hyperion uav: an international collaborationciec/proceedings_2013/cipd/cipd443_koster.pdf ·...

ASEE-CIEC 2013, Mesa, AZ, February 7, 2013

Jean Koster, University of Colorado Boulder

Hyperion UAV: An International Collaboration

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• Opportunities made available by software and internet

• 3D CAD software, Product Lifecycle Management (PLM)

• Common digital environment

• Global companies operate Design Bureaus around the world.

– Opportunities to expedite design work on new systems

– Opportunities to harvest bright minds

– Leveraging expertise and talent

– Limit or eliminate duplication of efforts

• Focus on technological Innovation and diverse approaches to find solutions

– Leverage diverse critical thinking

2

Why a Global Collaborative Project?

-Purpose-

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“If you have an apple and I have an apple and we exchange apples

then you and I will still each have an apple.

But if you have an idea and I have an idea and we exchange these

ideas, then each of us will have two ideas.”

Why Global Collaboration?

-Purpose-

Performance: • Decreasing the learning curve • Responding rapidly to customer needs and inquiries • Preventing “reinvention of the wheel” • Spawning new ideas for products and services • Fast and lean time to (new) market(s)

G.B. Shaw

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Hierarchies Become Networks

-Purpose-

“The corporation as we know it is unlikely to survive the next 25 years. Legally and financially, yes. But not structurally and economically.”

Peter Drucker, 2000

Daly, James (22 August 2000), “Sage Advice: An Exclusive Interview with Peter Drucker,“ Business 2.0.

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A collaborative network is the collection of businesses, individuals and other organizational entities that possess the capabilities and

resources needed to achieve a specific outcome

Collaborative Business Concepts

-Purpose-

Jeffrey Shuman and Janice Twombly, Collaborative Networks Are The Organization, July 2009

Communities of practice are groups of people who share a concern or a passion for something they do and learn how to

do it better as they interact regularly

Etienne Wenger, Communities of Practice - Brief Introduction, June, 2006

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The perspective of communities of practice affects educational practices along three dimensions:

• Internally: How to organize educational experiences that ground school learning in practice through participation in communities around subject matters?

• Externally: How to connect the experience of students to actual practice through peripheral forms of participation in broader communities beyond the walls of the school?

• Over the lifetime of students: How to serve the lifelong learning needs of students by organizing communities of practice focused on topics of continuing interest to students beyond the initial schooling period?

Education for Community of Practice

-Purpose-

Etienne Wenger, Communities of Practice - Brief Introduction, June, 2006

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Benefits of Collaboration

-Purpose-

Need: A better understanding of the process of collaborating and the skills it takes to realize its benefits are required.

Shuman, Jeffrey and Janice Twombly with David Rottenberg (2001), Collaborative Communities: Partnering for Profit in the Networked Economy, Dearborn Trade, Chicago, IL.

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Network Model and Governance

-Purpose-

Daly, James (22 August 2000), “Sage Advice: An Exclusive Interview with Peter Drucker,“ Business 2.0.

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Aircraft Market Diversity is Increasing

-Purpose-

Source: Boeing Commercial Airplanes, 2012 CMO

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• Customers and customer support in 150 countries

– Total revenue in 2011: ~$70 billion

– 70% of commercial airplane revenue historically from customers outside the United States

• Contracts with 22,000 suppliers and partners globally

• 6 research, design and technology-development centers and programs in multiple countries

• Boeing has employees in 50 states and 70 countries

Boeing’s global footprint…

-Purpose-

Stephen Emmert, Global Collaborations PNWER Annual Summit, July 2012.

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Boeing 787 Global Work Breakdown Structure

-Purpose-

• Manufacturing dispersed in many countries

– For Boeing’s Dreamliner, 28 suppliers are located outside USA, e.g.

• Wings produced in Japan

• Ailerons produced in Australia

• Fairings produced in Canada

• Doors produced in France and Sweden

• Final assembly in USA

• Preassembled parts delivered allow for a vastly reduced final assembly crew.

