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May 16, 2006

Integrated Shipbuilding Environment 4 (ISE 4) Demonstration Overview Presentation for Seattle NSRP Panel Meetings. May 16, 2006. Ron Wood. Burt Gischner. Agenda. Product Data Interoperability Overview Dan Billingsley, NSRP Program Manager, NAVSEA 05DM

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May 16, 2006

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  1. Integrated Shipbuilding Environment 4 (ISE 4)Demonstration OverviewPresentation for Seattle NSRP Panel Meetings May 16, 2006 Ron Wood Burt Gischner

  2. Agenda • Product Data Interoperability Overview • Dan Billingsley, NSRP Program Manager, NAVSEA 05DM • Pete Halvordson, Vice President, Engineering, GD Electric Boat • Rick Self, NSRP Executive Director, ATI Corporation • ISE Project • Overview/Background of ISE • ISE 4 • Live Demonstration This is only a recap of a 2.5 hour slide & live demo done in Washington on April 27th. Full content of presentation is available on http://www.isetools.org

  3. Attendees • Total Qty: appx 50 • Navy Qty: 16 including Senior Navy attendees: • Deputy PEO Subs (McNamara), • 2 PEO Ships Deputies (Art Divens and Al Weyman) • NAVSEA 08 rep • Howard Fireman (SEA05D) • RAN Representative

  4. The Problem Addressed • While credited with major reductions in design and manufacturing cost, IPDEs pose a significant software development / integration challenge and expense. • IPDE cost for a major ship or submarine construction program can total $150M to $200M, of which 45-55% is for integration planning, information engineering and interface software development. • Typically each ship or submarine program develops an IPDE to take advantage of latest hardware and software and to suit • program requirements, • team member work practices, and • team member business relationships • Interoperability among components has been achieved by ad-hoc and proprietary interfaces resulting in: • Duplication of development effort, • 8-10 partially integrated systems that are not interoperable with others, • Annual integration expenses of $10M-$30M for each major program, • Multiple incompatible systems at each shipyard, and • Numerous inconsistent sources of product information for Navy engineering and service life support.

  5. The Problem (con’t) • Information technology ages quickly - access to vital product data becomes problematic early in the ships life cycle • Managing the Cost and Risk of Computer Systems Development – IDE / IPDE / PLM • The development of these systems represents a significant investment in time and money • It can represent a significant amount of Program risk • Interoperability of disparate systems remains a significant challenge

  6. Shipbuilders’ 3D CAD Systems by Program by CAD system

  7. Business Drivers for Interoperability • Across organizations • Co-production / Co-design - more flexibility in teaming & 2nd sourcing. • Acquisition programs can re-use engineering tools and data management components developed by preceding programs. • Expedited review of shipbuilder designs by government engineering agents. • Enable common methods of handling product data for service life support • Within shipyards • Components can be upgraded or replaced without major disruption or redevelopment of the rest of the IPDE infrastructure – yielding improved flexibility, improved leverage with vendors and reduction of recurring cost. • Third-party capability can be introduced in specific areas including discipline-focused software developed by ABS, ONR, DARPA, academia and industry. • Reduce/eliminate need for multiple IPDE’s within a single yard.

  8. Information interoperability lifecycle Roles Well-Defined Solution Path –- much progress -- $17M to complete Standard Development Standard Approved ISO Technology Information Model Prototype Translators Testing Framework NSRP Contractual Specification NAVSEA Business Decisions Deployment, integration, testing NAVAL PROGRAM Information interoperability specification Requirements definition Production deployment Phases:

  9. Interoperability Status Substantially complete Shared Concept of Information Content and Relationships STEP Substantially complete XML Exchange Format Spec Prototyped by NSRP Native A Native B T T Contract Terms Negotiated program by program Acquisition Policy DoN Policy Memo Oct 2004

  10. ISE Background • First NSRP major systems technology project • Phase 1: Requirements definition and architecture for shipbuilding systems interoperability • March 1999 to December 1999 • Phase 2: Deployment for Structure & Piping • March 2000 to December 2003 • Phase 3: Deployment for HVAC & CPC Interfaces • October 2003 to October 2004 • Phase 4: Current Project • Deployment of Ship Compartmentation • Deployment for Engineering Analysis • Prototype for Electrical • Prototype, Steel Processing with Rules Processing • April 2005 to July 2006

