How system simulation addresses aerospace industry challenges

Overview

• Webinar topic: Using system simulation (Simcenter / Amesim) for aircraft design to manage complexity, speed development, and support safety and sustainability goals (electrification, hydrogen, novel configurations).
• Purpose: Demonstrate how 1D system simulation and model-based systems engineering (MBSE) enable front-loading virtual tests, digital-twin workflows, and cross-supplier model exchange.

Key technological concepts and product capabilities

System simulation = coupling of plant (physical) modeling and control modeling to predict steady-state and transient system performance.

Simcenter / Amesim capabilities highlighted:

• Prebuilt domain libraries (aircraft fuel system, hydraulic, electrical, thermal, propulsion).
• Drag-and-drop component blocks (tanks, pipes, pumps, probes, valves, materials such as Jet A-1).
• Componentization for reuse and MBSE-style virtual system integration (supporting supplier/OEM workflows).
• Co-simulation with 3D CFD/FEA tools (e.g., STAR-CCM+) and hardware links (SIL/HIL).
• Ability to model complete engines (primary/secondary flows, nacelle, accessory gearbox) and hybrid/electric propulsion systems.

Covered modeling domains and use cases:

• Fuel systems
• Electrical/power systems
• Environmental control systems (ECS)
• Hydraulics
• Thermal and power management
• Propulsion hybridization and battery thermal modeling

Typical applications (examples discussed)

• Refueling optimization (vent-tube sizing, refuel-time tradeoffs)
• Fuel management under severe maneuvers (spin, rigid takeoff with asymmetric engine failure)
• Integrated thermal/power management for electric/hybrid aircraft (steady and transient battery/thermal behavior)
• Cabin comfort: coupling 1D ECS models with 3D cabin airflow CFD
• Hydraulic system front-loading and coupled dynamics for landing gear/actuation
• Virtual testing for structural loading (hydrostatic pressure) and system-level verification & validation

Workflow / practical guide (summarized)

1. Build a 1D system model using library components (drag & drop).
2. Import CAD geometry of tanks (STEP or other formats) and run the fuel-system plug-in to create tank-shape description files.
3. Use tank-shape files plus reference/orientation information to create Amesim tank blocks and visualization (.stp / .info / .shape).
4. Attach measured/recorded flight dynamics (acceleration, pitch, roll time histories) to the model for transient simulations.
5. Run batch parametric studies (e.g., vent tube diameters, probe placements, fuel amounts, pitch angles).
6. Visualize fluid motion inside tank geometry with the visualization assistant; analyze outputs (probe signals, fuel CG, inertia tensor, hydrostatic pressures).
7. Optionally co-simulate with 3D CFD/FEA or hardware (SIL/HIL) for higher-fidelity tradeoffs and verification.

Case study — Diamond Aircraft (ACAM Engineering)

Context:

• Partner: Diamond Aircraft (small composite aircraft, flight trainers, turboprop “Dart” trainer).
• ACAM used Siemens Simcenter / Amesim fuel system library to model a wet wing plus center tank for aerobatic/turboprop trainer missions.

Specific projects and simulations:

• Refueling optimization: tested vent and rib hole sizes to trade fueling time versus in-flight fuel stability.
• Spinning maneuver simulation: combined wing + center tank + flight dynamics data to compute transient hydrostatic pressures, fuel center of gravity, and inertia changes; validated dynamics visually against recorded flight.
• Stable inverted flight study: ran 55 simulations (11 pitch angles × 5 fuel states) to investigate fuel probe behavior and cockpit fuel-display anomalies during inverted steady flight.

Outcomes:

• Detailed insight into internal fuel motion, probe readings, CG shifts, and structural loading.
• Enabled design changes and troubleshooting without extensive flight testing.

Benefits emphasized

• Early detection of system-level issues (safety, fuel management, probe/display anomalies).
• Reduced time-to-market by front-loading virtual tests and enabling rapid parametric studies.
• Facilitates supplier/OEM collaboration via reusable component models and model exchange.
• Supports design and evaluation of novel propulsion systems (electric, hybrid, hydrogen) and rethinking mass/flow distribution for new configurations.

Speakers / sources

• Caroline Maitre — webinar host (Bordeaux, France)
• David Morand — Aerospace Business Development Manager, Simcenter Systems Simulation, Siemens Digital Industry Software
• Florian Schussler — CEO, ACAM Engineering (presented Diamond Aircraft fuel-system case study and simulation workflow)
• Diamond Aircraft — industry partner/customer in the case study