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ㆍProduct:
Fighter Aircraft
ㆍPurpose of Analysis: Optimization of winch system for lowering and hoisting the engine during engine removal/installation process
An aircraft engine is housed in and integrated into an aircraft’s rear fuselage. The engine weighs about 1500 kgs. Engine R/I (Removal/Installation) is a vital activity that needs to be carried out quickly with minimum manpower and tools. During this process, a winching system is used. It must ensure smooth engagement without any interference within the allowable loads.
This process was simulated using RecurDyn to find the optimum geometry and design variables.
Process
① The engine winching device and the engine assembly (CATIA model) were imported to RecurDyn.
② 2 types of models were created and simulated: One with a guide rail and one without a guide rail.
③ Optimization of the guide rail to define the ideal geometry to reduce loads and ensure smooth engagement of engine mount trunnions and lip seal
④ Finding the optimum location of the winch hooking fixture on the airframe
⑤ Finding the optimum forward inclination angle of the winch cable during engine pitch up/down
⑥ Decision making after comparing 2 types of design
Key Technologies for Analysis
• Multi Flexible Body Dynamics to properly calculate the stress on the moving components
• Easy-to-use contact algorithm to test various cam profiles
• Accurate MBD solver to predict the required torque to actuate the system
Toolkits
• RecurDyn/Professional
• RecurDyn/FFlex
Customer Challenges
• Need to find the optimum mounting points without any interference on the fuselage for the engine hoist system
• Accurate prediction of the maximum load, including shock load, to ensure that it is within the allowable range
• Smooth dismounting and mounting of the engine are required to avoid damage and ensure safety.
• The winch system has complex contacts.
• Many components, such as cables, experience large, nonlinear deformation.
• Needs extensive testing or simulation to ensure reliability in actual operating conditions.
Solutions
• A fast and robust dynamic solver was used to find the optimum design parameters, including mounting points, inclination angle, and geometry of the guide rail
• Fast and accurate simulation using powerful contact algorithms
• Accurate prediction of the deformation, vibration, and loads using high-fidelity multi-flexible body dynamics
Outcomes
• Optimum results of the winch system
• Optimum design that reduces the load on the guide rail
• Alternative winching mechanism that eliminated the guide rail, which is a simpler system for field maintenance
Other Applications
◀ Analysis of structural oscillations on linear handling axes
ㆍEstablishing the digital twin model of the linear handling axes to analyze its structural oscillations
• RecurDyn can be very beneficial for analyzing the design of the components of the landing gear of an airplane. The forces acting on such a component can be accurately predicted in a simulation of the multibody dynamics of the landing gear system.
