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Structural and thermal engineers currently work independently of each other using unrelated tools, models, and methods. Without the ability to rapidly exchange design data and predicted performance, the achievement of the ideals of concurrent engineering is not possible. Thermal codes have been unable to exploit the geometric information in structural models and the CAD design database, and do not facilitate transfer of temperature data to other discipline’s analysis models. This paper discusses the key features in Thermal Desktop for supporting integrated thermal/structural analysis. Approaches to thermal modeling in an integrated analysis environment are discussed along with Thermal Desktop’s data mapping algorithm for exporting temperature data on to structural model grid points.

Productivity bottlenecks for integrated thermal, structural, and optical design activities were identified and systematically eliminated, making possible automated exchange of design information between different engineering specialties. The problems with prior approaches are summarized, then the implementation of the corresponding solutions is documented. Although the goal of this project was the automated evaluation of coupled thermal/optical/structural designs, significant process improvements were achieved for subset activities such as stand-alone thermal, thermal/ structural, and structural/optical design analysis.

Automated design space exploration was implemented and demonstrated in the form of the multidisciplinary optimization of the design of a space-based telescope. Off-the-shelf software representing the industry standards for thermal, structural, and optical analysis were employed. The integrated thermal/structural/optical models were collected and tasked with finding an optimum design using yet another off-the-shelf program. Using this integrated tool, the minimum mass thermal/structural design was found that directly satisfied optical performance requirements without relying on derived requirements such as isother-mality and mechanical stability. Overdesign was therefore avoided, and engineering productivity was greatly improved. This ambitious project was intended to be a pathfinder for integrated design activities. Therefore, difficulties and lessons learned are presented, along with recommendations for future investigations.