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Developing an Integrated Shipbuilding Environment for the Ship's Life Cycle

Developing an Integrated Shipbuilding Environment for the Ship's Life Cycle. Presented by : Ron Wood Dr. Burton Gischner January 25, 2006. Agenda. Interoperability Use of STEP and XML Development of STEP for Shipbuilding

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Developing an Integrated Shipbuilding Environment for the Ship's Life Cycle

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  1. Developing an Integrated Shipbuilding Environment for the Ship's Life Cycle Presented by : Ron Wood Dr. Burton Gischner January 25, 2006

  2. Agenda • Interoperability • Use of STEP and XML • Development of STEP for Shipbuilding • Integrated Shipbuilding Environment (ISE) Implementation Projects • Summary

  3. Need for Interoperability

  4. Inter-business system domain Shipyard B Shipyard A ERP/CAM ERP/CAM Inter- component Inter- component PDM/CAD PDM/CAD Inter-System Inter-System Parts Library Parts Library IDE IDE INTOP Levels of Interoperability

  5. Co-design Co-production * Web-based system diagrams * Web-based interop with simulation & analysis * Web-based product model sharing * Browser access to product related documents ISE Maritime Supply Chain Logistics Information Support Integrated Shipbuilding Environment * Web-based supplier catalogs * Shared parts library * Web access to as-planned & design product model Integrated Development Environment * Collaboration best practices * Shipbuilding enterprise components 5

  6. Collaboration among Shipyards is Required in Today’s Environment • Almost every major recent U.S. Navy ship design and/or construction contract has involved collaboration among multiple shipyards • For example: • CVNX (NGNN & EB) • DDX (NGSS - Ingalls & Bath) • Initial LPD Award (NGSS - Avondale & Bath) • VIRGINIA (EB & NGNN) • This trend will continue • Navy views system interoperability as enabling multiple yards to be viewed as “One Shipyard”

  7. Goals of Integration • Better analysis through simulation • Re-use of data instead of redundant data • increased accuracy • eliminates unnecessary checking • speed of data entry (already entered) • Facilitates partnering with other firms • Reduce overhead costs

  8. Data Archiving: STEP Standard Formats Preserve Datafor Future Use Regardless of changes to Hardware, OS or CAD System

  9. Information Interoperability Roadmap

  10. Joel Cawley, the head of IBM's Strategic planning unit, “Standards don't eliminate innovation, they allow you to focus it. They allow you to focus on where the real value lies, which is usually everything you can add above and around the standard” Quote in "The World Is Flat" by Thomas L. Friedman

  11. Development of STEP and XML for Shipbuilding

  12. XML and STEP Transactions of Data Packaged in Standards XSLT - map data to another XML schema Standards Virtual Ship part(s) XML = Industry Standard Container for Data Company A Company B STEP = ISO Standard Language for Data* Data • XML: • Accepted format/schema method • Web-enabling • STEP: • Standards for data expression • Standards for geometric exchange

  13. ISO Shipbuilding – Background • Effort of Shipbuilders, Regulatory Bodies, CAD Software Companies, MOD, DOD from Various countries • 1996 to 1999 U.S. Effort under MariSTEP Project • Funded under DARPA/MARITECH • DARPA (Defense Advanced Research Projects Agency) • Prototyped early versions of AP215, 216, 217 and 218 • Exchanged AP218 data with European SeaSprite Project • Current U.S. effort under NSRP ASE

  14. MariSTEP Project1996 - 1999 First U.S. STEP Shipbuilding Implementation Project ISDP Export: MariSTEP APs 215, 216, 217, 218 GSCAD Import: MariSTEP 218 NAVSEA & NGSS - Avondale Industries ISDP (Intergraph) Import and Export: MariSTEP APs 215, 216, 217, 218 Import and Export: MariSTEP APs 215, 216, 217 Electric Boat Corporation CATIA NGSS - Ingalls Shipbuilding Cvaec Dimension III (CV / PTC / Ciarrai) STEP Northrop Grumman Newport News VIVID NASSCO TRIBON (Kockums Computer Systems) Import and Export: MariSTEP APs 215, 216, 217, 218 VIVID Export: MariSTEP APs 215, 216, 217, 218 GSCAD Import: MariSTEP APs 216, 218

