Vipac Engineers & Scientists Ltd is an engineering systems development and consultancy company with offices located throughout Australia and South-East Asia. With nearly 30 years experience, Vipac offers a unique combination of design, analysis and testing services, providing system level solutions to complex problems in the defence, aerospace and space industries.

Extensive test laboratories (acoustic and climatic chambers, solar simulators, vibration rigs) and field instrumentation are used with advanced Computer Aided Engineering software to support the design and test processes. Vipac, classified as an Authorised Engineering Organisation by the RAAF, is NATA accredited for a wide range of laboratory tests and adheres to ISO9001 quality assurance procedures.

Furthermore, Vipac is a core member of the Cooperative Research Centre for Satellite Systems and is involved in the project management, design, and supply of satellite systems. This includes the development of space-based, remote sensing instruments and multi-level environmental data products.

Systems Development
A variety of techniques are used to verify that a product will meet the client’s needs. Beginning with the initial concept, Vipac’s engineers work closely with the customer to develop product requirements and performance specifications. Design optimisation is achieved through systems performance modelling and advanced detailed analysis. Where appropriate, a prototype will be developed and evaluated through bench top testing and operational trials. Final delivery includes a joint customer review to ensure traceability and compliance of all requirements.

Structural Analysis
Finite Element (FE) and other analysis methods are used in conjunction with 3D CAD modelling to provide workable design solutions. Detailed analysis tools include ANSYS, NISA and NASTRAN FE software for structural analysis, SolidWorks CAD software, AutoSEA for vibro-acoustics as well as SHELTR and NISA for system level thermal simulations. Modelling capability includes non-linear materials and geometry, dynamic simulations such as shock, random and harmonic excitation, as well as vibro-acoustic and thermal environmental loads. These techniques are combined with traditional stress analysis methods to provide fully validated structural designs.

Life Extension
The life of a structure depends on various factors such as the operational usage, the loading environment, and the design of the structure itself. Mission usage spectra are constructed and combined with environmental load definitions obtained through analysis and testing. Fatigue life assessments are performed using traditional methods such as Miner’s Rule supported by FE techniques. Fracture mechanics methods are also used when fatigue life is extended to determine post-crack behaviour.

Dynamics
Vibration and thermal stresses have long been principal design considerations in achieving high performance requirements for payloads and equipment. Predicting the local dynamic environment involves the use of advanced techniques such as Computational Fluid Dynamics (CFD) to assess the effects of aero– and thermo-dynamic loads. FE and CFD codes ANSYS and Fluent are used together to determine the fluid loading environment upon the structure and the local equipment environment. High frequency vibro-acoustic loads, such as caused by engine noise, are assessed using the AutoSEA Statistical Energy Analysis code. Vipac has extensive design, analysis, and test experience with noise and vibration control in military vehicles, aircraft, and underwater-radiated noise from marine platforms. Typical assessments include thermo-dynamics, acoustic emissions, structural dynamics, fatigue and interior noise.

Performance Simulation & Measurement
System performance models can be developed to investigate the effects of aircraft modifications on flight performance characteristics like drag, fuel consumption and operational time-on-station. Such modifications include alternative stores configurations, antenna-farms as well as weight and balance changes.

Flight Testing & Trials
Airframe life extension and structural analysis assessments often require flight-testing and trials. Vipac can develop flight test plans and instrumentation packages to acquire process and reduce data for further analysis. A wide range of instrumentation including a flight qualified 32-channel data acquisition system and appropriate dynamic and loads sensors are available.

Environmental Testing
A variety of test facilities is available for a broad range of environmental requirements including thermal testing to temperatures ranging from –40 to +350°C and up to 98% humidity, shaker tests up to 27kN capacity with sine and random vibration and limited shock capability, as well as dust/sand/rain and moisture ingress and salt/fog tests. Testing can be carried out to a variety of standards, including AS, ASTM, MIL STDs (810E), ISO and DEF-STAN. Tests can also be performed to individual specifications.

Satellite System Design & Supply
With its experience in space projects, Vipac has the capability to design, build, and operate micro-satellites to suit clients’ requirements. A range of infrastructure and modelling tools support the development and test process, including operations control and power modelling software. These contribute to other space development programs such as multi-level environmental data products and the Greenhouse Gas Monitor (GGM™), to map global distribution of atmospheric CO2.