1. Cryomodule Overview and EDMS Usage
June 26, 2008
Don Mitchell, FNAL, TD

2. Cryomodule Design Overview The Collaboration Common CAD Tools
Agenda
Cryomodule Design Overview
The Collaboration
Common CAD Tools
The EDMS environment
Sharing data and working together
The pros and cons
Beyond the paper specifications
The Virtual “Buck” neutral 3-D model
Visualization Files
Closing remarks and vision statement

3. Cryomodule Design

4. Managing the CAD Assembly with Excel & I-DEAS
ACF: Associated Copy Features
Parts automatically update when the “master part” is modified.

5. Integrating Excel into your Design
Basic piece-parts > Not Excel Driven
Master Coordinate System > Excel Driven
“Key” Components > Excel Driven
Assemblies: Not Directly driven by Excel (Master Spreadsheet is used with parts constrained to master coordinate system)

6. The simple building blocks of our assemblies
Basic Piece-Parts
The simple building blocks of our assemblies
Always begin with the BORN. Base Orphan Reference Node
Best modeling practices are always used.
Reference geometry
Well defined wireframe
Good naming conventions
Updating & part modification is easily managed
Although Excel can be used to control these parts, we choose not to so that we can minimize our data management.

7. Master Coordinate System
The single, most powerful tool that can be used in controlling your large assemblies is to develop a well thought-out master coordinate system. (Even if you don’t plan on using Excel!)
Define the origin and axes of your assembly
Define critical component location points
Create reference points and coordinate systems
Label these points with annotation
Color code these items for easy identification
Spend the time to do this right!
This Master C.S. will become the backbone of your entire assembly and will be the glue that holds it all together.

8. The Master Coordinate System continued
The ILC cryomodule Master C.S.

9. The Master Coordinate System continued

10. The Master Coordinate System continued

11. Creating the Annotation in I-DEAS NX
Attached to your reference points, add coordinate notes. They are much more informational than simple notes.
Name the reference points first. The names will show up on the annotation as well as in the Excel sheets. This is very useful for later data modification.

12. The Master Coordinate System continued
The Master C.S. is placed in many of the sub-assemblies to provide a consistent base for part placement.
Assembly constraints are kept within one assembly. We avoid crossing assembly boundaries with our constraints.

13. “KEY” Parts also use the Master C.S.
Certain parts are “key” to the construction of the assembly.
These parts will be constructed by first using the master coordinate system.
The Master C.S. becomes the BORN.
The Master C.S. part is:
Copied
Renamed
Enhanced with additional features to complete the part.
These parts will be later driven by Excel.

14. “Key” Parts built with the Master C.S.
Additional features continue to be added
The completed part with a Master C.S. BORN

15. Using Excel to Drive your Part Design
Excel files are easily created from I-DEAS parts.
In the past, Part Equations were used.
Part Equations can still be used and are preferred when the parts can be easily managed all from within I-DEAS.
For complicated parts as well as for managing larger assemblies, the Excel format is preferred.
Excel can be manipulated easily.
Functions can be used, such as conditionals and complicated mathematical equations.
Graphics and hyperlinks can also be added.
A draw-back in I-DEAS is that the Excel file is NOT stored with the item in the database!
The Excel file is hard-coded to the I-DEAS part GUID.
A copied part loses the Excel connection.

16. Create the Excel File in I-DEAS NX
In Master Modeler, select Modify
Select the part and click on dimension values
Click on Use Excel
Type in a name and location for the Excel file and click OK.
An Excel file will be written and saved.
All of the variables defined within your part will be written to the Excel file.

17. The Part Excel File in I-DEAS NX
Only a portion of the file is shown.
Column A shows the variable names used in your part’s history.
Includes names of:
Ref Pts.
Coord. Sys.
Wireframe variables
Column C shows the variable’s current value.
Yellow highlighted items cannot be modified.
The Data / Protection can be turned off to give you more editing control.

18. Modify the Part via Excel
Open the Excel file and modify any non-yellow cells.
Save the Excel file. You don’t have to exit Excel.
In I-DEAS, modify the part and, once again, click on Use Excel.
Toggle on Update I-DEAS from Excel.
Make sure the correct file name is selected.
Select OK and the modified values in the Excel file will be read and will replace the old values within the part’s variable listing.
Last, you will need to update your part to see the changes.

19. The Master Excel Spreadsheet
I-DEAS assemblies cannot be directly managed with Excel; only parts.
However, a stand-alone spreadsheet can be used to:
Identify all of the assembly parameters
Perform complicated engineering calculations
Display graphics to convey more of your design intent
The Master Spreadsheet stands on its own.
There are no hard links to any particular part.
It can be used over and over again.
It can be copied.
It can be modified.
The Excel files which drive the 3-D parts can get their values from the Master Spreadsheet by setting up cell links.

20. Managing the CAD Assembly with Excel & I-DEAS

21. The Master Spreadsheet, A Closer Look
Hyperlinked to a detailed PDF drawing
Values which can be modified
Shrinkage Calculations

22. Change the Master … The master spreadsheet will automatically adjust all computed values.
Update the individual Excel files by just opening them and clicking save. The linked cells will update.
Modify the I-DEAS “Key” parts by selecting Update from Excel.
Access your assemblies and perform an update.

