2021 NSRP All Panel Meeting Virtual Poster Session
National Shipbuilding Research Program
Filter displayed posters (64 keywords)
Additive Manufacturing (2)
Fiber Optics (2)
ShipConstructor (2)
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3D Printing (1)
AM (1)
ATA (1)
Altair (1)
Analysis (1)
CAD (1)
CAD Integration (1)
Cabling (1)
Certificate Program (1)
Connector (1)
DED (1)
Data Exchange (1)
Data Reuse (1)
Digital Data Workflow (1)
Electrical Integration (1)
Eliminate corrosion (1)
FEA (1)
Fiber optic remote source lighting (1)
Fiber optics (1)
Fiber terminations (1)
Fusion Splice (1)
HLAW (1)
Hybrid Laser GMAW (1)
Hybrid Laser Gas Metal Arc Welding (1)
HyperMesh (1)
Insulated Bus Pipe (1)
Interface (1)
Knowledge Provisioning (1)
LEDs (1)
Laser Diodes (1)
Laser ablation (1)
Long source life (1)
Manufacturing (1)
Modeling (1)
Navy Distribution Equipment (1)
Optical Networks (1)
Power Distribution (1)
Robotic Arc Directed Energy Deposition (1)
Rule Processing (1)
Ship Networks (1)
Shipbuilding (1)
Simulation (1)
Tele-welding (1)
Thick Section Welding (1)
Trades Training (1)
condition based maintenance (1)
electrical connections (1)
hot fluid immersion requirements (1)
iMAST (1)
improved abrasion resistance. (1)
jacket scrape abrasion (1)
laser hazards (1)
no electricity topside. (1)
non-conductive (1)
ocular hazards (1)
reconfigurable. (1)
remote control (1)
remote temperature sensing (1)
tele-manufacturing (1)
tele-operation (1)
work-force development (1)
Show Posters:
Tracks
▼ ManTech - Institute for Manufacturing and Sustainment Technologies (iMAST) Back to top
Institute for Manufacturing and Sustainment Technologies (iMAST)
Tim Bair, Tim Eden, Brenda Kephart
Abstract
Penn State Institute for Manufacturing and Sustainment Technologies Virtual Poster Session
Presented by
Brenda E. Kephart
Institution
Applied Research Lab, Penn State (iMAST)
Keywords
iMAST
▼ NSRP - Business Technologies Panel Back to top
Structural Interface for Automated Compliance Checking
Steve Boisvert, Patrick David
Abstract
The focus of this project is to streamline the regulatory compliance workflow by provisioning digitized structural rules directly into the 3D Design Model workflow with compliance verification against the ABS Rules and contract specification. By automatically verifying and capturing the design’s compliance, the system will enhance the ABS structural requirement verification early in the 3D Design Model where the verification would be maintained on file for future compliance auditing. It will also provide evidence of compliance that can be used by the regulatory agency, reducing the time required to verify compliance.
Presented by
Steve Boisvert
<steve.boisvert@aurosks.com>
Institution
SSI / Auros Knowledge Systems
Keywords
ShipConstructor, Knowledge Provisioning, Rule Processing, CAD Integration
LiftShip 2
Pat David
Abstract
Following on the successful 2018 NSRP LiftShip (2018-438) RA project, this project proposes
the extend the functionality further in direct response to feedback from the shipyard participants
to address Lifting and Turning of the assemblies, better visual reporting, ability to manage level-of-detail required in the Finite Element Analysis (FEA) model, importing modifications from the
FEA model to the ShipConstructor lifting arrangement, locking the production model when being
analyzed, and the ability to integrate 3D scanning to account for extra, non-production
components/loads on the lift structure.
