SIPAL Aeronautics Showcase

GCT

SIPAL SPA OVERVIEW

May 27 2013

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.

HEADQUARTER

OPERATIONAL SITES

Via Invorio, 24/A – 10146 Torino

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

Company General Data Offices

TORINO

PIACENZA

LIVORNO

ROMA

NAPOLI GROTTAGLIE

LECCE

GALLARATE

FOGGIA

CASSOLA

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)

Company General Data SIPAL S.p.A. - General Data

Company General Data SIPAL - Frameworks Agreements

Product Engineering

Engineering Support

Core Business Engineering Activities

Core Business Product Engineering

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

AEROSPACE STRUCTURES

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

AEROSPACES SYSTEMS


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);

B787-8, B787-9 (Alenia-Boeing – Section 44, 46 and 49)


Main Activities

Cargo Door Surround

Passenger Door Surround

FUSELAGE SECTION 46 - Boeing 787

AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

• Design using CATIA V5

• Primary structure design (composite and metals)

• Parts sizing (static and fatigue analysis) using tradictional

methods and FEM

CARGO FLOOR - Boeing 787 Program

AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

Stiffners (composite material)

Frame (composite material)

Machined element (Titanium alloy)

Machined element (Aluminum alloy)

Floor Beam (composite material)

Frame to skin-tie element (composite material)


AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

Machined element (Aluminum alloy))

• Detailed analysis using FEM:

• Joints

• Stress of machined parts

• Strain of composites elements

Skin with stiffners

Floor Beam


AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

Analysis of results (the picture shows the displaicement of the structure)


AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

• 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).

DOOR SURROUND - Boeing 787

AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

Analysis of results (the picture shows the stress over the metallic parts)

DOOR SURROUND - Boeing 787

AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

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.


Main Activities


• Primary structure design (CFRP and Metals)

• Study of Cinematics

• Parts sizing (Static, Fatigue and Damage Tolerance analysis)

FLAPS - C-Series Program

AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S




FLAPS - C-Series Program

AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

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.

P-180 AVANTI – MPA3 (Piaggio Aero Industries)


Main Activities




WING - Piaggio Aero Industries, MPA Program

AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

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


Main Activities


• Primary structure design (metals)

COCKPIT - P1XX Program

AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

WING - P1XX Program


• Primary structure design (metals)

• Parts sizing (static and fatigue analysis) using tradictional methods and FEM

AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

Design of Flight Control System; System Installation

Integration and Testing of Avionic Sub-Systems

System modeling and simulation of electromagnetic fields

C-27J (Alenia)

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


Main Activities

Design of Composite Tail Plane

Stress analysis and report:

• Rear ramp

• End flap rear ramp

• Norway Observer Seat

• Weapon Integration Assy

Bird Strike analysis and report:

• Protection Tube


• New Pilot Collective Tube

AW169 (Agusta Westland)


Main Activities

NH90

AW109


• Co-Pilot Pedal Assembly

Design, Stress analysis and report:

• Rear cowling, IRSS Sistem


• Fixed Flight Controls

A129BCH


Main Activities

AW139

AW189

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

AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

WING BOX M346 – AERMACCHI

• WING BOX STRUCTURE (metal and composite materials):

• spars

• stringers

• ribs

• skin

• fitting elements (pylon junction,hinges…)

Finite elements model for loads extractions and sizing using tradictional methods

• Detailed FEM analysis of critical items (loads concentration

factors near to fillets, complex jonts analysis, …)

• Overall structure analysis (evaluation of the wing behaviour under

bending and torsional loads)

WING BOX M346 – AERMACCHI

AE

RO

NA

UT

ICA

L S

TR

UC

TU

RE

S

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

Core Business Engineering Support

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)


MGSE Design, Analysis, Testing, Qualification;

DRD Technical Documentation , TAS-I PLANT TURIN

PCM-CYGNUS – MGSE 1-G FLOOR (Orbital)

PCM-CYGNUS (Orbital)

Secondary Structure Static Test

Tool Design, Analysis and CE Technical Documentation

Main Activities


FSW Tool Design, Analysis , Manufacturing, Installation and Technical

Documentation.

CLAMPING EQUIPMENT FOR FSW WELDING STATION

A380 ENGINE NACELLE TOOL (Airbus)

Tool Design, Analysis and CE Technical Documentation

Main Activities

Avionic Sub-Systems

General System & Propulsion

System Modeling

Flight Mechanics

Engineering & Ground Test Concurrent Engineering


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

AVIONIC SUB-SYSTEMS (EFA-TORNADO-C27J)

Analysis and preliminary design of the propulsion and overall systems starting

from the mission requirements

GENERAL SYSTEM & PROPULSION (EFA-TORNADO)


System modeling and simulation.

Simulation of electromagnetic fields inside irradiated systems and subsystems.

SYSTEM MODELING (C27J)

Complete analysis of the performance.

Analysis of stability and handling qualities.

FLIGHT MECHANICS (EFA)

Hardware / Software Tools

CAD - CAE

Software

Dassault Catia V5

Enovia

FiberSim (Advanced Composite Engineering)

PTC Pro/Engineer

Autodesk Autocad

Logical Cable – MG

Siemens Teamcenter (VisMockup)

Siemens Robcad

CAD

MSC NASTRAN/PATRAN.

ALTAIR HYPERWORKS

NASGRO

FEM

Engineering Location & Capability

SIPAL Engineering Location and Capability

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 ENGINEERING CAPABILITIES Direct Employees

SIPAL Engineering Location and Capability Engineering Location & Capability

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

SIPAL TORINO - PIEMONTE

SIPAL Engineering Location and Capability Engineering Location & Capability

100 mq


Conference halls

Separable areas



5 employees 1 STR / 4 DES

SIPAL FOGGIA - PUGLIA

400 mq


Conference halls

Separable areas

24 stations set up with

network/phone

50 Network spots.


16 employees 5 STR/11 DES

SIPAL GROTTAGLIE - PUGLIA

400 mq


Conference halls

Separable areas



29 employees 11 STR/18 DES

SIPAL NAPOLI - CAMPANIA

Complete Security Clearance (NOSC NATO SECRET)

EAD Restricted Areas (NATO SECRET)

COMSEC Areas (NATO SECRET)

Certifications

Security

Partecipations

UNI EN ISO 9001:2008 UNI EN 9100: 2009

Thanks for the attention!

Prepared by Ing. Alessandro Barretta

SIPAL Aeronautics Showcase

Technology

Transcript of SIPAL Aeronautics Showcase