Assembly Production and Integrated Information Management in ...
Assembly Production and Integrated Information Management in ...
Assembly Production and Integrated Information Management in ...
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Lead<strong>in</strong>g Bus<strong>in</strong>ess Solutions for the Mar<strong>in</strong>e Industry<br />
<strong>Assembly</strong> <strong>Production</strong> <strong>and</strong> <strong>Integrated</strong><br />
<strong>Information</strong> <strong>Management</strong> <strong>in</strong> Shipbuild<strong>in</strong>g<br />
Sigurd Hildebr<strong>and</strong>t<br />
Atlantec Enterprise Solutions GmbH
Overview<br />
Subjects:<br />
• <strong>Integrated</strong> <strong>Information</strong> <strong>Management</strong><br />
• Cutt<strong>in</strong>g <strong>and</strong> Weld<strong>in</strong>g <strong>in</strong> Shipbuild<strong>in</strong>g <strong>Production</strong><br />
Processes<br />
• Features <strong>and</strong> Capabilities of Shr<strong>in</strong>kage <strong>Management</strong><br />
• Automation of <strong>Assembly</strong> Def<strong>in</strong>ition<br />
• Generation of Nest<strong>in</strong>g Tasks<br />
Research Programs:<br />
•InterShip IV-1<br />
•Autogen<br />
•Sh<strong>in</strong>Cos<br />
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<strong>Integrated</strong> <strong>Information</strong><br />
<strong>Management</strong><br />
• Focus: <strong>Information</strong> flow <strong>in</strong> shipbuild<strong>in</strong>g production<br />
systems<br />
• Bus<strong>in</strong>ess Problem<br />
– Proliferation of proprietary formats<br />
– Complex, unmanaged flow of <strong>in</strong>formation<br />
– Modifications or <strong>in</strong>tegration of new technologies are costly<br />
<strong>and</strong> disruptive<br />
– These severe restrictions limit flexibility for decisions<br />
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Common Situation<br />
• Numerous CAD/CAM systems<br />
• Individual <strong>in</strong>terfaces<br />
• Regular problems with release<br />
changes<br />
CAD CAD System 1<br />
<strong>in</strong>-house developed l<strong>in</strong>k<br />
CAM CAD System 1<br />
<strong>in</strong>tegrated (same vendor)<br />
IGES<br />
CAD CAD System 12<br />
CAD CAD System 13<br />
miss<strong>in</strong>g l<strong>in</strong>k<br />
manual <strong>in</strong>put<br />
XLS<br />
<strong>in</strong>-house developed l<strong>in</strong>k<br />
proprietary format<br />
DXF<br />
CAM CAD System 13<br />
CAM CAD System 12<br />
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Enterprise Solution<br />
Basic<br />
Design<br />
Adapter<br />
Adapter<br />
Construction<br />
(CAM)<br />
Detailed<br />
Design<br />
Adapter<br />
CAD-CAM<br />
Connector<br />
Adapter<br />
Simulation<br />
Plann<strong>in</strong>g<br />
(ERP)<br />
Adapter<br />
Adapter<br />
Material<br />
<strong>Management</strong><br />
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Focus<br />
• Two Bus<strong>in</strong>ess Cases<br />
– Nest<strong>in</strong>g Control (Plate <strong>Production</strong> Doma<strong>in</strong>)<br />
– Shr<strong>in</strong>kage <strong>Management</strong> Control (<strong>Assembly</strong> <strong>Production</strong><br />
Doma<strong>in</strong>)<br />
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<strong>Production</strong> <strong>Information</strong> Flow<br />
CAM<br />
Shop<br />
CAD<br />
<strong>Assembly</strong><br />
Def<strong>in</strong>ition<br />
Detail<br />
Design<br />
Part<br />
<strong>Production</strong><br />
Preparation<br />
<strong>Assembly</strong><br />
<strong>Production</strong><br />
Preparation<br />
Part<br />
<strong>Production</strong><br />
<strong>Information</strong><br />
<strong>Assembly</strong><br />
<strong>Production</strong><br />
<strong>Information</strong><br />
Cutt<strong>in</strong>g<br />
Form<strong>in</strong>g<br />
Shop<br />
Manual<br />
<strong>Assembly</strong><br />
Station<br />
Panel L<strong>in</strong>e<br />
Weld<strong>in</strong>g<br />
Robot<br />
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Basic Requirements (1)<br />
Features to be developed:<br />
• Identify the weld jo<strong>in</strong>ts def<strong>in</strong>ed <strong>in</strong> the design process<br />
• Def<strong>in</strong>e the weld sequence accord<strong>in</strong>g to the assembly<br />
trees<br />
• Investigate the<br />
<strong>in</strong>fluence of the weld<br />
MS021<br />
sequence <strong>and</strong> weld<strong>in</strong>g<br />
parameters on the<br />
041B<br />
predicted shr<strong>in</strong>kage<br />
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Basic Requirements (2)<br />
Features to be developed<br />
(cont’d):<br />
• Convert design geometry<br />
<strong>in</strong>to production geometry<br />
based on predicted material<br />
deformation<br />
• Shr<strong>in</strong>kage management to be separated from<br />
the design <strong>and</strong> to become part of the<br />
production preparation<br />
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<strong>Production</strong> Control<br />
Workflow<br />
Work steps require consideration of:<br />
• Def<strong>in</strong>e the shipyard’s production facilities<br />
• Def<strong>in</strong>e the production levels generally available at the yard<br />
from part cutt<strong>in</strong>g to slipway assembly <strong>and</strong> their related<br />
boundary conditions<br />
