Digital Engineering at Rheinmetall Air Defense

Introduction

The latest military conflicts, notably in Ukraine, have stressed the need for modern, effective short-range air defence systems that protect against attacks from small, fast and agile targets. With almost 100 years of experience on the market, Rheinmetall Air Defence (RAD, formerly Oerlikon Contraves) is a global leader in the field of gun-based air defence and the sole single-source supplier of automatic gun, command and fire control systems. The core competency of RAD is the development, manufacturing and servicing of advanced air defence systems.

Challenges

The challenges to the development of modern air defence systems lie in the change in the operational and industrial environment. New threats, such as drones or standoff weapons, are being equipped with increasingly advanced technology that is relatively cheap and available for mass production. Ever-shorter technological innovation cycles that enhance threats and defence systems alike are set against long procurement and life cycles of products. Products are also networked with systems from other manufacturers in the course of use. As a result, the trend toward horizontal and vertical networking at systemic and industrial levels continues to increase while the available qualified workforce is decreasing.

Digital Engineering

In order to be able to anticipate these challenges, new paths must be taken in product development. An important building block for this is the consistent entry into digitalisation. RAD, therefore, adopted the Department of Defense (DoD) vision of digital engineering (DE) for itself shortly after it was published in 2018 ^[1]. According to DoD's definition, DE combines model-based techniques, digital practices, data and IT infrastructure in order to transform the lifecycle of engineering activities.

DE has great potential, especially for RAD as an air defence system provider. Development and test phases are time-consuming and cost-intensive, involving large teams, systems and test equipment in order to meet high requirements, e.g. intercepting incoming missiles. In addition, our products have a long service time of sometimes several decades, during which development, maintenance and modernisation may be performed by different workforce generations.

While the application of engineering tools and digital data, such as CAD models, are industry standards, the implementation of DE goes well beyond that.

It encompasses end-to-end processes: the same data is used not only in development but also for concise exchange between upstream and downstream processes, such as sales, manufacturing and services. A model mostly consists of the physical, functional and logical representation of a system. We found it useful to add lifecycle, configurational and performance data. The model is then used within the development phase for feasibility studies and simulations, design reviews, hit calculations and post-firing analysis. Properly tailored models are an important means for internal and external communication fostering mutual understanding and supporting better decisions. They are essential to the education of our workforce and also serve for the training of our users.

Implementation

As an example, DE is applied to the development of the inertial stabilisation algorithms for our drive system. Superior stabilisation accuracy is a key factor in counteracting threats with our new mobile air defence system Skyranger®. For this purpose, a digital twin of the electromechanical gun system is modelled, which is constituted by the two-axis turret and the complete drive train. Within the gun model, complex control algorithms can be designed and extensively tested under different scenarios. Field tests on the real system are conducted at a very late project stage only, on a pre-tested software version. In this way, travelling and activities in the field are reduced to a minimum since only the final parameters tuning has to be conducted. The software is generated according to a certified development process that fulfils severe safety standards, and thus, the prototype software can be improved and applied to serial production with minimal effort. Thanks to this approach, we can reduce the development iterations and the test activities in the field and, last but not least, our ecological footprint.

“While the Application of Engineering Tools and Digital Data, Such as Cad Models, Are Industry Standards, The Implementation of de Goes well Beyond that. It Encompasses End-To-End Processes: The Same Data is Used not only in Development but also for Concise Exchange Between Upstream and Downstream Processes, such as Sales, Manufacturing and Services”

Evaluation

Some issues exist. DE involves significant investments in the transformation of digital processes, equipment, tools and employee training. In addition, the need for coordination of processes within and outside the company may be considered since, for example, standards are lacking. Organising and tailoring the right data for the model is an art to be mastered. Furthermore, digital data are sensitive and exacerbate the need for IT security. Last but not least, the workforce must embrace this transition.

Overall, the advantages outweigh the disadvantages latest in the medium term: with DE, innovation times and the transition to market are shorter overall. It helps to master the complication of systems by providing a single source of information to the existing and future users. The accrued data in the lifecycle of our systems will allow new technologies, such as artificial intelligence and additive manufacturing, to open up a new spectrum of opportunities, including production and maintenance.

Outlook

We have just taken our first steps. For us, DE is not a destination but a journey of continuous transformation of the whole defence industry. It enables us to continue to manufacture and deliver relevant solutions and products to a rapidly changing environment. RAD has embarked on this journey. It is yet another journey for a company that has already seen quite a lot in the last 100 years.

[1]Office ot the Deputy Assistant Secretary of Defense for Systems Engineering, “Digital Engineering Strategy,” Department of Defense, Washington, DC, 2018.