• Faster assembly: 3 days

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• Plan: First Dreamliner test plane to be rolled out on 07/08/07

– Originally planned to enter service in May 2008

• Boeing anticipated 1,200 components for final assembly

• Instead: Partners dumped ~30,000 pieces on Boeing

– Resulted in a delivery date pushback to 2010

– Maiden test flight took place on December 15, 2009,

– Boeing completed flight testing in mid-2011

– First model entered commercial service on October 26, 2011

Huge Organizational Challenges

-Purpose-

Young Engineers need to learn to choreograph

delocalized design and manufacturing

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NASA’s ERA Goals

Reduce:

Aircraft fuel consumption

Emissions

Noise

…Simultaneously!

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Motivation: Green Aviation

-Motivation-

Image credit: NASA

“In 2009, … [the] United States flew 704 million passengers, a number forecast to reach 1.21 billion by 2030.” – NASA Facts

[1]

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Fuel Problem:

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Motivation: Reduce Fuel Burn

-Motivation-

In 2008 U.S. Commercial air burned 19.7 Billion Gallons D.O.D. burned an additional 4.6 Billion Gallons

Goals

[1]

+

250,000,000… Tons of Carbon Dioxide (CO2)

Nitrogen Oxide (NOx)

Reduce NOx Emissions:

20% by 2015 50% by 2020

>50% beyond 2025 [1]

Reduce Fuel Burn:

33% by 2015 50% by 2020

>70% beyond 2025 [1]

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Airport Noise Challenge: Aircraft noise regarded most significant hindrance to National Airspace System

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Motivation: Reduce Noise

-Motivation-

Image credit: NASA

[1]

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Motivation: Blended Wing Body

-Motivation -

[2]

Image credit: NASA

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WHY HYPERION?

• Society/ industry needs:

– Aerodynamically & energy efficient aircraft

– Prepare workforce in global environment

• History:

– Colorado students developed hybrid propulsion system

– Boeing interest in follow-the–sun design process

– AIAA-ASM Meeting January 2010, Orlando:

o NASA: “Environmentally Responsible Aviation (ERA) Project”

Boeing X-48B prominently presented

o Focus on aviation alternative fuels, fuel savings, reduced noise

Purpose

-Motivation -

Image credit: NASA

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System Configuration

- Hyperion - Hyperion 2012-13

Hybrid-Electric Engine

BWB Carbon Fiber / Composite

Structure

Integrated Control System

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• Increasing complexity in the breadth of technologies • Technical expertise • Diversity in educational programs • Highly educated labor forces in (developing) countries,

including skill sets specialized by region • Special attention shall be paid to skills that are required to

undertake a global collaboration project.

Partner Value

- Valuation -

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Goals

-Project Overview-

1. Investigate new technologies for improved capabilities and efficiencies

2. Practice international collaboration in education

1. Conceive, design, build, and test a 2nd generation hybrid propulsion system to be integrated into the Hyperion

Boulder + Stuttgart + Sydney

Undergraduate CU Team

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Global Team

- Follow The Sun -

Engineering students need to develop skills in orchestrating (delegating) and coordinating multi‐site teams, not just acquire deep technical knowledge.

Follow-The-Sun

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Pain: Efficiency in Global Industry Collaborations: needs improvement

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FTS Collaboration Experiment

-Global Collaboration-

Concept 3 Teams, distributed 8 hours apart relay work daily.

Follow-the-Sun (FTS), produces 3 work-days in one 24 hour period

New Challenge: Write Interface Documents for delocalized team Work Breakdown Structures

Project has 3 components: Mechanical, Electronics, Software

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Internet Communication and Cloud File Sharing

Best Practices


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IT Plan

- Integration & Testing -

Detail IT Plan

Concept of Operations

Integration

Manufacturing

Develop and define mission phases

Project Requirements

Determine verification method and develop tests

System Architecture

Identify subsystem interfaces and risks

Project Decomposition

Time

Testing

Operation

Verification andValidation

Implement IT Plan

Systems Engineering

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Project teams SHALL have sufficient expertise to address their design problems

– Technical skills are necessary for success – Assess the skills needed to analyze the proposed system – If you don’t have the required technical skills:

• are you committed to learning these skills (“lifelong learning”)?

