Presentation on the need for global student projects given at the ASEE International Forum in Atlanta, GA on June 22, 2013.

1. ASEE International Forum 2013, Atlanta, GA, June 22, 2013
Jean Koster,
University of Colorado Boulder
Students from around the World Design,
Manufacture, and Fly an Aircraft

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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
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Why a Global Collaborative Project?
-Purpose-

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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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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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Aircraft Market Diversity is Increasing
-Purpose-
Source: Boeing Commercial Airplanes, 2012 CMO
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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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Huge Organizational Challenges
-Purpose-
Young Engineers need to learn to
choreograph
delocalized design and manufacturing
• Constraint: Global project is high risk!
• Risk management skills is a most important
qualification requirement to industry employers
• Goal: Global project significantly strengthens the
risk management skills of students
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1. Critical thinking and problem solving
2. Collaboration across networks and leading by influence
3. Agility and adaptability
4. Initiative and entrepreneurship
5. Accessing and analyzing information
6. Effective oral and written communication
7. Curiosity and imagination
8. Capacity to add value through innovation
Skills to be Developed
Purpose
Tony Wagner, Harvard
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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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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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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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System Configuration: HYPERION
- Hyperion -
Hyperion 2012-13
Hybrid-Electric
Engine
BWB Carbon
Fiber / Composite
Structure
Integrated
Control
System

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Schedule
-Global Collaboration-
PDR CDRStart
Flight
Testing

14. 𝑪 𝑳 𝒎𝒂𝒙
~1
𝑳/𝑫 𝒎𝒂𝒙 ~18
𝑽 𝒔𝒕𝒂𝒍𝒍 13.2 m/s (29.5 mph)
𝑽 𝑻𝑶 15.8 m/s (35.4 mph)
𝑽 𝑪𝑹 30 m/s (67 mph)
𝑺 1.693 m2 (18.22 ft2)
𝒃 3.2 m (10.5 ft.)
𝑾 16 kg (35 lb)
𝑾/𝑺 9.45 kg/m2
ΛLE 35°
Aerodynamics
14Hyperion 2012-13
Lift Distribution of Hyperion 2.1.
Solid Line represents the lift per unit span. Dashed
Line represents local lift coefficient CL.
Design demonstrates the key characteristics of a
blended wing body in its lift distribution
S-5010 airfoils for the wings
S-5016 airfoil for center body

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Wind Tunnel Tests
Hyperion 2012-13
 Goal: Find out if takeoff pitch-flip behavior is systematic, or a ½
scale proto manufacturing flaw
 Compare: CFD models and experiments
 Method: 3D print scaled model wind tunnel tests 10” wingspan

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Aerodynamics & Structures
-Technology Overview-
½ Scale Wind Tunnel Model Internal Structure Center Body/Integration
Aerodynamic Validation
CFD Validation
Wing Integration/Assembly

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Global Integration Manufacturing
IDT (Interface Dimension
Template)
• Device used to ensure
German center body
matches USA wings
Similar ideas used for
wing manufacturing
Winglet  Wing
-Integration-
Delocalized manufacturing increases integration risk!
Risk
Mitigation

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Global Integration
-Global Collaboration-
“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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FTS Example
-Global Collaboration-
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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Lessons Learned
-Global Collaboration-
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
-Global Collaboration-
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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Student Global Team
-Team-
Michaela Cui
Tyler Drake
Arthur Kreuter
Gavin Kutil
Brett Miller
Corey Packard
Marcus Rahimpour
Gauravdev Soin
Martin Arenz
Holger Kurz
David Pfeiffer
Matthias Seitz
Baris Tunali
Jonas Schwengler
Pascal Weihing
Benjamin Arnold
Kai Lehmkuehler
Matthew Anderson
Joshua Barnes
Byron Wilson
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
Kristin Uhmeyer
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)
Raytheon IDS (student support)

25. Questions?
Contact: jean.koster@colorado.edu

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Project Papers
- Papers -
Hyperion 2012-13
The Hyperion 2.1 Green Aircraft Project, AIAA-2013-0817 (Best Paper AIAA-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
http://www.youtube.com/watch?v=OM825EZGhS0
http://www.youtube.com/watch?v=u2qjvbLs_t0