  11. ISE Project Approach • Develop and demonstrate tools that are low cost • can be selectively used by shipyards to support interoperability • capitalize on XML and related Internet technologies • Flexibility is critical • allow shipyards to transform their data to/from common information model • Drive development of international shipbuilding product data standards (e.g. STEP, PLIB) • Construct a single Shipbuilding Information Model • Demonstrate and educate U.S. shipbuilding community • Now approved international standards

  12. ISE Architecture • Accessible to large and small shipyards • Only system dependency is Web infrastructure • Utilizes open standards • Innovative integration of STEP and XML technologies • Supports sharing of geometry & geometric product models • Permissive (mediation) architecture • Lets each enterprise choose its own tool set • Incorporated into CAD platforms used by U.S. shipbuilders ISE architecture represents an innovative, practical solution to the information interoperability challenge

  13. The Navy and Shipbuilders Are Using Product Model Data Technology Product Model Data = 3-D CAD + definitions + other documentation Continued investment is key indication of value

  14. The ISE Test Ship - TWR 841 This ship is used to locate and retrieve torpedoes and missile drones. It has a maximum payload capacity of 42 long tons which includes the deck cargo plus full liquids, full complement, and normal stores. This ship was selected because it is in-service, has a complete set of drawings available for distribution, and is: Approved for Public Release: Distribution Unlimited.

  15. Team Participants

  16. ISE2 Demonstration

  17. ISE3 Demo Overview

  18. DONXML • The Department of Navy (DON) vision for Extensible Markup Language (XML) is to fully exploit XML as an enabling technology to achieve interoperability in support of maritime superiority • For cataloging product data in XML format, the DONXML working group has agreed to allow the STEP Schemas developed under the ISE Project to be registered in the DONXML repository. Schemas registered to date: • Ship Moulded Forms (AP216): 2 Use cases • Ship Structures (AP218): 2 Use Cases • Piping (AP227): 2 Use Cases • HVAC (AP227): 1 Use Case • Common Parts Catalog: 1 Use Case • ISE4 Schemas will be registered

  19. ISE Product Model Prototyping

  20. Presentation Agenda • Interoperability Demo Scenario • Ship Arrangements Exchanges using AP215 and AP216 • Initial Design in TRIBON • Transfer from TRIBON to LEAPS • Modifications in FORAN • Transfer from FORAN to LEAPS (and ISDP) • Transfer from ISDP to Intelliship • Electrical Demonstration using AP212 • Engineering Analysis Exchanges using AP218 and AP209 • Steel Processing Exchanges using AP218

  21. Demo will Feature Product Model Data from the TWR Engine Room ISE4: Arrangements Engineering Analysis Electrical Design Steel Processing TWR 3D Product Model Geometry Engine Room

  22. Demo Scenarios for the Four ISE4 Tasks Manufacturing Detail Design Initial Design Lifecycle Support Engineering FEA Analysis Steel Processing Electrical Four Tasks and Demonstrations Arrangements Concept & Preliminary Design Stage Detail Design Stage

  23. Systems Involved in the Interoperability Demo Initial Design Detail Design Manufacturing Lifecycle Support Concept & Preliminary Design Steel Processing Engineering FEA Analysis Electrical ADAPT Feed Mfg from ISDP KSS/KM AP212 P21 EBC AP209 P21 A AP212 P28 Preliminary Arrangement Modify Arrangement AP218 P28 C Partnership Yard GDEB NGSS Repair Shipyard AP218 P28 Atlantec Sener Intergraph B AP215 P28 INTELLISHIP TRIBON FORAN ISDP AP215 P28 Approval Suggest Design Changes B AP215 P21 Final Product Model Delivered to Navy Submit Design AP215 P21 Arrangements Submit Design For Approval LEAPS Navy Response Center Detail Design LEAPS Navy Analysis Programs Engineering Analysis Key: = Mediators Required = Demonstrated = Not Demonstrated

  24. Ship Arrangements Demo Details Initial Design Detail Design Manufacturing Lifecycle Support Concept & Preliminary Design Preliminary Arrangement Modify Arrangement Partnership Yard Repair Shipyard Atlantec Sener B AP215 P28 INTELLISHIP TRIBON FORAN ISDP Intergraph AP215 P28 Approval Suggest Design Changes B AP215 P21 Final Product Model Delivered to Navy Submit Design AP215 P21 Arrangements Submit Design For Approval LEAPS Navy Response Center Detail Design LEAPS Navy Analysis Programs Engineering Analysis Key: = Mediators Required = Demonstrated = Not Demonstrated

