ISE3 - HVAC Project
Development of ISE Interoperability
Modules
Final Demonstration
Washington, D.C.
October 21, 2004
1
Agenda
• ISE Project Overview
• Interoperability and Integration
• Common Parts Catalog (CPC)
• Navy Vision
• Highlights of ISE2 Demo - April 10, 2003
• Overview of TWR841 Test Ship
• ISE3 - HVAC Demo
• Return on Investment
2
ISE3 Team Participants
Gulf Coast Region University of
Maritime Technology Center New Orleans
3
Other Team Members
from ISE2 Project
• American Bureau of Shipping (ABS)
• Altarum
• Anteon Corporation (Proteus)
• Marine Machinery Association (MMA)
• Naptheon
• Northrop Grumman Ship Systems Avondale Operations
• Northrop Grumman Newport News
• University of Connecticut
4
ISE Builds tools to Support
2nd Generation IPDE
First Generation Integrated Product Development
Environment (IPDE)
Digital
Virtual Product
& Process
Collaborative
Design-Build
MOCKUP
3D Design
Electronic
DRAWING
• Data Config. Mgmt.
• 3D
• 3D Visualization
Wireframe/Solids
(Polygonal)
• Computer-Aided
• Rudimentary Data
Drafting
Mgmt
• Desktop
Visualization
• Business Process
Modeling
• Interactive
Walkthrough
• Integrated
Design/Build
Process
• Anthropomorphic
Modeling
• Sophisticated
Eng.Analysis
Digital Ship Design Process Evolution
• Enhanced Product
Model
• Lean Design
• Rule Based Design
• Internet
Technologies
• Remote
Collaboration
• Intensive
Simulations
• High-end Integrated
Analysis
• Simulation Based
Design
2nd Generation
IPDE 5
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
6
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
7
ISE Architecture
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 geometric & geometric product
models
• Permissive (mediation) architecture
– Lets each enterprise choose its own tool set
• Incorporated into CAD platforms used by U.S.
shipbuilders
8
Levels of Interoperability
Inter-business
system domain
Shipyard A
Shipyard B
ERP/CAM
ERP/CAM
Intercomponent
Intercomponent
PDM/CAD
PDM/CAD
Inter-System
Inter-System
Parts
Library
Parts
Library
IDE
INTOP
IDE
9
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”
10
11
NAVSEA Vision of “One Shipyard”
11
11
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
12
Integration Strategy
• STEP (Standard for Exchange of Product
Model Data)
– Is a good common language for CAD Product
Models
• XML (Extensible Markup Language)
– Is good for CAE applications
• Therefore, combine the two, and embed
small strings of STEP into XML, based on
industry agreements, such as ISE
13
XML + STEP = Ideal Combo
• XML brings:
– Accepted format/schema method
– Web-enabled
• STEP brings:
– Standards for data expression
– Standards for geometric exchange
Leverages development of interfaces
14
XML and STEP
Transactions of Data Packaged in Standards
Company
A
Virtual
Ship
part(s)
XML = Industry Standard
Container for Data
STEP = ISO Standard
Language for Data*
Standards
Company
B
Data
XSLT - map data to another XML schema
15
Product Configuration : AP203
Shipbuilder Parts : PLIB
Structural
Analysis: AP209
: AP209
Structural
Analysis
HVAC
: AP227
Cable
harness
design ed.2
: AP212
Ship
Arrangement :: AP
AP215
ShipArrangement
Ship
Forms: AP
: AP216
ShipMoulded
MouldedForms
Ship
ShipStructures
Structures :: AP218
AP
Ship
Machinery:
AP227
Ship
Machinery:
AP ed.2
Process
ProcessPlant
PlantPiping:
Piping:AP227
AP
Technical Data Package : AP232
System Engineering : AP233
Shipbuilding Product Data
in STEP
and
System Product Definition Analysis / Simulation Results
Delivery
16
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
17
Endorsement from
Northrop Grumman
"The development and testing of international
standards for product data is important to the
Shipbuilding industry for interoperablility and
data archiving which will enable NAVSEA's
"One Shipyard" Concept."
Dave Whiddon
VP Research, Development & Design
Northrop Grumman Ship Systems
18
Endorsement from
Electric Boat
"Electric Boat endorses the development of
interoperability tools and the use of
international standards for product model
exchange in the shipbuilding industry. We
feel that these efforts (undertaken under the
NSRP ASE Program) will enhance
collaboration among U.S. shipyards and
foster the Navy's goal of "One Shipyard".
