Digitisation of exchanges and designs is the answer to the challenges posed by the distances between the partners on the EC175 programme. Without this solution, the programme would never have succeeded so quickly... and so well.

The result of the cooperation between Eurocopter and China, the EC175 poses serious organisational challenges on both sides of the planet. But the nature of these challenges is not just international. As Philippe Legendre, the programme’s chief engineer explains, the complexity of the Chinese organisation is equally widespread:
“We are working with four Chinese partners based at four different sites. The HAIG company is located in the north of the country, and this is where the Chinese assembly line will be based. Then the CHRDI, CAPI and ZTMW organisations are all located in southern China. CHRDI (the China Helicopter Research and Development Institute) is working on the structures, fuel system, landing gear, flight controls and power plant; CAPI is the research institute developing the transmission systems; while ZTMW (Zhongnan Transmission Machinery Works) is producing the dynamic components. At best, journeys between each site can take hours; at worst, between northern and southern China, they can take days.”
It takes two days of travel from Marignane to visit CHRDI or HAIG. As a result, getting the various entities to work together has called for extensive use of innovative solutions based on a digital mock-up (DMU). This is a virtual helicopter that is entirely represented in 3D, right down to the smallest parts.

High-level integration
“The DMU (1) is the working base used by everybody involved in the programme,” stresses Philippe Legendre. “Its high level of precision allows us to identify any interference between components. The suppliers’ design offices can also use this tool to validate the integration of their equipment, keeping an overview of all the helicopter’s constraints. We have also set up a virtual reality room with a 12 m2 screen, which we use to visualise the largest parts in their actual size, in 2D or 3D.”
CHRDI is responsible for centralising all the digitised data on the Chinese side. These data are then sent to Marignane where they are integrated in the digital mockup. A new DMU is produced every week and sent to each partner on the project via an encrypted data link that has been set up between France and China. Detailed reviews of specific areas are also organised at regular intervals to make sure there is no interference. Finally, the French and Chinese designers frequently get together and discuss issues at videoconferences.
“This is the first time that we have gone so far in integrating a digital mock-up,” continues Philippe Legendre. “The Chinese have made major investments in order to be able to work in this computer environment, which is new to them. As for us, we have consulted other organisations that are extremely knowledgeable in this field, such as Dassault Aviation or Astrium Space Transportation at EADS. We also benefited from the experience gained in the use of digital mock-ups on the Tiger and NH90 programmes.”

The human factor
Philippe Legendre is quick to point out, however, that the virtual team is only operating so effectively today because of the experience gained from the physical multi-skilled work unit that was organised between French and Chinese engineers.
“Initially, and especially for a project like this which was started from scratch, it was vital that the teams met up physically, that names were put to faces and voices, and that relationships based on trust were built. We also needed to set up the exchange protocols and common tools, and get everybody accustomed to using them.” Fifty to seventy Chinese engineers worked in Marignane in 2006. The links forged with their French colleagues have been instrumental to the smooth functioning of the DMU throughout 2007.