24. ILC International Resources
INFN-Milan: Carlo - Paolo - Nicola - Serena
Bladetuners – main effort
Titanium vessel & cryomodule consultants
Future cavity end-group development – low effort
INFN-Pisa: Franco – Andrea
Bi-metallic transitions w/ Dubna – main effort
Cavity interconnect bellows – medium effort
Vibration studies – low effort
KEK: Norihito – Norio – many others
R&D efforts on internal magnetic shielding
Coupler and tuner concepts
Interface document support

25. ILC International Resources
RRCAT: Jishnu, Prashant, Avinash – others
Cryomodule design & fabrication
Jack stands for cryomodule
Cavity End-Groups
Titanium-Stainless transitions at end-groups
DESY: Lars – Norbert – Andreas – Jasper – Silke – others
EDMS support
Working very closely with Siemens-PLM to solve database problems with assy check-in / check-out
Vis-View and Web-Ex support
Select EDMS training
Dubna (Russia) New to the collaboration

26. A Working Collaboration
A real international collaboration!
Cryomodule development as a team!
Sharing common data!

27. Communication is essential!
We needed a way to share information.
We needed common tools.
DESY has been very accommodating and has provided their Team Center Enterprise (EDMS) as well as their IT services as part of their collaboration effort. –Thanks!

28. Dubna: I-DEAS (recent purchase), JLAB: I-DEAS INFN Milan: UG-NX
Common CAD tools
FNAL: I-DEAS v.12, NX
Dubna: I-DEAS (recent purchase),
JLAB: I-DEAS
INFN Milan: UG-NX
INFN Pisa: I-DEAS v.12
KEK: I-DEAS (recent purchase), and others
DESY: I-DEAS v.12
RRCAT: NX
Note: These are mainly Siemens-PLM CAD products and are “team browser” compatible with Team Center Enterprise. However, the current supported platform is I-DEAS v.12 with plans to add other CAD packages in the distant future.

29. Common CAD tools (cont.)
Common CAD software: I-DEAS v.12m4
Common database: DESY EDMS
Live
Daily use
Integrated with collaboration
Web viewable data and BOM structure
CAD and data file storage
3-D, 2-D, specs, engineering notes, etc.
Visualization and collaborative meetings
VisView software from Siemens-PLM
EDMS Licenses supplied by DESY
On-line collaborative meetings with file sharing.
WebEx meetings with desktop sharing

30. Team Center Enterprise EDMS Team Browser hosted by DESY

31. Team Center Enterprise EDMS Thin-Client hosted by DESY

32. Sharing Data and Working Together
Documents:
Easily shared by all team members
Software independent
PDF files created automatically
Revision control is managed easily
CAD data
Currently supports one CAD system: I-DEAS
Automatic creation of drawing viewing files
Automatic creation of 3-D viewing files

33. Sharing Data and Working Together
Advantages:
Web-based control of documents; no need to send files around to team members
Live data: current snapshot of design and parameters
1 working model shared by entire team
Disadvantages:
1 CAD tool requires all players to migrate to one software package. Very challenging!
Training: Regional training and compliance to rules. Cost of setting up and maintaining a training program.

34. Beyond the Specifications
EDMS can easily handle the documents that define the project and parameters
EDMS can also handle the “real” design
Solid model (Virtual “Buck”)
Supporting documents such as:
2-D drawings
Engineering specifications
QC documents
BOM’s
Variances in the design (alternate BOM’s)

35. Virtual “Buck”
JT file removed due to size restrictions: Show demo instead

36. 3 Approaches for collaboration
How do we collaborate?
3 Approaches for collaboration
1. DESY Model
ALL users will use I-DEAS, ILC-EDMS
2. One central model
Maintained in ILC-EDMS in I-DEAS
Collaborators use I-DEAS or supply STEP files that must be imported into I-DEAS and then uploaded into the EDMS
very labor intensive
Design is usually out-of-date
Data uploads always create new items in EDMS
No version control with STEP file imports
Drawings are not imported easily and loose associativity

37. How do we collaborate? cont.
3. JT neutral format
3-D model maintained in I-DEAS & ILC-EDMS
Collaborators work in any CAD package but must be able to create their own compatible JT files
Users upload their JT files into EDMS
JT files are revision controlled
Newer JT files become the next revision
new EDMS items are not created
EDMS numbers are retained
Master 3-D model maintained by 1 institution
JT files imported into the I-DEAS model
EDMS notification when newer JT files are available
JT files must be converted into B-rep surface models
Master model checked into EDMS
Automatic creation of JT visualization files
Complete master JT available via EDMS by all users
Downloadable through EDMS thin client (web)

38. Coordination and training is required.
Vision Statement
My vision for the ILC is that the designs proposed by all collaborators will be:
Current and up-to-date
Maintained in one system
Easily accessible
Shows all design proposals
Maintained in a neutral format that anyone can view without the need for high-end PC’s
JT’s for viewing solid models
CGM and PDF for viewing drawings
PDF for viewing documents
MUST have complete support by management at all levels and at all collaborating institutions
Coordination and training is required.