Millard Firebaugh
VP-Innovation and Chief Engineer
Electric Boat Corporation
19
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
20
ISE Tools
• Tools developed by the ISE Project are made
available on the Web at: www.isetools.org
• These include:
– Formal information requirements published
•
•
•
•
Ship Piping
Ship Structures
Ship HVAC
CPC Interfaces
– Translator generators for custom representations
– XML schema generators
• ISO 10303-28 ed 2
– Automated test frameworks for conformance testing
21
NAVY Ships are a
Highly Complex Product
SSBN
12,000,000 HRS
1,000,000 PARTS
18,750 TONS
SSN
BOEING 777
FIGHTER
AIRCRAFT
LAND VEHICLE
8,000,000 HRS
950,000 PARTS
6,900 TONS
50,000 HRS
103,000 PARTS
254 TONS
MISSILE
5,500 HRS
14,000 PARTS
65 TONS
1,700 HRS
5,000 PARTS
1.6 TONS
AUTOMOBILES
57,000 HRS
30,000 PARTS
10 TONS
INCREASING
COMPLEXITY
23 HRS
3,000 PARTS
1.9 TONS
Labor Hours
0
10
20
30
40
50
60
Parts
Weight
70
80
MANUFACTURING TIME (MONTHS)
22
Roadmap - Past
Ship Product Model Data Exchange
ISO TC 184/SC 4/WG 3
AP 233 Systems Engineering Data
Representation
AP 239 Product Life-cycle Support
Ship Structural
Envelope
Distribution Systems
Piping
Ship Arrangement
ISO AP 215:2004
(Plant Spatial Configuration)
Ship Moulded Forms
ISO AP 216:2003
(Plant Spatial Configuration)
Ship Structures
ISO AP 218:2004
(Plant Spatial Configuration)
ISO AP 227:2001
HVAC
ISO AP 227 Edition 2
Equipment/Subsystems
Parts Library
ISO 13584
Finite Element
Analysis
ISO AP 209:2001
Reference Data
Libraries
ISO 15926
Computational Fluid
Dynamics
ISO AP 237
Cable Trays
Logistics/Spares
ISO AP 232:2002
ISO AP 227 Edition 2
Mechanical Systems
(Plant Spatial Configuration)
ISO AP 227 Edition 2
Electrical
(Electrotechnical Design & Install)
ISO AP 212:2001
Miscellaneous
•Ship Structural Envelope
(hull form, arrangements,
structure)
•Distributed Systems
(piping, electrical, HVAC,
cable trays, mechanical)
•Equipment/Subsystems
Automotive
ISO AP 214:2001
23
Roadmap - Present
Ship Product Model Data Exchange
ISO TC 184/SC 4/WG 3
AP 233 Systems Engineering Data
Representation
AP 239 Product Life-cycle Support
Ship Structural
Envelope
Distribution Systems
Piping
Ship Arrangement
ISO AP 215:2004
(Plant Spatial Configuration)
Ship Moulded Forms
ISO AP 216:2003
(Plant Spatial Configuration)
Ship Structures
ISO AP 218:2004
(Plant Spatial Configuration)
ISO AP 227:2001
HVAC
ISO AP 227 Edition 2
Equipment/Subsystems
Parts Library
ISO 13584
Finite Element
Analysis
ISO AP 209:2001
Reference Data
Libraries
ISO 15926
Computational Fluid
Dynamics
ISO AP 237
Cable Trays
Logistics/Spares
ISO AP 232:2002
ISO AP 227 Edition 2
Mechanical Systems
(Plant Spatial Configuration)
ISO AP 227 Edition 2
Electrical
(Electrotechnical Design & Install)
ISO AP 212:2001
Miscellaneous
•Ship Structural Envelope
(hull form, arrangements,
structure)
•Distributed Systems
(piping, electrical, HVAC,
cable trays, mechanical)
•Equipment/Subsystems
Automotive
ISO AP 214:2001
24
Roadmap - Future
Ship Product Model Data Exchange
ISO TC 184/SC 4/WG 3
AP 233 Systems Engineering Data
Representation
AP 239 Product Life-cycle Support
Ship Structural
Envelope
Distribution Systems
Piping
Ship Arrangement
ISO AP 215:2004
(Plant Spatial Configuration)
Ship Moulded Forms
ISO AP 216:2003
(Plant Spatial Configuration)
Ship Structures
ISO AP 218:2004
(Plant Spatial Configuration)
ISO AP 227:2001
HVAC
ISO AP 227 Edition 2
Equipment/Subsystems
Parts Library
ISO 13584
Finite Element
Analysis
ISO AP 209:2001
Reference Data
Libraries
ISO 15926
Computational Fluid
Dynamics
ISO AP 237
Cable Trays
Logistics/Spares
ISO AP 232:2002
ISO AP 227 Edition 2
Mechanical Systems
(Plant Spatial Configuration)
