the project (including GL certification and tests) and AirWorks personnel was in charge in all the key roles. The entire sizing and design was carried out in < 5 months. Client’s main tasks (weight, performances, stiffness, manufacturing process optimization) were completely fulfilled. Static, fatigue and dynamic loads were obtained by an internally developed Visual Basic code and the commercial software Focus-6. CatiaV5 was used for 3D and 2D CAD.
27 WIND POWER From Scratch to Certification through Manufacturing (2/2) Aerodynamic predesign is usually carried out using the proprietary code WARP (see attached presentation for details). As soon as the blade aerodynamic layout is sufficiently mature, FEM and Focus 6 modeling starts. From that moment on, a feedback loop is constantly running between structural computations and Aeroelasticity ones. The loop will close when all the tasks will be fulfilled. In the meanwhile, detailed 3D and 2D design will have started. Some detailed analyses (like root bolts) will be independently developed via dedicated FE-Models but may affect the entire design process. AirWorks has faced many hard challenges in its technical history and background. Wind turbine blade design and certification process is without any doubts one of the most open-minded and complete, and for sure one of the ones to be most proud of. The strong integration of many disciplines, along with the usually tight leading times, makes the blades definition extremely critical and, under some aspects, fascinating. No many companies around the world exist, which can perform such a job, in such a way/time, and AirWorks is nowadays definitely one of them. As the call for renewable energies raises, AirWorks keeps investing in R&D projects a big part of its income. Our attention is now focused on optimization processes, to cut delivery times and improve blades performances.
29 WIND POWER VHARP is an in-house developed software for the complete Vertical and Horizontal Axis Wind Turbine Aerodynamic Design and Performance Prediction CP-LAMBDA diagram computation for both Vertical and Horizontal Axis Wind Turbine Automatic Power Curve Generation AEP calculation Automatic Creation of 3D CAD model for CATIA V5 and FOCUS
30 WIND POWER Multi-body Kinematic Model Elastic Model – Galerkin Modal Approach Fully Potential 3D non-Stationary Aerodynamic Model (Boundary Element Method) 3D Effect Rotating Effect Dynamic Stall Effect Free-Wake model Wake Impact Effects Acoustic Noise Emission We are currently involved in a research program “Assessment of an aeroelastic solver for the optimization of HAWT “ in cooperation University Roma Tre Mechanical and Industrial Engineering Department ( Prof. M.Gennaretti) WIND BLADE AEROELASTIC DESIGN
31 WIND POWER ROTOR BLADE INTEGRATED OPTIMIZATION (mode FRONTIER) Highly complex problems, involving different disciplines and multiple objectives, require not only engineering understanding but also a systematic approach through process automation and mathematical optimization. We are currently working in creating a fully integrated optimization approach integrating aerodynamic design (WARP) with load calculation (FOCUS) and structural optimization tool (OPTISTRUCT)
32 WIND POWER FLAT BACK AIRFOILS The Inboard Region of large wind turbines blade requires large (t/cmax ) airfoils to meet structural requirement Use of the flat back airfoils benefit Structural improvement by increasing sectional area and moment of inertia for a given (t/cmax ) Improved sectional maximum CL and lift curve slope Reduced sensitivity to leading edge surface soiling Blunt trailing edge reduces the adverse pressure gradient on the upper surface by utilizing the wake off-surface pressure recovery The reduced pressure gradient mitigates flow separation thereby providing enhanced aerodynamic performance The airfoil is not truncated but thickness distribution is modified to provide blunt trailing edge
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