Presented by
Patrick David
Institution
National Shipbuilding Research Program (NSRP)
Keywords
Shipbuilding, FEA, CAD, Data Exchange, Data Reuse, ShipConstructor, ATA, Altair, HyperMesh
NSRP Advance Knowledge Provisioning Using Artificial Intelligence (AI) & Augmented Reality (AR)
Pacific Shipyards International | Conrad Shipyard, LLC | Fincantieri Marine Systems NA
Abstract
This project will deliver AI-assisted capture and packaging of critical knowledge, such as customer requirements, standards, and shipyard crowd-sourced knowledge to allow AR-assisted automated provisioning directly into ship repair workflows. This capability will automate the mapping of customer specifications and regulatory requirements into work control artifacts such as estimating packages, test and inspection plans, planning work instructions, job safety hazard notices, and standard production work while providing visibility of compliance.
Presented by
Greg Burek
<gburek@aurosks.com>
Institution
Auros Knowledge Systems, LLC | D’Angelo Technologies, LLC | Hepinstall Consulting Group, LLC
Keywords
▼ NSRP - Electrical Technologies Panel Back to top
Electrical Connector Standardization: Reduce connector variation to lower ship costs.
Larry Boyce | Rickey DeLoge | Paul Fellows | Mike Binekey | Tru Nguyen | Greg Stevens | Maurissa D’Angelo | Joe D’Angelo | John Walks | Harold Howard | Jason Farmer | Christopher Nemarich | Peter Andrich | Mark Smitherman |
Abstract
Presented by
Larry Boyce
Institution
GD Bath Iron Works | D’Angelo Technologies | HII Ingalls Shipbuilding
Keywords
Fiber Optic Distributed Temperature Sensing for Remote Monitoring of Electrical Systems
Linda Tomasi, Giovanni Tomasi
Abstract
Electrical systems on U.S. Navy ships are becoming increasingly complex, driven by the growing power demands. The criticality of the connection points and the high vibrations of the shipboard environment mandate annual inspection of bolted electrical connections using thermographic scanning, a time consuming and hazardous process. Additionally, new power transmission technologies such as Insulated Bus Pipes (IBP) are under development to save space, labor costs, and improve the electrical system performance but require bolted connections at each of the many joints between IBP sections. Annual inspection of these joints would be extremely labor intensive, negating the benefits of the IBP implementation.
Fiber optic Distributed Temperature Sensing (DTS) based on Raman Scattering provides the solution by using the entire length of an optical fiber as a continuous temperature measuring device. Changes in temperature as low as 0.5°C (1°F) can be detected with the exact location along the fiber identified. DTS devices can monitor up to 1,000 sensing zones per fiber, at distances exceeding 30 Km (100,000 ft). The fiber cable can be fully non-conductive, making it ideal for applications in electrical systems. Differences in conductors’ temperatures can be identified to detect a fault well before it becomes critical.
Presented by
Linda Tomasi
Institution
RSL Fiber Systems, LLC
Keywords
Fiber optics, electrical connections, remote temperature sensing, condition based maintenance, non-conductive, reconfigurable.
Advanced Topside Lighting - For TOC Reduction through Solid State Lighting Technologies
Giovanni Tomasi
Abstract
Address issues with legacy topside lights (corrosion, short source life, high maintenance costs, EMI/RFI) by utilizing advanced lighting technologies including LEDs, laser diodes, and fiber optic remote source lighting. These technologies are mature and widely used in many commercial applications. They can be adapted and qualified for use on naval combatants to improve reliability, lower total ownership costs, and provide cost saving of over $ 6 million/year to the U.S. Navy fleet.
Presented by
Giovanni Tomasi
<gptomasi@rslfibersystems.com>
Institution
RSL Fiber Systems, LLC
Keywords
Eliminate corrosion, Long source life, LEDs, Laser Diodes, Fiber optic remote source lighting, no electricity topside.
Shipboard Fiber Optic Cables Design Enhancement
Billie Jo Mitchell, Giovanni Tomasi
Abstract
The NSRP Panel Project “Shipboard Fiber Optic Cable Design Enhancement” investigated the causes of breakage of shipboard fiber optic cables built to MIL-PRF-85045 during installation and in-service to determine if enhancements to the cable designs and/or installation process can be implemented to reduce damage and improve overall system reliability.