ISO AP 227 Edition 2
Electrical
(Electrotechnical Design & Install)
ISO AP 212:2001
Miscellaneous
•Ship Structural Envelope
(hull form, arrangements,
structure)
•Distributed Systems
(piping, electrical, HVAC,
cable trays, mechanical)
•Equipment/Subsystems
Automotive
ISO AP 214:2001
25
ISE2 Demo Storyboard
April 10, 2003
FlagShip
SafeHull 7b
7a
2
1
IntelliShip
5
3
LEAPS
Foran
6
4
CAE
9
CAM
Database Deliverables
ST-Viewer
Pipe
Stress
Tribon
Tribon
SIMSMART
Parts Lib
CATIA
CATIA
Supplier
CAM
(IPT)
AutoCAD
26
ISE Process - Detail Piping Design
Demonstration on April 10, 2003
CATIA
V5
ISE
Tribon
M2
27
ISE Process for Feeding Analysis
Programs from Structural Design
Atlantec
TRIBON
Intergraph
ISDP
Intergraph
IntelliShip
28
Common Parts Catalog
(CPC) Interfaces
• Developed formal information for
– CPC parts data
– CPC documents
• Basis for sharing parts data outside the CPC
community
• Specification of parts information
requirements between Navy and shipbuilders
– DONXML repository (in progress)
29
Integrated Shipbuilding Environment
HVAC Demonstration
Washington DC • October 21, 2004
Simsmart
30
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.
21 Oct. ‘04
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.
31
3
TWR Walkthrough
myShipVi
Selective
HVAC
STEP
Export
TWR
IDE
• Utilize ship CAD geometry data where possible
• Access ship data in multiple systems
• Technology leverages ISE XML schemas
• Technology will be deployed on LPD 17-20
32
Business Case
Concept Design
Analysis
Initial Design
Parts
Contract Design
Teaming Shipyard
Detailed Design
Manufacturing
33
ISE3 Demo Overview
Parts
(CPC)
Analysis
(Simsmart ™)
Teaming Shipyard
Detailed
Design
(FORAN)
Order Material
Legend
demonstrated
discussed
Initial HVAC
Design
(ISDP)
Detailed
Design
Tool 1
(TRIBON)
Parts
(CPC)
Parts
(CPC)
Analysis
Detailed
Design
Tool 2
(CATIA)
Manufacturing
(EB Sheet Metal)
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing
34
Initial Design – Part 1
Parts
CPC
(CPC)
Analysis
(Simsmart ™)
Teaming Shipyard
Shipyard
Detailed
Design
(FORAN)
OrderMaterial
Material
Order
Legend
demonstrated
discussed
Initial
Initial HVAC
Design
(ISDP)
Detailed
Design
Tool 1
(TRIBON)
Parts
CPC
(CPC)
Parts
CPC
(CPC)
Analysis
Detailed
Design
Tool 2
(CATIA)
Manufacturing
Manufacturing
(EB Sheet Metal)
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing
35
Initial Design - Part 1
ISDP
Selective
HVAC
STEP
Export
STEP file
ISDP ISE HVAC
Translator
ISE
XML
Analysis
(Simsmart ™)
36
Initial Design Analysis
Parts
(CPC)
Analysis
(Simsmart ™)
Teaming Shipyard
Detailed
Design
(FORAN)
Order Material
Legend
demonstrated
discussed
Initial HVAC
Design
(ISDP)
Detailed
Design
Tool 1
(TRIBON)
Parts
(CPC)
Parts
(CPC)
Analysis
Detailed
Design
Tool 2
(CATIA)
Manufacturing
(EB Sheet Metal)
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing
37
HVAC Design &
Performance Analysis
38
Common Parts Catalog
Parts
(CPC)
Analysis
(Simsmart ™)
Teaming Shipyard
Detailed
Design
(FORAN)
Order Material
Legend
demonstrated
discussed
Initial HVAC
Design
(ISDP)
Detailed
Design
Tool 1
(TRIBON)
Parts
(CPC)
Parts
(CPC)
Analysis
Detailed
Design
Tool 2
(CATIA)
Manufacturing
(EB Sheet Metal)
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing
39
Common Parts Catalog
40
Initial Design – Part 2
Parts
(CPC)
Analysis
(Simsmart ™)
Teaming Shipyard
Detailed
Design
(FORAN)
Order Material
Legend
demonstrated
discussed
Initial HVAC
Design
(ISDP)
Detailed
Design
Tool 1
(TRIBON)
Parts
(CPC)
Parts
(CPC)
Analysis
Detailed
Design
Tool 2
(CATIA)
Manufacturing
(EB Sheet Metal)
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing
41
Initial Design - Part 2
ISDP
Selective
HVAC
STEP
Export