– Is it reasonably clear how you will make a technical contribution to the project?

– Carefully consider the technical skills needed for each project. A Team Skills Document is 1st deliverable.

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Team Expertise

- Team -

The team as a whole and each individual team member together are accountable for that delivery!

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1. A good understanding of engineering fundamentals.

2. Possesses a multi-disciplinary, systems perspective.

3. A profound understanding of and commitment to teamwork.

4. A basic understanding of context of engineering practice.

5. An understanding of design and manufacturing processes.

6. Good communicator.

7. High ethical standards.

8. An ability to think both critically and creatively.

9. An ability to think both independently and cooperatively.

10. The ability and self-confidence to adapt to rapid changes.

11. Curiosity and desire to learn for life.

Desired Attributes of An Engineer

-Team -

*A Manifesto for Global Engineering Education, Summary Report of the Engineering Futures Conference, January 22-23, 1997. The Boeing Company & Rensselaer Polytechnic Institute.

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• Filled out by candidate students

• Evaluated by “Project Champion” and faculty

Team Skills

- Team -

0 = minimal experience 1 = proficient 2 = excellent

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Project Manager

Web

Safety Engineer

PAB-Advisor External Advisor

CAD Engineer

Systems Engineer

Subsystem 1 Lead Engineer



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Projects Team Structure

- Team -

Entrepreneurial

Leadership

Manufacturing Engineer

Customer

CFO

Subsystems: Energy and Propulsion Structures & Materials Weights/Mass Properties Handling and Controls Flight Mechanics /Performance Leadership

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Subsystem Design

-Technology Overview-

Manufacturing

Electronics

Aerodynamics

Materials/Structures

Weights

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Schedule


PDR CDR Start Flight

Testing

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System Configuration

-Project Overview-

•Hybrid-Electric Engine to explore quiet take-off and landings, quiet loitering, and improved efficiencies (CONOPS dependent)

• Aerodynamic design started by Sydney team

• Raked wingtips & vertical stabilizers designed by Stuttgart team

• Management, electronics, internal structure design & systems integration by CU

See: AIAA-2012-0878

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FTS Example


Colorado Team • Changes structure component • Does it meet Requirements? • What does this mean for manufacturing

and aerodynamics?

Sydney Team • Evaluates Structural Implications on

Aerodynamic Design • Proposes design changes • Provides aerodynamic feedback

Stuttgart Team • Evaluates Manufacturing implications on

aerodynamic and structural designs • Proposes design changes • Provides manufacturing feedback

8 Hours

8 Hours

8 Hours

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Aerodynamics & Structures


½ Scale Wind Tunnel Model Internal Structure Center Body/Integration

Aerodynamic Validation

CFD Validation

Wing Integration/Assembly

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Aerodynamic Analysis


L/D greater than 20 Statically stable Stall velocity less than 15 m/s Span efficiency (e) greater than 0.8 Wing loading less than 15 kg/m²

Aerodynamic Requirements: Aerodynamic testing was performed using multiple methods CFD 1/2 scale wind tunnel testing

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Manufacturing: Center Body


Project Goal and Objectives Distributed Manufacturing

• Negative molds milled from CAD-data

• Fiberglass-foam-core skin laminated by hand

• Integration of internal structure from University of Colorado

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Global Integration Manufacturing

-Integration-

IDT (Interface Dimension

Template)

Device used to ensure German center body matches USA wings

Similar ideas used for wing manufacturing

Winglet Wing

Delocalized manufacturing increases integration risk!

Risk

Mitigation

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Global Integration


“Flat Sat” Approach (Simulation and Test-bed) - Used while center body is in Germany -

• Full Scale Mockup of Center Body

• Wire Length and placement

• Hardware placement platform

• Full system testing for electronics

Need: Electronics integration into plane Problem: Plane center body in Germany!

