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BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 1
MBD Interoperability Challenges and Solutions
Doug Cheney Tony Provencal
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 2
MBD Interoperability Challenges and Solutions
The adoption of Model Based Definition (MBD) practices promises savings due to the elimination (or significant reduction) of CAD drawings. New MBD compliant models can be easily created and shared using today's CAD and PLM software, but what about all of the existing legacy drawing based data? Is MBD data reliable when reused downstream? As companies develop strategies to implement MBD, questions about interoperability play a central role in planning.
• How is the drawing checking function replaced? • What about all of the legacy 2D CAD drawings? • Without drawings to red line, how will engineering changes be documented? • Are lightweight visualization models (JT, 3D PDF etc...) complete and correct? • Are direct translations to other CAD formats successful? • Can we rely on neutral standards for translation? • What are the risks when switching CAD versions? CAD platforms? • How are archiving strategies (LOTAR) impacted? This session will highlight how migration, translation, and validation technologies are being deployed by leading aerospace companies to address these challenges and ensure successful MBD implementations. It will also include updates on recent standardization initiatives within the US Department of Defense and the International Standards Organization.
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 3
Introductions
• ITI TranscenData • Private company headquartered in Cincinnati since 1983 • Development offices in the United States, England,
Israel and India • Engineering software and services
– PLM system migration solutions – CAD interoperability solutions
Doug Cheney • Engineering education
(Caltech and BYU) • CAD validation specialist
• Algorithms • International
standards • Process improvement
consulting
Tony Provencal • Engineering education
(Notre Dame) • CAD translation specialist
• Feature based translation
• Multi-CAD administration
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 4
MBE
3D CAD Model &
PMI
3D Lightweight Model plus 3D PMI, e.g.
JT
2D Paper Drawing
3D Lightweight Geometry, e.g. JT, 3D
DMU
3D CAD Model
The Digital Product Model Evolution
2D CAD
2D Electronic Drawing
2D Paper Drawing 2D Paper Drawing 2D Paper
Drawing
3D CAD
3D CAD Model
2D Electronic Drawing
2D Paper Drawing 2D Paper Drawing 2D Paper
Drawing
1970 1980 1990 2010 2000
2D Drawing
2D Paper Drawing 2D Paper Drawing 2D Paper
Drawing
1781
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 5
Technical
• Incomplete CAx system functionality
• Limited Interoperability
• Lagging standards and regulations
• Digital data variation
Barriers to a Model-Based Enterprise (MBE)
Non-Technical
• Limited capital expense budgets
• Legacy product reuse rather than new product design
• Process Re-definition
• Human resistance to change
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 6
Generating MBD Models from 2D Drawings
Use Case
A CAD plug-in which identifies 2D PMI information in an associative drawing, and automatically creates the equivalent 3D PMI information in the solid model.
Input Single Part and Associated Drawing
Output Single Part w/ 3D PMI
Output Details
• Drawing Views converted to 3D Named Model Views
• Datums, Dimensions, Notes, & Feature Control Frames
• Drawing Frames • Semantic and Non-Semantic
DrawToPMI
6 Confidential
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 7
NIST MBE PMI Validation and Conformance Testing
Develop • test case definitions • test case models • software algorithms
…for the purpose of testing CAD system conformance testing of ASME standards for PMI.
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 8
NIST MBE PMI Project Participants
Government Sponsor • National Institute of Standards and Technology (NIST) • http://www.nist.gov/el/msid/infotest/simca_mbe.cfm Contractors • Advanced Dimensional Management (test cases) • RECON Services (test models) • ITI TranscenData (validation) Vendor Partners • Dassault Systemes, Siemens PLM and PTC Collaboration Partners • PDES/ProSTEP CAx Implementors Forum • ProSTEP JT Implementors Forum • 3D PDF Consortium Technical Committee
8 NIST MBE PMI Validation Project Update
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 9
NIST MBE PMI Project Task Summary
• Test Case Definition • Create representative set of GD&T constructs
– ASME Y14.5M-1994, Y14.6-2001 and Y14.41-2003 • Native Model Creation and Verification
• Model each test case in each native CAD system – CATIA V5 R21, NX 8, Creo Parametric 1 and SolidWorks 2012
• Compare native test models to each other – Ensure semantic equivalence – calibrate validation process – Assess level of PMI semantic definition
• Derivative Model Creation and Validation • Export each test model to neutral formats
– STEP AP203E2 or AP242, JT 9.5 Rev D and 3D PDF PRC • Compare each derivative model to its native model
– Assess level of PMI semantic translation • Document methodology and high-level testing results
9 NIST MBE PMI Validation Project Update
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 10
NIST 3D MBE PMI Validation Data Process Flow
50 Test
Cases
50 CATIA V5 Models
50 Creo
Models
50 NX
Models
Verification Validation
50 SolidWorks
Models
200 STEP
Models
200 JT
Models
200 3D PDF Models
CAx (STEP) Implementor
Forum
JT Implementor
Forum
3D PDF Implementor
Forum
Implementor Forum = Vendor partnership to resolve implementation issues
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 11
NIST 3D MBE PMI Validation Test Case Example
Creo Model
NX Model CATIA Model
Test Case
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 12
NIST MBE PMI Semantic Verification and Validation Criteria
• Product Geometry • Annotation Entity • Associated Geometry • Annotation Geometry • Annotation Text • Annotation Type • Associated Annotations • Annotation Parameters • Saved Views • Saved View Annotations • Saved View Geometry
12 NIST MBE PMI Validation Project Update
Non-Semantic Characteristics (NOT verified and validated) Annotation Label Annotation Location Annotation Orientation Font Font Size Text Spacing Leader Line Routing Arrowhead Style
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 13
NIST MBE PMI Project Schedule (milestone dates)
13 NIST MBE PMI Validation Project Update
CATIA, NX and Creo • 08/12: Test case definition • 08/12: Test model creation • 09/12: Test model verification • 11/12: Expert review • 12/12: Test model refinement • 02/13: Neutral file exports • 03/13: Neutral file validation
• 09/13: Final Report
SolidWorks • 08/12: Test case definition
• 03/13: Test model creation • 04/13: Test model verification • 04/13: Expert review • 05/13: Test model refinement • 06/13: Neutral file exports • 08/13: Neutral file validation • 09/13: Final Report
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 14
Lagging Standards and Regulations – Not for long!
