Long Term Retention of Product Model Data TWR-49: Long Term Retention of Product Model Data Paul J. Rakow Naval Surface Warfare Center Carderock Division

Project accomplishments Agenda Project Description Project accomplishments 2009-2011 Objectives Group Discussion Close-out

Why product model information? As DOD acquisition contracts transition from electronic drawing based archive data sets to digital product model data, the respective agencies need to ensure that future users have access to the required data to support the lifecycle of their weapon system. This includes the requirements and issues involved with the: Transition to 3-D geometry in numerous forms and quantities. Aggregation of product models and related data from individual components to complete weapons systems Long-term accessibility and interpretability of the archived digital data by future generations. It will require highly scalable processing mechanisms, international standards, digital engineering data, and other technologies to address NARA’s, DoD’s and the individual service’s critical requirements for preserving and providing access to weapons systems information required for the nation’s security and defense

Origination of the data The design spiral is actually a convoluted path Concept Shipbuilder involvement Design & Construction Core data Commissioning Evaluations & applications of core data 30-70 years In-service Retirement

What types of data? Long Term Data Retention of Weapon System 3-D Geometry engineering properties associative relations analysis data process definition logistics definition manufacturing data work breakdown structure product structure links to M&S links to documentation drawings models photographs manuals

Product model data: Multiple data types Piping Images Not only multiple tools, multiple data types 2D Drawings

Product model data: Multiple data types Piping 3D model

What will we do with it? Research and evaluate through objective measurement, issues related to long-term data retention of large amounts of structured weapons system product data in native and neutral formats.

Stakeholders National Archives and Records Administration (NARA) Primary Interest National Archives and Records Administration (NARA) R&D - Long Term Knowledge retention of product model data for historical data retrieval and governmental reconstitution JEDMICS / NESDR Storage and retrieval of engineering drawings and product model data Defense Logistics Agency (DLA) Use of product model data for weapons system support NAVSEA use of product model data for ships and ships systems evaluation and support Who is interested in this data? JEDMICS is a DoD initiative for the management and control of engineering drawings and related text in a standard repository. NESDR - NAVAL SHIPS ENGINEERING DRAWING REPOSITORY (NSEDR) IS THE CONSOLIDATED NAVSEA ENGINEERING DATA MANAGEMENT AND REPOSITORY SYSTEM FOR U.S. NAVAL SHIPS DRAWINGS. The Defense Logistics Agency (DLA) is DOD's largest combat support agency, providing worldwide logistics support in both peacetime and wartime to the military services as well as several civilian agencies and foreign countries.  DLA headquarters is located at Fort Belvoir in Northern Virginia - With a force of 53,000 civilian, military and contract support personnel, NAVSEA engineers, builds, buys and maintains the Navy’s ships and submarines and their combat systems

Navy Uses for Long Term Retention of Data New Ship Designs Even when revolutionary, large portions are based upon extension of existing designs In-service Operational and Logistical support Repairs USS Cole, USS Intrepid, USS New Orleans and SSN Hartford, etc Decommissioning: Identification of hazardous materials if scrapped, Live Fire Test & Evaluation (LFT & E) analysis and documentation, National Defense Reserve Fleet Why is it important for the Navy to have access to data? USS Cole (Yemen) had engineering analysis and repair BOMs developed before the ship reached Pascagoula USS Intrepid was commissioned in 1943 (66 years ago). In 2006 it was stuck in the mud and the Navy used drawings to determine how to free the ship USS New Orleans (LPD-18) and SSN Hartford (SSN 768) in the Strait of Hormuz in March 2009

Use Cases Assist in the definition of data requirements User case #   001 002 003 004 005 User case name Repair Ship Design new ship Analyze ship Cost analysis of ship Decommission ship Description Designer - @ Navy repair yard / commercial repair yard Needs existing ship data to facilitate repair Designer - new ship class Needs legacy data to derive new design Analyst - Uses Asset/LEAPS to perform Analysis of Alternatives Archived ship becomes parent ship for future class - Compare estimate to actual cost of ship - Use baseline costs to estimate $ of new ship Scrap yard is decommissioning ship Types of Query needed Compartment Discipline System Zone EWBS Materials Originator NSWC RD-NAVAIR 006 007 008 009 010 Historical User Bid for Construction Logistical Support Operation Deployment A private citizen wants to review the info in the National Achieves for historical purposes Shipyard "A" designed the lead ship in the class. Shipyard A, B & C will bid on Construction of follow ships Long Term Support - complete technical specifications for open procurement of all components for the weapon system. This is to include process specifications, material designations and up to date drawings. Operation - operational manuals; operational and periodic maintenance manuals repair parts listing Deployment - requirements for docking, operation, crew stand down, housing, special facilities and any other equipment, structure of operator needs for the ship to be fully operational at a forward deployed port. EWBS Compartment Discipline System Zone Part Number Manufacture Material Criticality Code Cost Shelf Life/Time Change Compartment System Zone Discipline Time Change Repair Parts Compartment System Zone Discipline Technical manuals Structures Equipment Operational Supplies Technical Manuals Facilities Crew Requirements Criticality Codes Classified Needs DLA

