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SIPAL Aeronautics Showcase
- 1. GCT SIPAL SPA OVERVIEW May 27 2013
- 3. SIPAL S.p.a. The Sipal S.p.a. Engineering Department is specialized in designing complex Work Packages for the Aerospace sector and in supplying onsite consultancy service. More than thirty years of experience in the management of technologically complex project allows SIPAL to help its clients with concrete ideas, rapid interventions and reliable solutions. The Specialized Staff, deal with preliminary design, detailed design, process and product optimization, product support and certification support throughout all steps to final assembly and certification. All activities include project management, design and stress analysis.
- 4. Company General Data Offices HEADQUARTER GALLARATE ? Via Invorio, 24/A ¨C 10146 Torino CASSOLA TORINO PIACENZA OPERATIONAL SITES ? Via Monte Verena, 58/60 - 36022 Cassola (Vicenza) ? Largo Camussi n. 8 - 21013 Gallarate (Varese) ? Via Caorsana, 79 - 29100 Piacenza ? Via Grotta delle Fate, 41 - 57128 Livorno ? Via Affile, 102 - 00131 Roma ? Via E. Gianturco, 23 - 80146 Napoli ? C.so Giuseppe Garibaldi, 62 - 71121 Foggia ? C.so Europa, 3 - 74023 Grottaglie (Taranto) ? Viale Francia, 11 - 73100 Lecce LIVORNO FOGGIA ROMA NAPOLI GROTTAGLIE LECCE
- 5. Company General Data SIPAL S.p.A. - General Data ? Founded in Turin (ITALY) in 1978, SIPAL is the Engineering Company of the FININC S.p.A. Group since 1988 and represents in the national scene a strong and reliable partner, in both civil and military field. ? SIPAL is now active on the market in three main fields of : ? Product and Manufacturing Engineering ? Civil Engineering and Infrastructure ? Integrated Logistic Support (ILS) ? SIPAL¡¯s Turnover ? 2013 ? € 25.000.000 (expected achievement) ? 2012 ? € 20.500.000 (+27%) ? 2011 ? € 16.150.000 ? 2010 ? € 15.100.000 ? SIPAL¡¯s Employees ? More than 300 employees ? 90% Technical Degree (Master & Bachelor)
- 6. Company General Data SIPAL - Frameworks Agreements
- 7. Core Business Engineering Activities Product Engineering Engineering Support
- 8. Core Business Product Engineering AEROSPACE STRUCTURES ? ? ? ? B787-8 S46 Cargo Floor Assy Pre-project/preliminary studies on aero-structures Aero structures design (systems and primary structure integration/ installation) Structural Analysis (Static/Modal/Fatigue/DamageTolerance) Product certification analysis
- 9. Core Business Product Engineering AEROSPACES SYSTEMS ? ? ? ? ? ? Pre-project/preliminary studies on systems Wiring and pipeline layout design Electric, hydraulic, fluidic and flight control installation design Onboard systems installation design Electronic Design on Customer Specifications Special systems and data network design
- 10. Core Business Product Engineering Main Activities B787-8, B787-9 (Alenia-Boeing ¨C Section 44, 46 and 49) ? ? ? ? ? ? 787-8 (Alenia) - Stress and Design activity (from concept layout to certification dossier) for Main Structure and Systems Integration (Frame, Passengers Door Surround, Cargo Door Surround, Cargo Beam Assy, Floor Beams, EEBay Door Surround, Hydraulic, Wiring,); 787-8 (Alenia) - Stress and Design activity (from concept layout to certification dossier) for Systems Integration (Hydraulic, Wiring,); 787-8 (Alenia) - Engineering support for Final Assembly Line (Everett, Charleston, Grottaglie); 787-9 (Alenia) - Stress and Design activity for Main Structure and Systems Integration Primary structure design (composite and metals) using CATIA V5; Parts sizing (static and fatigue analysis) using Boeing Tools, hand calculation methods and FEM (Nastran, Patran, Hypermesh);
- 11. FUSELAGE SECTION 46 - Boeing 787 AERONAUTICAL STRUCTURES Passenger Door Surround Cargo Door Surround
- 12. CARGO FLOOR - Boeing 787 Program AERONAUTICAL STRUCTURES ? ? ? Design using CATIA V5 Primary structure design (composite and metals) Parts sizing (static and fatigue analysis) using tradictional methods and FEM
- 13. CARGO FLOOR - Boeing 787 Program Frame (composite material) Machined element (Titanium alloy) AERONAUTICAL STRUCTURES Floor Beam (composite material) Machined element (Aluminum alloy) Stiffners (composite material) Frame to skin-tie element (composite material)
- 14. CARGO FLOOR - Boeing 787 Program AERONAUTICAL STRUCTURES ? ? ? ? Detailed analysis using FEM: Joints Stress of machined parts Strain of composites elements Machined element (Aluminum alloy)) Floor Beam Skin with stiffners
- 15. CARGO FLOOR - Boeing 787 Program AERONAUTICAL STRUCTURES Analysis of results (the picture shows the displaicement of the structure)
- 16. DOOR SURROUND - Boeing 787 ? AERONAUTICAL STRUCTURES ? The detailed FEM model created by Sipal has been integrated into the complete FEM model of the fusolage section created by Boeing. The analyzed structural parts are made of titanium alloy (shown into red box).