Solution

Image credit: NASA

Cubesat Broken Down Flat Layout Electronics

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Manufacturing – External Structure

- Manufacturing - Hyperion 2012-13

Wing Dissection Small pieces for 3D printer

3D Print Arrangement of pieces inside 3D printer

Mold Pieces 3D printer output Digital Cardboard layout for mold

integration

Stepwise procedure for 4 negative molds

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Manufacturing – External Structure


• 24 pieces for each cradle • dxf file implemented into cutting

table software • Modified fabric cutting machine

Mold Layup Connecting mold pieces together

Cutting cardboard cradle

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Wing Integration


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Hybrid Gas-Electric Engine


Project Goal and Objectives Design, build and test a hybrid propulsion system to be integrated into the aircraft

Offset drive

No control system

Focus: Efficiency, proof of

concept

Coaxial drive

Multiple flight mode control

Focus: Reliability, operations

Objective:

See: AIAA-2012-0147

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• Test aircraft capability and characteristics.

• Identify unforeseen problems.

• Pilot familiarization

• Test: Taxi, takeoff, cruise, land

• Test: Mass sensitivity, cg

• Test: International analysis of data

Testing


Dynamically (1/2) Scaled Prototype

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• Electric propulsion

– Hybrid Engine fully bench tested, but not flight tested (maturity)

• R/C Piloted – Successful takeoff, cruise, and landing

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System Testing

Flight Test

http://www.youtube.com/watch?v=OM825EZGhS0 http://www.youtube.com/watch?v=u2qjvbLs_t0

http://www.youtube.com/watch?v=OM825EZGhS0

http://www.youtube.com/watch?v=u2qjvbLs_t0

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Lessons Learned


Language and Cultural Barriers Although everyone speaks Englineerish….

Encodes/Writes Message

Decodes/Misinterprets Message

Cloud Noise Filter Can Cause: -Loss of Tone

-Loss of Intent -Misinterpretation

Encodes Counter Productive Feedback Message

Decodes Message

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Lessons Learned


Follow-the-Sun (FTS): • Great for CAD design work • Ideas across border • Dynamic positive synergy • Benefit of diversity in critical thinking • Helps mitigate risk through smaller team delegation • Difficult in academic environment due to schedules

Follow-The-Week (FTW)

• Suited for concept designs • Specialized tasks assignments to small local teams • Finished tasks reviewed by global team • Weekly global team meetings.

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• Project needs managerial infrastructure – Needs strong Project Manager (Choreographer)

– MBA candidate on team

– Economics student on team

• Understand international shipping requirements – International Traffic in Arms Regulations (ITAR)

– Understand international trade and regulations

• Collaboration on “trust” and “respect” – Limited control over non-local teams’ efforts

– Understand skills and capabilities of partners

– Free sharing of information leads to IP issues

• Planning – Extend the planning process significantly!

– Better understand skills and capabilities of partners

– Each partner should have own funding

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Lessons Learned

- Global Collaboration-

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• Successes:

– Designed, built, and flew HYPERION in 9 months

• Planning for 3 months

• Design layout within 4 months

• Aerodynamics and structures analysis using FTS

• Controls system development

• Delocalized manufacturing in 3 months

• Under mass and finance budgets

• Successful maiden flight

Conclusion

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• Current Project Charter:

– Design and Manufacturing shared by Stuttgart and Colorado

– New wing design

From Flying Wing to Blended Wing Body

– Autonomous Control System

– FAA COA

– Integrate hybrid propulsion system and flight test

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Current Development

- Current -

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Project Papers

- Papers - Hyperion 2012-13

The Hyperion 2.1 Green Aircraft Project, AIAA-2013-0817 (Best Paper DETC)

The HYPERION 2 Green Aircraft Project, AIAA-2012-0878 (Best Paper DETC)

HYPERION UAV: An International Collaboration, AIAA-2012-1223

Design of a Hybrid Propulsion System for Aircraft. AIAA-2011-1011 (Best Paper DETC)

Design of a Blended Wing Body UAS with Hybrid Propulsion, ASME-IMECE2011-62126

Work Force Development for Global Aircraft Design, ASME-IMECE2011-62273

SOLSTICE, AIAA-2012-0147 -1st Place at AIAA Region V Student Competition 2011

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Student Global Team

-Team-

Michaela Cui Tyler Drake Arthur Kreuter Gavin Kutil Brett Miller Corey Packard Marcus Rahimpour Gauravdev Soin