Why the TWR 841? This ship is used to assist in sonar tests & locate and retrieve torpedoes and missile drones. This ship was selected for our project because it is in-service, has a complete set of drawings available for distribution, and is: Approved for Public Release: Distribution Unlimited. Before we can determine the requirements for Long Term Retention of Product Model data, we need to have data. We chose the TWR 841 due to its Manageable data set size and complexity

What is the TWR 841? Torpedo Weapons Retriever Characteristics Length overall 120 ft Beam, Max 25 ft. Draft (full load) 7 ft. 5 in. Displacement (full load) 248 LT Displacement (minimum operating load) 221.75 LT Speed 14.7 knots. Engines Two (2) Caterpillar Model 3512 V12 Power 1140 shp at 1800 rpm. Propellers Two (2) manganese bronze, 54 in diameter, 46.8 in pitch, 4 blade 120 Foot Torpedo Weapons Retriever The Torpedo Weapons Retriever is utilized in support of underwater acoustic submarine operations and torpedo exercises. It is designed to launch and retrieve acoustic devices as well as retrieve missiles and torpedoes in the ocean. The TWR 841 is based out of the Naval Undersea Warfare Center located in Newport Rhode Island. Fuel Capacity 8,700 gal.  Potable Water Capacity  1,300 gal. Missile Washdown Water Capacity 1,100 gal. Range 1700 nm Electrical 450 VAC three phase 60 Hz. 120 VAC single phase 60Hz. 24 VDC. Crew 18 Construction Welded steel construction with plates welded over transverse and longitudinal bulkheads and transverse frames A complete weapons systems, only on a smaller scale than a destroyer, submarine or air craft carrier. It contains representative systems.

Path to TWR-49 CM controlled native source data Navy Common Product Model Archived TWR Hull/molded forms Rhino Now that we have a data source, what is the path to our archive ship – TWR-49 Deckhouse Structure SolidWorks Ship LEAPS Archived Ship Product Model LEAP STEP Native Sensors/Antennas SolidWorks Hull Structure/ER Machinery ShipConstructor Data content Data format Supplies data Attributes/Analysis results/ requirements Project IDE / Native DB References data

Common Product Model Data Environment as directed by COMNAVSEA on 04 Feb 2008

Leading Edge Architecture for Prototyping Systems (LEAPS) LEAPS is a framework developed to support virtual prototyping in the context of conceptual and preliminary ship design and analysis. Navy Common Product Model

One Program, Many CAD systems DDG 1000 Feasibility study /Concept Design Preliminary Design Contract Design Detail Design & Construction (DD & C) O & S activities Design AutoCAD – JJMA – early stage design, machinery arrangements Fastship – Proteous / JJMA – Hull form Rhino - Hull form modifications Proteous / JJMA/ NSWC – Hull apendages CATIA V4 & V5 - NGSS Ingalls operations – Preliminary design, detail design UGS – UDLP / BAE - AGS gun, PVLS Pro E – Raytheon -sensors ShipConstructor – NGSS Ingalls, production hull AutoCAD- FASTship, Rhino, UGS, Pro-E, CATIA V4 & 5, (CAD) AutoCAD, CATIA & UGS (CAD) CATIA V5 & ShipConstructor (CAD) AutoCAD? CATIA? (CAD) CAD Tools UC2 UC4 UC1 UC5 Use case UC3 UC6 UC8 UC9 UC10 UC7 Tools usage from DDG-1000 program DDG-1000 image from http://www.globalsecurity.org/military/systems/ship/dd-x-schem.htm

Data Sources : TWR 841 Native systems ShipConstructor SolidWorks AutoCAD based Equipment below main deck Structure below main deck Distribution Systems below main deck SolidWorks Deckhouse Structure ShipConstructor – purpose built CAD system for Shipbuilding Most Navy programs use a different CAD system, they all use multiple RhinoCAD Molded Forms Compartmentation Equipment LEAPS NAVSEA Product Model Repository Integration tool

Modeling Tool ShipConstructor ShipConstructor was selected as our product modeling tool as it is relevant to NARA, NAVAIR and DLA because it is AutoCAD based. It is also relevant to NAVSEA due to the following shipbuilding projects. Deepwater – National Security Cutter (NGSS Avondale) LCS – both variants (Gibbs & Cox on Lockheed Martin program, Austal on General Dynamics program) CVN – 21 deckhouse (NGSS Avondale for Newport News) ONR E-Craft (Guido Perla for Alaska Ship & Drydock) ONR X-Craft (Sea Fighter) – Nichols Brothers

Secondary Modeling Tools Tool Selection SoldiWorks was chosen due to current Navy Ship Design program usage Rhinoceros CAD: Used for Hullform, molded surfaces, compartmentation, HVAC. LEAPS (Leading Edge Architecture for Prototyping Systems).