  15. Ship APs Now ISO Standards • AP215, ISO TC184/SC4 10303-215 IS "Application protocol: Ship Arrangement". • available from Geneva or National Standards bodies as ISO 10303-215:2004. • AP216, TC184/SC4 10303-216 IS "Application protocol: Ship Moulded Forms”. • available from Geneva or National Standards bodies as ISO 10303-216:2003. • AP218 ISO TC184/SC4 10303-218 IS "Application protocol: Ship structures". • available from Geneva or National Standards bodies as ISO 10303-218:2004. • AP227 ISO TC184/SC4/WG3 10303-227 IS “Plant Spatial Configuration”. • available from Geneva or National Standards bodies as ISO 10303-227:2005 • Includes all the information needed for the marine industries to exchange information about piping, HVAC and machinery.

  16. 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

  17. Implementation of the STEP Standards

  18. 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: Arrangements, Electrical, Analysis, Steel Processing • January 2005 to April 2006

  19. ISE Team Participants

  20. Collaborative Design-Build VirtualProduct &Process Digital MOCKUP 3D Design Electronic DRAWING • Enhanced Product Model • Lean Design • Rule Based Design • Internet Technologies • Remote Collaboration • Intensive Simulations • High-end Integrated Analysis • Desktop Visualization • Business Process Modeling • Integrated Design/Build Process • Sophisticated Eng.Analysis • Simulation Based Design • Data Config. Mgmt. • 3D Visualization (Polygonal) • Interactive Walkthrough • Anthropomorphic Modeling • 3D Wireframe/Solids • Rudimentary Data Mgmt • Computer-Aided Drafting Digital Ship Design Process Evolution ISE Builds tools to Support 2nd Generation IPDE First Generation Integrated Product Development Environment (IPDE) 2nd Generation IPDE

  21. 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 shipbuilding product data standards (e.g. STEP, PLIB) • Construct a single Shipbuilding Information Model • Demonstrate and educate U.S. shipbuilding community

  22. ISE architecture represents an innovative, practical solution to the information interoperability challenge • 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

  23. The ISE Test ShipTWR 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. 23

  24. ISE-2: Moulded Forms, Structure and Pipe

  25. 1 7b 7a IntelliShip 2 3 4 ST-Viewer 6 19 15 5 8 9 16 18 13 11 10 17 12 14 Demonstration Storyboard April 10, 2003 Structural Detailed Design SafeHull Structural Functional Design FlagShip Foran CAE LEAPS CAM APP Advanced Product Portal Database Deliverables Pipe Stress Piping Functional Design Tribon Tribon SIMSMART Parts Lib Supplier Piping Detailed Design CATIA CAM (IPT) CATIA AutoCAD

  26. Send request via SOAP Web / SOAP Return Hydrostatics results via SOAP View data in Browser Convert to EDO XML AP 216 STEP translator Export Using STEP AP 216 Demo Scenario - Design & Analysis FlagShip reads data, performs hydrostatic analysis User invokes tool through command

  27. Demo Scenario: SENER-FORAN v50STRUCTURAL DETAILED DESIGN and STEP EXPORT Standards Seams & FORAN Preliminary Design Butts Internal structure, TWR ship Hull,Decks FORAN Structural Detailed Design TWR ship’s structure ready to be exported by FORAN-AP218 STEP Export translator Selective STEP Export To ABS To EB Midship Section Calculations Finite Elements Calculations Transverse Bulkheads Whole Structure

  28. ISE Process - Detail Piping Design Demonstration on April 10, 2003 CATIA V5 Tribon M2 ISE

  29. ISE Process for Feeding Analysis Programs from Structural Design Atlantec TRIBON Intergraph ISDP Intergraph IntelliShip