Mart in Arenz Holger Kurz David Pfei f fer Matthias Seitz Bar is Tunal i Jonas Schwengler Pascal Weihing Benjamin Arnold

Kai Lehmkuehler Matthew Anderson Joshua Barnes Byron Wi lson Andrew McCloskey

Julie Price Eric Serani Tom Wiley

Richard Zhao Kristen Brenner Corrina Gibson

Nathan Jastram Michael Johnson

Eric Kenney

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Jeremy Klammer Lydia Mcdowell Boris Papazov

Taylor Petersen Robert Whitehill Ben Benjamin

Andrew Haynes Andrew Gilbert

Greg Nelson

Pierce Martin Zach Dischner Vibin Mahdev

Adil Ali Wes Willits Alex North

Lucas Miller Sean Ortiz

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Acknowledgements

-Acknowledgements-

A special thanks to… Mike Kisska of Boeing Frank Doerner of Boeing Blaine Rawdon of Boeing Tom Hagen of Boeing Dr. Robert Liebeck of Boeing/USC Steven Yahata of Boeing Norman Princen of Boeing Diane Dimeff of eSpace Brian Taylor of NASA Joseph Tanner of CU Trent Yang of RASEI Dr. Donna Gerren of CU Prof. Eric Frew of CU Matt Rhode of CU Trudy Schwartz of CU Prof. Claus-Dieter Munz of Stuttgart Prof. Ewald Kraemer of Stuttgart Dr. KC Wong of Sydney Dr. Dries Verstraete of Sydney

Skip Miller of Skip Miller Models

James Mack of RECUV (Pilot)

Questions? Contact: [email protected]

Hyperion.mp4.m4v

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Customer Requirements → Project Definition (PDD)

–Background, Goal, Objectives, Functional Block Diagram, Concept of Operations

–Top level Project Requirements (0.PRJ.x)

–Top level System Requirements (0.SYS.x)

–Minimum Requirements for Success

–Deliverables

–Technical and Financial Risks

–Team Formation and Team Expertise

–Resources

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Deliverable 1 (PDD)

- Deliverable -

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Project Definition → Conceptual Design (CDD) – Team information

– System Architecture (3 design options)

– Requirements (3-5 most important Reqs., rank)

– Feasibility (for top ranked architecture option)

– Testing and Verification requirements for key systems

– Assess key risks and mitigation options

– Assess team qualifications

– Respond to criticism received on PDD

– Resources update

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Deliverable 2 (CDD)

- Deliverable -

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Conceptual Design → Preliminary Design (PDR) – Development and assessment of system design options; arguments for chosen architecture

• Flow-down from functional needs to identified requirements

– System Design-To specifications. Development and assessment of subsystem design options and design-to specifications

• Preliminary itemization of required performance parameters

– Project Feasibility Analysis and Risk Analysis • Define high risk sub-system for prototyping • Back-of-the-envelope, Matlab, preliminary analysis or test • Define optional “off-ramps”

– Project Management Plan (preliminary) • Myers-Briggs analysis

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Deliverable 3 (PDR)

- Deliverable -

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• System Architecture is fully documented at CDR

• All subsystems are checked for feasibility and are given a “go”

• Sub-system decomposition and integration is understood

– Mechanical, electrical, and software elements are analyzed

– All blue-prints are ready to enter the fabrication process

• Interfaces between sub-systems are working well

– Integration of sub-systems into units is understood

• Manufacturing and System Integration Plan

• The Testing and Verification Plan is finalized

– Test concepts of operation are documented

• Project Management Plan (PMP) is finalized

• The System Engineer signed off on the proposed design

• Manufacturing of components starts after successful completion of CDR.

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Deliverable 4 (CDR)

- Deliverable -

B. S. Blanchard, W.J. Fabrycky, Systems Engineering and Analysis, Prentice Hall,2006.