STEP file
Updated
Plenum
ISDP ISE HVAC
Translator
ISE
XML
Detailed Design
(TRIBON)
42
Importing into Tribon
(Atlantec)
Parts
(CPC)
Analysis
(Simsmart ™)
Detailed
Design
Tool 1
(TRIBON)
Teaming Shipyard
Detailed
Design
(FORAN)
Order Material
Legend
demonstrated
discussed
Initial HVAC
Design
(ISDP)
Parts
(CPC)
Parts
(CPC)
Analysis
Detailed
Design
Tool 2
(CATIA)
Manufacturing
(EB Sheet Metal)
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing
43
Export to Foran (Atlantec)
Parts
(CPC)
Analysis
(Simsmart ™)
Detailed
Design
Tool 1
(TRIBON)
Teaming Shipyard
Detailed
Design
(FORAN)
Order Material
Legend
demonstrated
discussed
Initial HVAC
Design
(ISDP)
Parts
(CPC)
Parts
(CPC)
Analysis
Detailed
Design
Tool 2
(CATIA)
Manufacturing
(EB Sheet Metal)
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing
44
Teaming Yard
Detailed Design
Parts
(CPC)
Analysis
(Simsmart ™)
Teaming Shipyard
Detailed
Design
(FORAN)
Order Material
Legend
demonstrated
discussed
Initial HVAC
Design
(ISDP)
Detailed
Design
Tool 1
(TRIBON)
Parts
(CPC)
Parts
(CPC)
Analysis
Detailed
Design
Tool 2
(CATIA)
Manufacturing
(EB Sheet Metal)
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing
45
Teaming Shipyard
Returns Part
FORAN
FORAN TWR’s
Preliminary
Design (ISE2)
FORAN TWR’s
Structural Detailed
Design (ISE2)
TWR’s HVAC Detailed Design
Selective
HVAC
STEP
Export
ISE3
FORAN HVAC
STEP Export
Translator
ISE3
P21 STEP file
OUTPUT
46
Teaming Shipyard
Returns Part
FORAN
Database
FORAN
HVAC STEP
Import Translator
ISE3
P21 STEP file
INPUT
FORAN
HVAC STEP
Export Translator
ISE3
OUTPUT
P21 STEP file
47
Import into Tribon
Parts
(CPC)
Analysis
(Simsmart ™)
Detailed
Design
Tool 1
(TRIBON)
Teaming Shipyard
Detailed
Design
(FORAN)
Order Material
Legend
demonstrated
discussed
Initial HVAC
Design
(ISDP)
Parts
(CPC)
Parts
(CPC)
Analysis
Detailed
Design
Tool 2
(CATIA)
Manufacturing
(EB Sheet Metal)
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing
48
Transfer to Manufacturing
Parts
(CPC)
Analysis
(Simsmart ™)
Teaming Shipyard
Detailed
Design
(FORAN)
Order Material
Legend
demonstrated
discussed
Initial HVAC
Design
(ISDP)
Detailed
Design
Tool 1
(TRIBON)
Parts
(CPC)
Parts
(CPC)
Analysis
Detailed
Detailed
Design
Tool 2
(CATIA)
Manufacturing
(EB Sheet Metal)
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing
49
Manufacturing
Parts
(CPC)
Analysis
(Simsmart ™)
Teaming Shipyard
Detailed
Design
(FORAN)
Order Material
Legend
demonstrated
discussed
Initial HVAC
Design
(ISDP)
Detailed
Design
Tool 1
(TRIBON)
Parts
(CPC)
Parts
(CPC)
Analysis
Detailed
Design
Tool 2
(CATIA)
Manufacturing
(EB Sheet Metal)
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing
50
Electric Boat HVAC
Demo Scenario
CATIA V5
STEP
FILE
Generate
Manufacturing
Parameters
Common
Parts
Catalog
CATIA V4 / CDM
Manufacturing
Process
Manufacture Part
51
EB Manufactures
Test Case 4
ELBOW
H = 4”
W = 6”
Rin = 4”
Rout = 12”
DUCT
H = 4”
W = 6”
L = 86””
TRANSITION
H1 = 4”
W 1 = 6”
H2 = 3”
W 2 = 12”
L = 12”
Revised Duct for Demo
H = 4”
W = 6”
L =12”
52
Return on Investment
(ROI)
• Professor Alley Butler of the Gulf Coast
Region Maritime Technology Center
(GCRMTC) and the University of New
Orleans is conducting a Return on
Investment Analysis as part of the ISE3
Project
• Although his study has not yet been
completed, the following slides give some
early results from his analysis
53
HVAC Data Exchange ROI
• Current estimates point to substantial
savings in engineering manhours by
employing the AP 227 neutral format for
porting information to Simsmart
• Estimates are incomplete, but analysis is in
progress
– Part 1 : Flow Analysis
– Part 2 : Manufacturing
• Additional cost savings are anticipated from