The project met the objective to improve the resiliency and reduce Total Ownership Cost by identifying ways of making the fiber optic cables more robust and reducing the cost of installation. In addition, the project also identified an area where the cable cost can be reduced and the performance improved by re-evaluating the requirements for the outer jacket materials. The requirements driving the use of the higher cost thermoset jacketed cables (hot fluid immersions) may not be very important; better performance in areas considered more critical such as resistance to abrasion can be achieved by revising these requirements and allowing the use of more durable thermoplastic jacket materials.
The project met the objective to improve the resiliency and reduce Total Ownership Cost by identifying ways of making the fiber optic cables more robust and reducing the cost of installation. In addition, the project also identified an area where the cable cost can be reduced and the performance improved by re-evaluating the requirements for the outer jacket materials. The requirements driving the use of the higher cost thermoset jacketed cables (hot fluid immersions) may not be very important; better performance in areas considered more critical such as resistance to abrasion can be achieved by revising these requirements and allowing the use of more durable thermoplastic jacket materials.
Presented by
Ms. Billie Jo Mitchell
Institution
RSL Fiber Systems, LLC
Keywords
Fiber terminations, jacket scrape abrasion, hot fluid immersion requirements, improved abrasion resistance.
Fusion Splice Enclosure at Equipment
John Mazurowski, Jason Farmer, Perry Haymon, Dan Morris, Shane Baker, Lucas Cashdollar, Harold Howard
Abstract
This project developed concepts for fiber optic fusion splice enclosures mounted onto equipment racks and consoles, in order to reduce impairments from fiber optic connectors. Multiple concepts were evaluated, feedback was acquired from downstream users and equipment manufacturers, and potential suppliers were identified. We used additive manufacturing simultaneously at multiple locations to quick-turn prototype iterations. The final concepts are at TRL-3 ready for further work toward qualification and implementation. We estimate that the cost savings from this enclosure is 75% of the connector acquisition and assembly cost. In addition, the fusion splicing operation performs an optical loss estimate during the splicing process, which decreases the incidence of unscheduled rework tasks.
Presented by
John Mazurowski
Institution
Penn State Applied Research Laboratory
Keywords
Fiber Optics, Connector, Fusion Splice
▼ NSRP - Environmental, Health & Safety Panel Back to top
Identifying, evaluating, and mitigating ocular hazards in laser processing
Melissa Klingenberg, Stephen Brown, and James Brooks
Abstract
Join the project presenter for a ZoomGov Meeting at
https://arlpsu.zoomgov.com/j/1617246456?pwd=b2pmZjNIMG1NMGg3cmhXYXU2QTdQQT09
Meeting ID: 161 724 6456 Passcode: 895448 One tap mobile +16692545252,,1617246456#,,,,*895448# US (San Jose) +16468287666,,1617246456#,,,,*895448# US (New York) Dial by your location +1 669 254 5252 US (San Jose) +1 646 828 7666 US (New York)
Meeting ID: 161 724 6456 Passcode: 895448 One tap mobile +16692545252,,1617246456#,,,,*895448# US (San Jose) +16468287666,,1617246456#,,,,*895448# US (New York) Dial by your location +1 669 254 5252 US (San Jose) +1 646 828 7666 US (New York)
Presented by
Melissa L. Klingenberg
Institution
Pennsylvania State University Applied Research Laboratory and Newport News Shipbuilding
Keywords
Laser ablation, laser hazards, ocular hazards
Chat with Presenter
Available Tuesday; 3/24/21; 10am - 10:30am, ET
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▼ NSRP - Research Announcement Projects Back to top
Tele-Welding: Leveraging Skilled Welders Through Remote-Access Operation
Connie Reichert LaMorte
Abstract
Tele-manufacturing offers the ability to accurately transfer manual skillsets from local personnel to remote automated systems. Tele-welding allows a worker to operate welding equipment from a remote location while still in control of the welding process and torch movements. By providing a functional system for “distance welding,” tele-welding supports workers – whether they are younger, older, or have a physical disability – who may not otherwise be able to serve productively in manufacturing and helps address today’s chronic shortage of skilled welders in the labor pool.