- 17. DOOR SURROUND - Boeing 787 AERONAUTICAL STRUCTURES Analysis of results (the picture shows the stress over the metallic parts)
- 18. Core Business Product Engineering Main Activities BOMBARDIER C-SERIES (Salver-Magnaghi) ? ? ? ? Design activity (from concept layout to certification dossier) for Main Structure (Composite Inboard and Outboard Flap, Composite Main Landing Gear Door, Composite Spoiler); Primary structure design (composite and metals) using CATIA V5 and FiberSim; Parts sizing (static and fatigue analysis) using hand calculation methods and FEM (Nastran, Patran, Hypermesh); Stress and F&DT Analysis.
- 19. AERONAUTICAL STRUCTURES FLAPS - C-Series Program ? ? ? ? Design using CATIA V5 Primary structure design (CFRP and Metals) Study of Cinematics Parts sizing (Static, Fatigue and Damage Tolerance analysis)
- 20. FLAPS - C-Series Program AERONAUTICAL STRUCTURES ? ? ? Design using CATIA V5 Primary structure design (CFRP and Metals) Parts sizing (Static, Fatigue and Damage Tolerance analysis)
- 21. Core Business Product Engineering Main Activities P-180 AVANTI ¨C MPA3 (Piaggio Aero Industries) ? ? ? ? ? Design Activities: Wing, Center Fuselage and Bulkhead; Wing - Flight Control System; SYSTEM (Design and Installation: Fuel System, Avionic System, Wiring Harness) Primary structure design (composite and metals) using CATIA V5.
- 22. WING - Piaggio Aero Industries, MPA Program AERONAUTICAL STRUCTURES ? ? ? Design using CATIA V5 Primary structure design (CFRP and Metals) Parts sizing (Static, Fatigue and Damage Tolerance analysis)
- 23. Core Business Product Engineering Main Activities P-1XX (Piaggio Aero Industries) ? Definition of Design Principles; Design of Front Fuselage; Design of Wing Box; Design of Interiors; Design of Cockpit Mock-up; Design of Engine Pylon and Power Plant Installation. ? P-1XX (Piaggio Aero Industries) - Definition of Design Principles - Design of Fuselage, Cockpit Mock-up, Engine Pylon and Power Plant Installation
- 24. COCKPIT - P1XX Program AERONAUTICAL STRUCTURES ? ? Design using CATIA V5 Primary structure design (metals)
- 25. WING - P1XX Program AERONAUTICAL STRUCTURES ? ? ? Design using CATIA V5 Primary structure design (metals) Parts sizing (static and fatigue analysis) using tradictional methods and FEM
- 26. Core Business Product Engineering Main Activities C-27J (Alenia) ? ? ? Design of Flight Control System; System Installation Integration and Testing of Avionic Sub-Systems System modeling and simulation of electromagnetic fields EF-2000 (Alenia) ? ? ? ? Design of Wing Box; Design of Fuselage Electro Mechanical and Hydraulic System; Design of Dass Pod Integration and Testing of Avionic Sub-Systems Analysis and preliminary design of the propulsion and overall systems Analysis of stability and handling qualities SKY-X (Alenia) ? Design of all Airframe, Metallic Fuselage, Composite Nacelle, System integration, System installation, Control Surface and Mechanism design, Flight controls design, Power generation and distributions system design, Engine Installation
- 27. Core Business Product Engineering AW169 (Agusta Westland) ? Design of Composite Tail Plane NH90 ? Stress analysis and report: ? Rear ramp ? End flap rear ramp ? Norway Observer Seat ? Weapon Integration Assy ? Bird Strike analysis and report: ? Protection Tube AW109 ? Stress analysis and report: ? New Pilot Collective Tube Main Activities
- 28. Core Business Product Engineering A129BCH ? Stress analysis and report: ? Co-Pilot Pedal Assembly AW139 ? Design, Stress analysis and report: ? Rear cowling, IRSS Sistem AW189 ? Stress analysis and report: ? Fixed Flight Controls Main Activities
- 29. Core Business Product Engineering M-346 (Aermacchi) ? ? ? ? ? ? ? ? ? ? Wing Box design and Weight optimization, Aircraft Systems installation, Qualification test support, Aircraft Wiring and Harness Design, Preliminary Pylon design, Wing modification and integration Composite /Metallic front fuselage design, Harness installation, Aircraft Ground Equipments design, Tooling Design Main Activities
- 30. WING BOX M346 ¨C AERMACCHI AERONAUTICAL STRUCTURES Finite elements model for loads extractions and sizing using tradictional methods ? ? ? ? ? ? WING BOX STRUCTURE (metal and composite materials): spars stringers ribs skin fitting elements (pylon junction,hinges¡)