  25. Integrated Shipbuilding Environment Arrangements Demonstration Washington DC • April 27, 2006

  26. Demo Scenario – Tribon Translator Translation Process – High Level Tribon Initial Design Tribon Output Files Atlantec AP215 Translator STEP / XML AP 215 File Mediators STEP AP 215 File FORAN LEAPS

  27. Overview – LEAPS AP215 Translators Product Data Services Corporation (PDSC) for NSWC Carderock Division • Project accomplishments: • Developed STEP AP215 Import and Export Translators for • Navy LEAPS system. • PDSC is ISO Editor of STEP AP215.Provided AP215 documents, • ARM/AIM EXPRESS schemas, and training/consulting to ISE team. • Developed and maintained ISE AP215 Implementation Agreements and • Issues Logs for ISE Team. • Submitted 20 SEDS (Standard Enhancement and Discrepancy System) • to ISO for inclusion in next version of ISO AP215 standard.

  28. Overview – LEAPS AP215 Translators LEAPS – LeadingEdgeApplicationforPrototypingSystems • Central Navy Repository for Ship design and analysis. • Developed and supported by NSWC Carderock Division. • Common database for 3D Product Model Data and Analysis results for new Ship Acquisition. • Direct translators from ASSET for initial arrangements and to NAVSEA analysis software for performance and vulnerability assessments.

  29. Overview – LEAPS AP215 Translators LEAPS – LeadingEdgeApplicationforPrototypingSystems

  30. Demo Scenario – FORANTranslator Preliminary Design done in TRIBON has been transferred to LEAPS for Navy review and suggestions for design changes are forwarded to shipyard using FORAN who will perform Detail Design Detail Design in FORAN SENER AP215 Translator STEP AP 215 File LEAPS for Customer Review and Approval ISDP used by Partnering Shipyard

  31. SENER - FORAN AP215 – SHIP ARRANGEMENTS Decks and Bulkheads Details Hull Forms FORANShip Arrangements FORAN – ISE4 Import STEP Translator Detailed Design FORAN – ISE4 AP215 STEP Translator TRIBON - LEAPS Selective STEP Export to LEAPS ( P21 AP215-AIM STEP FILE) List of Ship Spaces Zones Spaces Deck zones

  32. Overview – Transfer to Life Cycle Support • Transfer construction product model to Life Cycle Support for • Engineering support • Onboard applications • Distance support • Maintenance aids • Analysis tools • Decision support / simulation • Logistics support • Typical deliverables are drawings / documents • Must be re-converted to electronic data • Manual, labor intensive, incomplete process • Integrated Product Model often lost • ISE information models designed to interoperate and preserve integrated product model • Supports automated, complete process

  33. As-Is Process –Transfer to Life Cycle Support Neutral File Geometry (IGES, STEP, ACIS, DXF) Or Drawings Molded Form Modeler C&A Drawings Arrangements Modeler Structural Drawings Structural Modeler Equipment Arrangement Drawings Equipment Modeler Manual, labor intensive & often incomplete process Life Cycle Support System Integrated Construction Product Model

  34. ISE Process –Transfer to Life Cycle Support AP 216 Molded Form Data AP 215 Arrangements Data ISE Translators AP 218 Structural Data ISE Translators AP 227 Equipment Data Highly automated, integrated, complete process Life Cycle Support System Integrated Construction Product Model Integrated Life Cycle Product Model

  35. Demo Scenario–Transfer to Life Cycle Support AP 215 Arrangements Data ISE Translators ISE Translators ISE exchanges interoperate &preserveproduct model Previous exchange AP 216 Molded Form Data ISDP:Integrated Ship Design & Production IntelliShip AP 218 Structural Data Integrated Construction Product Model Integrated Life Cycle Product Model AP 227 Equipment Data Compartments created using existing molded forms

  36. Electrical Demo Details Initial Design Detail Design Manufacturing Lifecycle Support Concept & Preliminary Design Steel Processing Engineering FEA Analysis Electrical KSS/KM AP212 P21 A AP212 P28 Preliminary Arrangement Modify Arrangement Repair Shipyard Intergraph ISDP Arrangements Detail Design Key: = Mediators Required = Demonstrated = Not Demonstrated

  37. Project Objectives • Exchange and ARCHIVE electrical shipbuilding data using STEP AP212 (developed by the auto industry). • Adopt XML to exchange STEP data. • Lay the groundwork to exchange data between CAD and knowledge-based software systems using STEP. • Leverage existing initiatives in the industry (STEP Part 21, STEP Part 28, STEP AP212, and the Navy XML repository). • Publish project results.