TWR 841 : Test Data Compartmentation/ Rhino Rhino – theoretical surfaces / compartment boundaries

TWR 841 : Test case HVAC / Rhino System defined in a general purpose CAD system Geometry only – to support fabrication, not analysis or design features

TWR 841 : Test case Ships Structure / ShipConstructor ShipConstructor

TWR 841 : Test case Ship’s Piping / ShipConstructor ShipConstructor

TWR 841 : Test case Ship’s Piping / ShipConstructor Not just graphics, property data also Geometry plus properties stored in a relational database.

Test Data : TWR 841 ShipConstructor Product Model Piping and Structure only

Test Data : TWR 841 SolidWorks Geometry SoldiWorks CAD, good assembly model Plates and siffeners only

Test Data : TWR 841 LEAPS Product Model

Retention of Data : TWR 841 Construction Units Life cycle support requires production hierarchy (interim products) and design hierarchy (system) Now that we have data, how do we need to use it, or store it and access it. Production Hierarchy 2310 2210 ASSY_003 ASSY_004 ASSY_002 ASSY_001 3110 ASSY_002 ASSY_001 ASSY_001 ASSY_002 ASSY_003 ASSY_003 2110 1110

Product Structure Product Model Based The achieve that we ultimately use must support multiple product views

Product structures are related Production / Design hierarchy Weapon System Subassembly Functional System Part A single component that is fabricated or purchased A collection of parts that are used together as portion of a functional system A collection of parts & sub-assemblies that operate together to accomplish a specific task A fully operational weapon system that is comprised of multiple functional systems to complete the intended mission Interrelation between Parts and assemblies -then part of functional system and weapon system

Files stored on Data Grid TWR Builders Drawings

Data stored on Data Grid Transverse Bulkhead at Frame 11

Accomplishments Created product model Research and Development of required Product Model Data to support engineering analysis Implemented a second native product modeling environment Developed, implemented, and testing STEP AP203 / AP214 for use in archiving Ship Product Model Data Transitioned the SolidWorks model to LEAPS Initiate the use of the Data Grid for storing native CAD models, STEP files, and the TWR source drawings. 2) Developing arrangements and habitability in a second CAD system, SolidWorks. 3) Developing a migration path from ShipConstructor and SolidWorks to LEAPS.  4) Developing, implementing, and testing STEP AP203 / AP214 for use in archiving Ship Product Model Data. 5) Work Breakdown structure - during creation of STEP files, extracted files into a product structure to suit future use 6) Identified SHCP as a candidate Engineering analysis tool to utilize with existing product model data During the second half of the fiscal year efforts will be focused on : 1) Transitioning ShipConstructor CAD data to LEAPS. 2) Increasing the level of detail in the SolidWorks model. 3) Transitioning the SolidWorks model to LEAPS. 4) Selecting candidate analyses that can be related to the product model data. 5) Performing a minimum of two analyses. 6) Relating the analysis data to the product model data, and to the results. 7) Determining the feasibility of all of the data on the Data Grid. 8) Integrating the data developed on the NARA project with other related data archiving and product life cycle support systems. 9) Export product model data into Navy Common Cost Model, capture cost estimate data and capture archive requirements 10) Continue applicability and requirements for work breakdown structure use. 11) Extend archive use of STEP APs 12) Address External Parts catalog tasks

Ongoing activities Developing, implementing, and testing additional STEP AP’s for use in archiving Ship Product Model Data Transitioning ShipConstructor model to LEAPS Transitioning the SolidWorks model to LEAPS Develop the product model repository architecture incorporating native CAD, the NAVSEA product modeling system, STEP, and ad-hoc neutral file formats using the Data Grid. Develop more automated methods for increasing our efficiency in populating the Data Grid. Develop a structural model of the engine room having enough detail to perform a stress analysis so that we can demonstrate the relationship between CAD models, FEM, analysis data, results, and documentation. Perform a topside analysis of the C4N equipment on the TWR and relate the LEAPS data, analysis data, results, and documentation. Perform intact and damage stability analyses using SHCP and capture results 2) Developing arrangements and habitability in a second CAD system, SolidWorks. 3) Developing a migration path from ShipConstructor and SolidWorks to LEAPS.  4) Developing, implementing, and testing STEP AP203 / AP214 for use in archiving Ship Product Model Data. 5) Work Breakdown structure - during creation of STEP files, extracted files into a product structure to suit future use 6) Identified SHCP as a candidate Engineering analysis tool to utilize with existing product model data During the second half of the fiscal year efforts will be focused on : 1) Transitioning ShipConstructor CAD data to LEAPS. 2) Increasing the level of detail in the SolidWorks model. 3) Transitioning the SolidWorks model to LEAPS. 4) Selecting candidate analyses that can be related to the product model data. 5) Performing a minimum of two analyses. 6) Relating the analysis data to the product model data, and to the results. 7) Determining the feasibility of all of the data on the Data Grid. 8) Integrating the data developed on the NARA project with other related data archiving and product life cycle support systems. 9) Export product model data into Navy Common Cost Model, capture cost estimate data and capture archive requirements 10) Continue applicability and requirements for work breakdown structure use. 11) Extend archive use of STEP APs 12) Address External Parts catalog tasks

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