The EWI-led joint research team of Newport News Shipbuilding, General Dynamics-Electric Boat, Robotic Technologies of Tennessee, and Visible Welding is currently completing a Navy-sponsored project through the National Shipbuilding Research Program (NSRP) to develop a mechanized welding system completely controlled by a worker who is remote from the welding site. The worker receives feedback from the operation and its environment via welding sensors, arc view cameras, and a real-time livestream of the entire process. The mechanized equipment can be operated through a control tool such as a computer mouse, haptic stylus device, or welding torch-like device attached to a desktop robot.
The first phase of this project centered on researching and developing technologies that, when combined, allow a worker to make a weld remote from the operation, but in 100% control of the welding process. A proof of concept was demonstrated in May 2020 where welding was completed at EWI by operators located in New England. The second phase of this project has centered on integrating down-selected technologies including a haptic stylus device and arc sensors onto both a mobile platform and a portable cobot arm. The final step of this project includes validating the technology with remote welding demonstrations on selected shipyard applications in May 2021.
The EWI-led joint research team of Newport News Shipbuilding, General Dynamics-Electric Boat, Robotic Technologies of Tennessee, and Visible Welding is currently completing a Navy-sponsored project through the National Shipbuilding Research Program (NSRP) to develop a mechanized welding system completely controlled by a worker who is remote from the welding site. The worker receives feedback from the operation and its environment via welding sensors, arc view cameras, and a real-time livestream of the entire process. The mechanized equipment can be operated through a control tool such as a computer mouse, haptic stylus device, or welding torch-like device attached to a desktop robot.
The first phase of this project centered on researching and developing technologies that, when combined, allow a worker to make a weld remote from the operation, but in 100% control of the welding process. A proof of concept was demonstrated in May 2020 where welding was completed at EWI by operators located in New England. The second phase of this project has centered on integrating down-selected technologies including a haptic stylus device and arc sensors onto both a mobile platform and a portable cobot arm. The final step of this project includes validating the technology with remote welding demonstrations on selected shipyard applications in May 2021.
Presented by
Connie Reichert LaMorte
Institution
EWI
Keywords
Tele-welding, tele-manufacturing, tele-operation,work-force development,remote control
Interface Design for Insulated Bus Pipe (IBP) to Navy Equipment
Dr. Patrick Lewis
Abstract
This project, Research & Develop Insulated Bus Pipe (IBP) Standard Interface to Naval Electrical Equipment, will research and integrate a common interface with Navy OEM equipment to improve the implementation and transition strategy for the Navy. The project team will research and evaluate the various interconnections required for a diverse set of electrical equipment onboard Navy ships, as well as various integration requirements (e.g. environmental factors such as EMI, shock, vibration).
Presented by
Patrick Lewis
Institution
Hepburn and Sons LLC
Keywords
Navy Distribution Equipment, Interface, Insulated Bus Pipe, Power Distribution, Electrical Integration
Chat with Presenter
Available March 24th, 2021 11:00 AM - 12:00 PM EST
Join the Discussion
▼ NSRP - Ship Design & Material Technologies Panel Back to top
Robotic Arc Directed Energy Deposition Additive Manufacturing for Shipbuilding
Dennis Harwig
Abstract
Additive manufacturing (AM) provides a wide range of potential benefits for optimizing design topology, shorter schedules/lead times, small batch manufacturing, less material usage, less total energy, smaller factory footprints, better properties then castings, and unique supply chain opportunities for sustainment. The challenges that each shipyard faces are the needs to develop the digital data workflow competencies, develop process-feature-property requirements, develop process metrics for their business case, qualify arc directed energy deposition (DED) AM process(es), and install robotic AM systems for implementation. There are hundreds of possible process-consumable combinations with arc DED, so shipbuilders need a focused set of services to minimize the learning curve, develop workforce competencies, streamline engineering manufacturing design-development, and reduce implementation costs. Without this focused set of services, these costs could be in the millions of dollars for each shipyard.