  30. Analysis Tool Electronically invoke analysis services Analysis Results Design Data Electronic format Electronic format 1. Designer requests analysis ISE Process Design & Analysis Interoperable tools Single virtual design & analysis environment User performs design & analysis Design & analysis results both electronic format Design Tool Designer Integrated process of design, analysis, evaluation of analysis on design

  31. Simulation and Modeling of Shipboard Piping Systems

  32. Overview – Piping Functional Design 32

  33. Additional Benefits • Validated As-Built model can be used to: • Validate the design and ensure that all requirements are met • Evaluate different design alternatives • Form a basis for creating an On Board Training System (OBTS) and schoolhouse training system • Evaluate refits and upgrades throughout the lifecycle of the vessel • Validate control system algorithms • Test the control system prior to delivery • Perform manning analyses

  34. ISE-3: HVAC

  35. Washington DC •Integrated Shipbuilding Environment HVAC Demonstration• October 2004

  36. Manufacturing Test Case 4 Revised Duct for Demo H = 4” W = 6” L =12” TRANSITION H1 = 4” W1 = 6” H2 = 3” W2 = 12” L = 12” ELBOW H = 4” W = 6” Rin = 4” Rout = 12” DUCT H = 4” W = 6” L = 86””

  37. ISE-3 HVAC Demo (October 2004) Initial HVAC Design (ISDP) Analysis (SIMSMART) CPC CPC Detailed Design Tool 2 (CATIA) Sister Shipyard Detailed Design (FORAN) Detailed Design Tool1 (TRIBON) Analysis Order Material CPC Manufacturing Legend demonstrated discussed PartsCatalog CAD Tool

  38. ISE-4: Ship Arrangements, Steel Processing, Engineering Analysis and Electrical

  39. ISE-4: New NSRP Project • Awarded – January 2005 • Includes • Ship Arrangements (AP215) • Steel Processing (AP218, 238, 240) • Engineering Analysis (AP209) • Electrical (AP212)

  40. AP215:2004Ship Arrangements Loading conditions • Compartments • types • properties • (shape, • coatings, • adjacency, • access….) • Zone Boundaries • Controlling Access • Design Authority • Cargo Stowage • Machinery Compartments • Crew Occupancy • Common Purpose Spaces • Stability • intact • damaged • Cargoes • assignment to compartments • weight, • centre of gravity General Subdivision of a Ship into Spatially Bounded Regions 40

  41. TWR Compartment Overview Compartment Name Compt # Volume (m^3) Air Handling Room 1-8-3-Q 9.344559387 Ballast Tank #1 2-6-1-V 5.621280313 Ballast Tank #2 1-6-2-V 5.621280378 Ballast Tank #3 2-23-6-V 10.94196403 Ballast Tank #4 1-23-0-F 11.45422363 Bosuns Stores 2-2-0-A 31.1542512 Bow Thruster 2-5-0-Q 29.65740748 Chain Locker 2-2-0-Q 2.128270093 CO State Room 1-5-2-L 15.19818335 CPO State Room 1-5-1-L 15.19818517 Crews Berthing 2-6-0-L 65.55600522 Deck Gear 1-14-3-A 5.256314651 Electrical Room 1-7-1-Q 4.672279696 Engine Room 2-16-0-E 164.4171673 Engine Room Exhaust Trunk 2-15-1-Q 2.803369266 Engine Room Supply Trunk 2-15-2-Q 1.897890198 Forepeak 2-0-0-V 9.703230573 Fuel Oil Tank #1 2-9-1-F 7.47810508 Fuel Oil Tank #2 1-9-2-F 7.47810645 Fuel Oil Tank #3 2-16-0-F 11.87955578 Fuel Oil Tank #4 2-23-2-F 4.791415503 Fuel Oil Tank #5 2-9-1-F 4.572601083 Galley and Mess Area 1-9-0-L 59.46537759 Hold Head 2-10-2-L 20.57645565 Hold Passageway 2-8-0-L 18.1679584 Lazarette 2-25-0-Q 45.19140913 Lazarette Passageway 2-23-0-Q 6.423977119 Linen Locker 2-9-1-A 2.786579543 Lube Oil Tank 2-23-4-F 0.987812699 Main Deck Head 1-7-2-L 7.00841954 Main Deck Passageway 1-7-0-L 6.371290497 Observers Berthing 2-10-1-L 17.82688618 Pilot House 01-6-0-C 45.87356833 Pilot House Passageway 1-9-1-L 4.014929551 Potable Water Tank #1 2-13-1-W 9.928594336 Potable Water Tank #2 2-13-2-W 9.928594336 Provisions Storeroom 2-11-0-A 7.495108964 Pump Room 2-12-0-Q 112.0118041 Pump Room Passageway 2-14-1-Q 3.82277429 Pump Room Supply Trunk 1-14-1-Q 0.424752699 Void 2-2-0-V 3.395942412 Waste Oil Tank 2-15-0-F 0.976931207