• International Data Modeling Standards • ISO 10303-242 STEP AP242 = AP203 x AP214 • ISO 14306 JT • ISO 14739-1 PDF with PRC
• FAA Aircraft Type Certification • MBD approved for Gulfstream G650 and Boeing 787 • Other aircraft programs pending
• Department of Defense Regulations • MIL-STD-31000 Revision A • Technical Data Package (TDP)
can be 3D with PMI
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 15
Technical
• Incomplete CAx system functionality
• Limited Interoperability
• Lagging standards and regulations
• Digital data variation
Barriers to a Model-Based Enterprise (MBE)
Non-Technical
• Limited capital expense budgets
• Legacy product reuse rather than new product design
• Process Re-definition
• Human resistance to change
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 16
Types of Digital Data Variation
1. Master Design Interpretation • Confusing structure • Inconsistent data • Unrealistic features
2. Data Translation/Migration
CAD A to CAD B or CAD A Rev 1 to Rev 2 • Data loss • Degradation • Unacceptable change
3. Engineering Revision
• Unintentional change • Undocumented change
Can it be manufactured? Is it equivalent? Is it correct and clear?
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 17
Master Design Interpretation Divergence
• Unrealistic (ambiguous) features in models must be interpreted by downstream users
• Different interpretations can affect part quality
Design Model
Prototyping Model
Analysis Model
Rework
Rework
Manufacturing Model
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 18
Master Design Interpretation Divergence Example
• Simulation approved the design • Manufacturing produced initial parts from native model • All parts failed during final testing • Caused last-minute schedule delay and retooling
Test Part
Fatigue Failure
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 19
Testing failure (missing material)
Manufactured Part
Master Design Interpretation Divergence Example
Unrealistic feature (zero thickness)
Native Design Model
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 20
Master Design Geometry Defect Examples
Blocked Hole Crack
Void Thin
Volume
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 21
Master Design PMI Defect Examples
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 22
Geometry Translation Variation Example
• Parametric feature definition preserved, with different geometric result
• Fillet converted into a round which extends along top of flange
Translated Model Legacy Model
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 23
PMI Remastering Variation Example
• Different graphical presentation (expected, acceptable) • Lost datum feature symbol • Tolerance value change
Remastered Model Legacy Model
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 24
Geometry Migration Variation Example
The highlighted geometry was added when all features were updated in the new version of the CAD system.
Updated Model Current Model
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 25
PMI Migration Variation Example
Dimension display values changed when model were updated in the new version of the CAD system
Updated Model Current Model
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 26
Unintentional Revision Change Example
• Pocket depth on back side increased • Hole break-out introduced • Missed by drawing checker reviewing as-is drawing
redline
To-Be Model As-Is Model
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 27
Intentional Revision Change Documentation
• Side-by-side 3D PDF with synchronized graphics • Each geometric and PMI change highlighted separately
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 28
Changing Landscape of Design Variation
2D DRAWING-Based
Enterprise
3D MODEL-Based
Enterprise Simple
(2D geom, text, notes) Complexity Complex (3D geom, relationships, pmi)
Visual Checking Software Sufficient Time Process Shortened/Automated
Human Interpretation Machine Graphic Translation LOD Graphic/Geometric/Semantic
Data Re-created Downstream Use Associative Links
Controlled with
Flexibility
Uncontrolled yet
Highly-Constrained
Global Product Data Interoperability Summit | 2012
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 29
Managing Variation in a Model-Based Enterprise
1. Automated design checking and expert review before release • Consistent and stable structure • Complete content • Realistic features
2. Automated translation validation before delivery • No data loss or degradation • Only negligible changes
3. Automated ECO validation before release • No unintentional changes • Clearly document intentional changes
Early warning systems
with Issue resolution
processes
BOEING is a trademark of Boeing Management Company Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Northrop Grumman Corporation. All rights reserved. GPDIS_2012.ppt | 30
Questions and
Discussion