- 31. WING BOX M346 ¨C AERMACCHI AERONAUTICAL STRUCTURES ? ? Overall structure analysis (evaluation of the wing behaviour under bending and torsional loads) Detailed FEM analysis of critical items (loads concentration factors near to fillets, complex jonts analysis, ¡)
- 32. Core Business Engineering Support MANUFACTURING ENGINEERING ? ? ? ? ? ? ? ? Production and assembly cycles development Definition of times and methods Production plant sizing Production cell workload and sizing analysis Manufacturing Plan development Production, assembly, support and test-set design and designation Aerospace Ground Equipment design, management and qualification Works Management and Safety Coordination MANUFACTURING ? ? ? ? ? Functional prototype and mock-up production Production, assembly and support tools and electromechanical/hydraulic test sets production Aerospace Ground Equipment production Electronic prototypes and test-sets production Tool, machinery and plant upgrading and re-certification)
- 33. Core Business Engineering Support PCM-CYGNUS ¨C MGSE 1-G FLOOR (Orbital) ? MGSE Design, Analysis, Testing, Qualification; ? DRD Technical Documentation , TAS-I PLANT TURIN PCM-CYGNUS (Orbital) ? Secondary Structure Static Test ? Tool Design, Analysis and CE Technical Documentation Main Activities
- 34. Core Business Engineering Support Main Activities CLAMPING EQUIPMENT FOR FSW WELDING STATION ? FSW Tool Design, Analysis , Manufacturing, Installation and Technical Documentation. A380 ENGINE NACELLE TOOL (Airbus) ? Tool Design, Analysis and CE Technical Documentation
- 35. Engineering & Ground Test Concurrent Engineering Avionic Sub-Systems General System & Propulsion System Modeling Flight Mechanics
- 36. Engineering & Ground Test Concurrent Engineering AVIONIC SUB-SYSTEMS (EFA-TORNADO-C27J) ? ? ? ? ? Analysis and preliminary design of new generation avionics systems. Multidisciplinary analysis of choice and integration of equipment / systems on the aircraft. Systems development, integration and testing of avionics subsystems. Characterizations of aircraft antennas Intra-system Testing between avionic equipments in order to detect susceptibility GENERAL SYSTEM & PROPULSION (EFA-TORNADO) ? Analysis and preliminary design of the propulsion and overall systems starting from the mission requirements
- 37. Engineering & Ground Test Concurrent Engineering SYSTEM MODELING (C27J) ? System modeling and simulation. ? Simulation of electromagnetic fields inside irradiated systems and subsystems. FLIGHT MECHANICS (EFA) ? Complete analysis of the performance. ? Analysis of stability and handling qualities.
- 38. Hardware / Software Tools CAD - CAE
- 39. Software CAD ? Dassault Catia V5 ? Enovia ? FiberSim (Advanced Composite Engineering) ? PTC Pro/Engineer ? Autodesk Autocad ? Logical Cable ¨C MG ? Siemens Teamcenter (VisMockup) ? Siemens Robcad FEM ? MSC NASTRAN/PATRAN. ? ALTAIR HYPERWORKS ? NASGRO
- 40. SIPAL Engineering Location and Capability Engineering Location & Capability
- 41. SIPAL Engineering Location and Capability SIPAL ENGINEERING CAPABILITIES Direct Employees ? ? ? ? ? ? ? ? ? 25 Structural Analysts 45 Designers 10 Methodists 10 Systems Engineers / Avionics / Propulsion 1 Composite Structures Expert 1 Systems Installation Expert 1 Equipment Expert 1 Tooling Expert 150.000 Hours / Year Developable SIPAL TORINO - PIEMONTE ? ? ? ? ? ? ? 800 mq Call conference room Conference halls Separable areas 100 stations set up with network/phone Network and Storage Server 40 employees 8 STR / 22 DES / 10 AVIONICS Engineering Location & Capability
- 42. SIPAL Engineering Location and Capability SIPAL FOGGIA - PUGLIA ? ? ? ? ? ? ? 100 mq Call conference room Conference halls Separable areas 6 stations set up with network/phone Network and Storage Server 5 employees 1 STR / 4 DES SIPAL NAPOLI - CAMPANIA ? ? ? ? ? ? ? 400 mq Call conference room Conference halls Separable areas 30 stations set up with network/phone Network and Storage Server 29 employees 11 STR/18 DES Engineering Location & Capability SIPAL GROTTAGLIE - PUGLIA ? ? ? ? ? ? ? ? 400 mq Call conference room Conference halls Separable areas 24 stations set up with network/phone 50 Network spots. Network and Storage Server 16 employees 5 STR/11 DES
- 43. Certifications UNI EN ISO 9001:2008 UNI EN 9100: 2009 Security ? ? EAD Restricted Areas (NATO SECRET) ? Partecipations Complete Security Clearance (NOSC NATO SECRET) COMSEC Areas (NATO SECRET)
- 44. Thanks for the attention! Prepared by Ing. Alessandro Barretta