  42. Steel Processing Steel Processing Stages Information Models Functions • Moulded Forms & Lines • Preliminary scantlings • Structural systems • Unit Breakdown Scantling Design CAD • Structural Part Definition • Structural Part Relationships • Seams • Features Detailed Design Production Planning • Assembly breakdown • Assembly order • Welds • Bevels • Bending lines 3D Neutral Manufacturing Piece Part Development 2D Neutral Piece Parts • Flat pattern parts • Marking Lines Manufacturing Definition • Shipyard specific parts • Added material • Marking lines, Labeling • Tabs • Manufacturing Aids 2D Shipyard Piece Parts Nesting Drawings & Reports NC

  43. Shop Process/Rules GD-EB NG-SS Weld type Weld symbology E7018 E7018 Weld ref. note Construction Symbol Line Heat Forming Method Roll Girth Tape Box Mold Quality Check Marking Line (Stiffener) Marking Line (Thk throw) … ISE Steel Processing System Overview • Manufacturing definition with explicit geometry • Joint/Edge preparations • End cuts • Added/Removed material • Marking lines • Design definition with ‘neat’ geometry • Connectivity/part relationships and structural hierarchy EB-specific Mfg Data (AP/216/218/238) Steel Processing System NC Nest Production Planning Reports, Dwgs, etc. AP216/ 218 Piece Part Development NG SS-specific Mfg Data (AP/216/218/238) NC Manufacturing Definition CAD Nest Reports, Dwgs, etc.

  44. Generate 2D Nesting Part Objects

  45. Engineering Analysis Task Overview XML Mediation Addresses CAD-CAE Interoperability with Ship APs A Mediation Example from 2003 NSRP ISE-2 Demos STP (Express) Files Interoperability CAE Analysis Tools Ship CAD Tools XSLT XML Files

  46. Engineering Analysis Demo Plans

  47. AP209 Analysis

  48. AP 212:2001 Electrical Design and Installation • Data Supporting • Terminals and Interfaces • Functional Decomposition of Product • 3D Cabling and Harnesses • Cable Tracks and Mounting Instructions • Electrotechnical Systems • Buildings • Plants • Transportation Systems • Electrotechnical Plant • Plant, e.g., Automobile • Unit, e.g., Engine Control System • Subunit, e.g., Ignition System • Equipment Coverage • Power-transmission • Power-distribution • Power-generation • Electric Machinery • Electric Light and Heat • Control Systems

  49. CAD Models & Drawings Engineering Analysis Electrical Task Overview Validates STEP Part 28 AP212 XML Schemas AP212 XML File AP 212 XML Schema Implementa- tion ISO 10303 AP212 AP 212 Data Conversion Reports Databases Knowledge Base Initial XML File Electrotechnical Component Data Interfaces Electrotechnical Data Sources

  50. AP212 Electrical

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