Weight management: control/ management/ prediction of mass properties

The actual recording and verification of data in weight management during development is used for the structured recording and plausibility check of all weight-specific information such as CAD data, FEM results, material parameters and weight break-ups. The aim is to identify possible inconsistencies at an early stage and systematically eliminate them in order to create a reliable database for weight evaluation. The verification of mass properties includes checking for completeness and consistency as well as validating centers of gravity and weight distributions using specialized tools such as WDT or SmartACT. These steps are essential for identifying risks in the development process, uncovering mass potential and ensuring reliable forecasting capability. This creates the basis for ensuring controlled mass management through targeted measures in system, structural and material lightweight construction.

The top-down/bottom-up analysis of mass properties is a central instrument of weight management during development. The top-down analysis begins with the derivation of a realistic target weight from reference data such as predecessor vehicles, competitor products, technology assessments and system requirements. In contrast, bottom-up analysis is based on real development data of individual components, whereby their weights are determined in detail using parts lists, CAD models or FEM results and cumulated at system level. These two methods are systematically combined during development in order to identify deviations from the target at an early stage and to adjust the weight of each development step to the overall target in a comprehensible manner. This interaction ensures transparency, risk minimization and decision-making reliability across all phases. This ensures that mass targets are structured, controlled and adhered to in terms of balance, center of gravity and moments of inertia while complying with lightweight construction principles.

The target derivation of mass properties in the context of development-accompanying weight management refers to the systematic determination and distribution of weight requirements within a product or system to determine a target mass and the total contractual mass not to be exceeded (NTEW). It is based on a realistic, ambitious and competitive overall target weight, which is broken down top-down to component level in the early development phase and checked for plausibility and compared bottom-up in the later development phase. Functional, installation space-related and component-specific mass structures are taken into account, as well as reserves for tolerances and change risks. The aim is to ensure compliance with weight specifications through consistent definition and control of masses throughout the entire development process. Consistent target derivation forms the basis for all mass control measures, weight transparency and the development of lightweight construction potential in the sense of a holistic lightweight construction approach.

The accompanying target achievement of mass properties, aircraft-specific loads or vehicle-specific suspension and axle loads as part of development-accompanying weight management describes the systematic coordination of weight and load targets across all development phases. Target values for total mass, subsystem weights and permissible loads are defined in the early concept phases and analyzed taking tolerances, development leeway and risk reserves into account. These target values serve as guidelines for component and system design so that design measures, material selection and load path design are always in line with the targeted mass budget. Iterative checks and bottom-up forecasts based on the maturity levels of the individual components ensure that both structural integrity and functional requirements are met. The interplay of target definition, continuous verification and digitally supported mass tracking (e.g. using FEM, WDT or SmartACT) ensures transparency, controllability and a reliable basis for decision-making in the weight management process.

The control and prediction of mass properties, aircraft-specific loads or vehicle-specific spring and axle loads is a central component of weight management during development in order to make reliable statements about masses, mass distributions, centers of gravity, moments of inertia, load distributions, spring and axle loads at an early stage of development. As part of Weight & Balance, these predictions are used to systematically analyze how masses affect the behavior, safety and performance of a land vehicle, aircraft or spacecraft. The forecast is based on historical data, comparative products, analytical methods, functional weight balances, system modeling as well as simulation-based methods such as FEM analyses or CAD-based mass estimation. This early analysis enables weight targets to be defined, risks to be identified and control measures to be initiated before cost-intensive changes become necessary later on in the project. The precise prediction of mass properties and loads thus forms the basis for a robust, sustainable and economically optimized lightweight construction concept.

The control and optimization of mass properties, aircraft-specific loads and vehicle-specific spring and axle loads in the context of weight & balance and weight management during development aims to ensure that the target approach of the mass properties is within a realistic and ambitious target corridor at an early stage in order to avoid sudden, unpredictable mass developments. Both top-down and bottom-up forecasts at component level are consistently monitored and adjusted with the help of mass data, center of gravity positions, moments of inertia and load data. By constantly evaluating and monitoring these mass parameters, it is possible to influence the mass distribution, the center of gravity and the static and dynamic loads in a targeted manner, which is crucial for the function and safety of the overall system. Supported by specialized software solutions such as WDT or SmartACT, weight scenarios are simulated, deviations are identified and control measures are initiated in a targeted manner. This approach enables proactive decision-making, ensures that set weight and load specifications are achieved and ultimately increases efficiency and system performance in terms of holistic lightweight design. The sustainable development of the weight spiral is steered in the desired direction.

The reporting of mass properties, aircraft-specific loads and vehicle-specific spring and axle loads is a central component of weight management during development in the context of Weight & Balance. It serves to create transparency at all times regarding the current mass distributions, moments of inertia, centers of gravity and load variables of a product or system. The basis for this is the continuous recording, evaluation and visualization of relevant mass data throughout the development process - supported by specialized software such as WDT or SmartACT, which can also document load distributions, loads or axle loads and spring loads in a structured manner. This not only allows deviations from weight targets to be identified at an early stage, but also enables well-founded decisions to be made on technical, economic and regulatory target fulfillment. This systematic reporting makes risks visible, prepares control measures and consistently maintains the balance between lightweight construction, safety and performance.

The development and optimization of a weight management system to accompany the development process in the development area includes the creation of a customer-specific process for the continuous recording, evaluation and forecasting of masses along the entire product development process. This involves developing structured weight data models as well as forecast and target derivation models for components that take into account linear and non-linear influencing variables as well as manufacturing tolerances, uncertainties and risks. Transparent definitions of roles and responsibilities and a consistent project and risk management system enable active control of mass progression in order to secure target weights at an early stage and avoid cost-intensive corrections later on. Implementation is carried out iteratively directly in the customer's development environment and is supplemented by training to ensure independent application and further development of the process. The overall goal is holistic, cross-functional and cross-system mass data management that creates transparency at all times and forms the basis for sound technical and economic decisions.

In development-related weight management, cost analysis refers to the systematic recording and evaluation of all weight-specific costs that may arise during product development, for example due to lightweight materials, manufacturing processes or functional separation. Cost clusters are used to structure these costs along functional or component-specific groups - for example according to lightweight system design, lightweight structural design or lightweight material design - and to enable a transparent comparison of weight savings and cost impact. This classification makes it possible to specifically identify and prioritize measures with a high weight reduction at a reasonable cost. In the context of holistic lightweight construction, such analyses are carried out with the help of digital tools (e.g. WDT, SmartACT) and validated using FEM-based simulations in order to ensure technical feasibility and economic efficiency at an early stage. Ultimately, this approach forms a crucial basis for decisions on the implementation or rejection of specific lightweight construction measures.