manufacturing implementation
54
Estimating Savings
from an ISE-3 Implementation
• The ISE-3 deliverables for HVAC permit
porting of information from most commonly
used CAD systems to the Simsmart analysis
tool
– This capability should save manhours of
engineering and designer time
– It avoids re-entering data to create the Simsmart
models
• Time is money.
So, how much time and
money is saved?
55
HVAC Data Exchange ROI
• The Cruiser/Destroyer/Frigate Case
– Potential Savings are estimated to be
• 6,903 manhours
• $414,162 for one ship design
56
HVAC Data Exchange ROI
• This preliminary analysis can be extended
to:
– Other classes of ships (e.g. submarines,
carriers)
– Additional systems
• i.e. for auxiliary systems that are not specifically
HVAC, such as engine/generator uptakes
• Additional exchange scenarios (such as
Manufacturing) should also be included in
calculating ROI
57
NIST: Economic Impact Assessment
- Product Data Sharing -
• The Shipbuilding Industry has the opportunity to
realize $147.1M in annual benefits by sharing
product data :
- $76.4M in cost avoidance
◦
◦
◦
◦
Elimination of redundant design, analysis, and manufacturing systems
Training
IT support
Productivity loss
- $70.7M in risk mitigation
◦ Model rework
◦ Manual data re-entry
◦ Delays
• Currently, the Shipbuilding Industry is only
realizing $25.7M in annual benefits.
Source : Planning Report 02-05 December 2002
58
Goal : Implement in Production
•
•
•
The ISE Project has developed tools and demonstrated interoperability
between shipyards in the areas of:
–
–
–
–
Structure
Piping
HVAC
Common Parts Catalog Interfaces
The goal of current and future efforts is to make these techniques and
tools available in production and to all U.S. shipyards
– STEP Shipbuilding Translators
– XML Tools
– Common Parts Catalog Interfaces
A Website has been established to contain the relevant software tools,
schemas, etc. as provided by the ISE Project
– www.isetools.org
59
Summary
• ISE3 has successfully demonstrated the
potential of standards based data exchange
to LEAN design and construction processes
for HVAC as ISE1 and ISE2 had done for
molded forms, structures and piping.
• Two major challenges lie ahead of us:
– Commercialization of this technology
– Continuing to prototype standards based data
exchange in other application areas such as
ships arrangements, ships electrical systems,
and system engineering
60
Conclusions
• In order to increase the availability and
lower the price of production ready tools:
– The ship owner / operator needs to insist that
data be delivered in a system neutral format
– The shipbuilder needs to insist that STEP
functionality be an integral part of product
• The next challenge is to move this
technology into the mainstream and that the
technology is mature enough to transition
into commercial CAD and Product Modeling
products
61
Endorsements
•
The technology works and it is supported by upper
management in major U.S. shipyards
– "The development and testing of international standards for
product data is important to the Shipbuilding industry for
interoperablility and data archiving which will enable NAVSEA's
"One Shipyard" Concept.”
Dave Whiddon
VP Research, Development & Design
Northrop Grumman Ship Systems
– "Electric Boat endorses the development of interoperability tools
and the use of international standards for product model exchange
in the shipbuilding industry. We feel that these efforts (undertaken
under the NSRP ASE Program) will enhance collaboration among
U.S. shipyards and foster the Navy's goal of "One Shipyard".
Millard Firebaugh
VP-Innovation and Chief Engineer
Electric Boat Corporation
62