  38. Knowledge Systems Solutions Knowledge management products and expert system software * Navy (SPAWAR) C4ISR Ship Shore Installation Design Tool (SSIDT) KSS KnowledgeManager Product to create user-defined knowledge bases * * Air Force (OC-ALC) SBIR Knowledge-based reverse engineering & automatic creation of 3D CAD models Navy (NAVSEA) SBIR Knowledge-based retention of shipbuilding expertise * Transition of NSRP STEP translator technology

  39. Spiral Development Knowledge-based system  STEP XML AP212 Design Configurator Single C4ISR Equipment Generic Objects Single C4ISR Circuit Framework Design Full Engineering & Design Data Sets Navy Air Force Integrated Prototype Commercial System Spec Full C4ISR System TWR Lighting TWR Power Distribution Component Design File Data Import STEP – Data – Translator

  40. Knowledge Management Demonstration • TWR Power Distribution System • Collect data and information into a knowledge base • Perform calculations and design functions

  41. Electrotechnical Results • Developed Component Design Framework for data translation and archival using STEP AP212. • Knowledge Management (knowledge & rules) • Engineering Data (results) • Created reusable STEP toolsets (mediator stylesheets) for DoN repository. • Tested AP212 with diverse electrotechnical test cases. • Demonstrated the joint use of STEP and XML with new programming resources.

  42. Electrotechnical Future • Continued joint service implementation and benefit. • ISE4 follow-on project • Facilitates detailed engineering along with early conceptual electrical engineering. • Integrates knowledge management with 2D and 3D CAD via STEP formatted files. • Automatically generate knowledge bases from existing CAD data elements.

  43. Engineering Analysis Demo Details Initial Design Detail Design Manufacturing Lifecycle Support Concept & Preliminary Design Engineering FEA Analysis Steel Processing Electrical ADAPT EBC EBC AP209 P21 XSLTs AP218 P28 ISDP NGSS, Intergraph NGSS, Intergraph Arrangements Detailed Design Stage Detail Design

  44. ISE-4 Engineering Analysis Project

  45. AP218: Ship Structures L

  46. AP209: Composite & Metallic Structural Analysis & Related Design • Analysis Discipline Product Definitions • Finite Element Analysis • Model (Nodes, Elements, Properties,...) • Controls (Loads, Boundary Constraints,...) • Results (Displacements, Stresses,...) • Analysis Report • Information Shared Between Analysis & Design • 3D Shape Representations • Composite Constituents • Material Specifications & Properties • Part Definitions • Composite Constituents • Ply Boundaries, Surfaces • Laminate Stacking Tables • Reinforcement Orientation • Design Discipline Product Definition • Shape Representations • Assemblies • Material Specifications & Properties • Composites • Homogeneous (metallics) • Configuration Control, Approvals • Part, product definitions • Finite element analysis model, controls, and results • 3D Shape Representation • AP202/203 Commonality Plus Composite Specific 3D Shapes • Advanced B-Representation • Faceted B-Representation • Manifold Surfaces With Topology • Wireframe & Surface without Topology • Wireframe Geometry with Topology • Composite Constituent Shape Representation R

  47. TWR Engine Room Twin Caterpillar Diesel Propulsion Engines Engines are Supported on Outboard and Inboard Girders Fuel Oil Tank Top R

  48. TWR Engine Room Partial Design Change - Additional Brackets Inserted at FR 17 & FR 19 Selected TWR Engine Room Solid Model Geometry with Port Caterpillar Engine L

  49. TWR Engine Room Selected TWR Engine Room Solid Model Geometry with Port Caterpillar Engine R

  50. Demo Geometry in ISDP TWR Engine Room Fuel Oil Tank & Engine Support Structure Shown in Intergraph’s ISDP Software Port-Side Outboard Girder - Solid Model Geometry for Analysis L

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