• Def<strong>in</strong>e the weld jo<strong>in</strong>ts<br />
• Def<strong>in</strong>e the production flow which any <strong>in</strong>dividual part has to<br />
pass through from cutt<strong>in</strong>g up to f<strong>in</strong>al assembly<br />
• Calculate the shr<strong>in</strong>kage values for each part applicable for the<br />
selected production flow<br />
• Distort all part geometries for nest<strong>in</strong>g <strong>and</strong> cutt<strong>in</strong>g<br />
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<strong>Integrated</strong> <strong>Production</strong><br />
SHR<br />
Parameters<br />
Weld<br />
parameters<br />
Topgallant®<br />
<strong>Assembly</strong><br />
<strong>Production</strong><br />
OGDB<br />
PLDB<br />
PRDB<br />
Tribon M2<br />
Hull<br />
Publisher<br />
Topgallant®<br />
<strong>Information</strong><br />
Server<br />
Graphical Application<br />
ASSDB<br />
PDM / ERP<br />
Adapter<br />
Topgallant®<br />
Plate<br />
<strong>Production</strong><br />
alma<br />
Nest<strong>in</strong>g<br />
.<strong>in</strong>i<br />
.agi<br />
…<br />
. xls<br />
.nc1<br />
.nc2<br />
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<strong>Assembly</strong> <strong>Production</strong> –<br />
Control Functions<br />
Control Functions:<br />
• Extracts all steel plates from CAD-system plus<br />
externally def<strong>in</strong>ed geometries<br />
• Automated analysis of assembly structure configuration<br />
• Automatic generation of weld<strong>in</strong>g data based on part<br />
geometry <strong>and</strong> connectivity <strong>in</strong>formation<br />
• Generation of production rules<br />
• Configurable selection of weld<strong>in</strong>g parameter sets<br />
• Automatic def<strong>in</strong>ition of sequences <strong>and</strong> paths<br />
• Distortion of geometry depend<strong>in</strong>g on assembly <strong>and</strong><br />
part parameters<br />
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Plate <strong>Production</strong><br />
Control Functions :<br />
• Efficient use of production rules<br />
• Manages the steel plate storage<br />
• Re-use of remnant plates<br />
• Automatic generation of „Nest<strong>in</strong>g Jobs“<br />
• Selection <strong>and</strong> „Release for Nest<strong>in</strong>g” of complete<br />
assemblies<br />
• Controls nest<strong>in</strong>g software<br />
• Shows all details of the nest<strong>in</strong>g results<br />
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AUTOGEN<br />
• NSRP Funded Project<br />
– S<strong>and</strong>ia National<br />
Laboratories<br />
– NGSS Ingalls<br />
• Analysis of part geometry<br />
<strong>and</strong> connectivity<br />
• Weld detection<br />
• Weld process assignment<br />
• Weld path generation<br />
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AUTOGEN Eng<strong>in</strong>e Features<br />
• Verification of robot movements <strong>and</strong><br />
collision control<br />
• Configurable geometric<br />
processor<br />
• Pluggable robot<br />
descriptions<br />
September 2004<br />
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<strong>Information</strong> <strong>Management</strong><br />
Features<br />
• Version <strong>and</strong> Change Control<br />
• Process Def<strong>in</strong>ition <strong>and</strong> Control<br />
• Direct l<strong>in</strong>k to robot facilities<br />
– Pluggable robot configuration<br />
• Fully <strong>in</strong>tegrated with exist<strong>in</strong>g CAD/CAM or ERP<br />
environments us<strong>in</strong>g CAD-CAM Connector adapters<br />
– St<strong>and</strong>ardized <strong>in</strong>terfaces <strong>and</strong> legacy formats readily available<br />
• Report generator<br />
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Technology Features<br />
• Fully distributable through consistent use of Java<br />
<strong>and</strong> XML<br />
– M<strong>in</strong>imized platform dependency<br />
– High reliability<br />
– Automated deployment <strong>and</strong> ma<strong>in</strong>tenance<br />
• Based on st<strong>and</strong>ards<br />
– STEP AP218, AP238, WfMC, X.500<br />
September 2004<br />
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Screenshots Plate <strong>Production</strong><br />
(1)<br />
September 2004<br />
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Screenshots Plate <strong>Production</strong><br />
(2)<br />
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Topgallant <strong>Assembly</strong><br />
<strong>Production</strong><br />
Benefits :<br />
• Provides full scope of design <strong>and</strong> production<br />
<strong>in</strong>formation to facilitate automated shr<strong>in</strong>kage<br />
management<br />
• Automates generation of production <strong>in</strong>formation<br />
– <strong>Assembly</strong> def<strong>in</strong>ition<br />
– <strong>Production</strong> geometry<br />
– Cutt<strong>in</strong>g<br />
– weld<strong>in</strong>g<br />
– panel l<strong>in</strong>e<br />
• Incorporates commercialized version of nest<strong>in</strong>g<br />
software for the generation of PCDs<br />
September 2004<br />
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Topgallant<br />
<strong>Production</strong> Control<br />
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End of Presentation<br />
Thank you for your attention!<br />
Questions?<br />
September 2004<br />
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