Evolution of Spacecraft Manufacture by Vertically Integrated Systems for Bill of Materials Interpretation

Investigators: Prof P G Maropoulos, Durham University
Dr M Ristic, Imperial College
   
Collaborators: Astrium Ltd (main partner)
Leica Geosystems Ltd
Delmia Ltd
Tecnomatix Ltd
IST Ltd
Matra Datavision (UK) Ltd

EPSRC Funding: £444,991

Abstract:

Spacecraft manufacture is characterised by engineering-led solutions for complex products with high levels of customization, short production runs, very short (by aerospace standards) life-cycles and lack of process standardization. Currently, commercially available design and manufacturing analysis systems cannot address those problems and consequently do not allow the sustained evolution of products and processes. The conditions prevailing in the space industry are typical of “high level systems integrators” with global extended enterprises such as, aerospace, formula 1 and power generation manufacture.

The project will investigate whether the lack of process and factory modelling and analysis in spacecraft design and manufacture can be addressed by the vertical integration of proprietary methods and systems for product modelling and manufacturing analysis with novel aggregate process modelling technology. The proposed integration will be based on aggregate process modelling techniques and methods for CAD-based measurement of free-form components developed at Durham University and Imperial College respectively. An evolution and synthesis of these technologies with methods supported by proprietary systems for design (CATIA V5), tolerance management (Tecnomatix), factory modelling (Delmia) and dimensional measurement using laser trackers (Leica Geosystems) would result in flexible process modelling and capability measurement methods. This integration will facilitate improved and seamless definition of design intent and process requirements by capturing process capability from the early stages of product design, which is essential for the application of design for manufacturability (6 sigma) practice in the space industry.

The new integration methods will be demonstrated and tested in the design and manufacturing environment of Astrium, particularly regarding the design of satellite panels and the automation of insert placement and joining processes using robotics.

Contacts: Paul Maropoulos, Durham University
Tel: 0191 - 374 2574
p.g.Maropoulos@durham.ac.uk)

Elfed Roberts, Astrium
Tel: 07887 826039
elfed.roberts@mmsuk.co.uk


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