The focus of this project is to develop robotic arc DED AM technology for shipbuilding. The objectives of this project are: • Develop digital data workflow (DDW) competencies for robotic arc DED AM of metals • Develop DED AM process models for arc processes, consumables, and shipbuilding material applications • Establish robotic computer-aided modeling (CAM) models for existing robot cells at EWI and shipyard partners • Develop process-feature-property relationships to establish structural properties, create build parameter windows, and build representative prototype process qualifications • Establish a standardized robotic arc DED AM gantry for large area/large volume AM to minimize system costs for wide scale implementation in shipbuilding and install a test bed version of the gantry at EWI for a range of applied research and prototyping services • Establish robotic arc DED AM training seminars and workshops for ongoing technical services to shipyards • Establish ongoing technical services for developing process-feature-property relationships, develop parametric CAM models for different arc welding process-consumable combinations, and build representative process qualifications to validate soundness and properties • Determine application opportunities and implementation priorities for robotic arc DED AM at American and Navy Shipyards
The focus of this project is to develop robotic arc DED AM technology for shipbuilding. The objectives of this project are: • Develop digital data workflow (DDW) competencies for robotic arc DED AM of metals • Develop DED AM process models for arc processes, consumables, and shipbuilding material applications • Establish robotic computer-aided modeling (CAM) models for existing robot cells at EWI and shipyard partners • Develop process-feature-property relationships to establish structural properties, create build parameter windows, and build representative prototype process qualifications • Establish a standardized robotic arc DED AM gantry for large area/large volume AM to minimize system costs for wide scale implementation in shipbuilding and install a test bed version of the gantry at EWI for a range of applied research and prototyping services • Establish robotic arc DED AM training seminars and workshops for ongoing technical services to shipyards • Establish ongoing technical services for developing process-feature-property relationships, develop parametric CAM models for different arc welding process-consumable combinations, and build representative process qualifications to validate soundness and properties • Determine application opportunities and implementation priorities for robotic arc DED AM at American and Navy Shipyards
Presented by
Nick Kaputska
Institution
EWI, Austal USA, Navus Automation, NSWCCD, ABS, Ingalls (Observer), NASSCO (Observer)
Keywords
Robotic Arc Directed Energy Deposition, DED, Additive Manufacturing, AM, Digital Data Workflow
Chat with Presenter
Available March 24th, 2021 from 1:00 to 4:00 p.m. E.T
Join the Discussion
Minimum Standardized Content to Enable a NAVY Digital Enterprise
Ariel Bond
Abstract
Presented by
Ariel Bond
Institution
Newport News Shipbuilding, Engineering & Design Process and Tools Department
Keywords
Chat with Presenter
Available 3/24/21 at 9am
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Simulation Workflow Development for Additive Manufacturing
David Najera & Elliot Haag
Abstract
ATA Engineering, in collaboration with GD-Bath Iron Works, HII-Ingalls Shipbuilding, HII-Newport News Shipbuilding, and the NAVSEA 05T Technical Warrant Holder for additive manufacturing (AM), has developed a physics-based modeling and simulation workflow capable of capturing the manufacturing process physics that drive the performance of as-built AM parts. The resulting workflow showed improved accuracy in predicting strength and mechanical response over conventional modeling methods. Outcomes from this project include the enablement of analysis-driven design for AM parts where designs can be improved to meet requirements prior to costly prototyping and testing campaigns.
Presented by
Elliot Haag
<elliot.haag@ata-e.com>
Institution
ATA Engineering, Inc.
Keywords
Additive Manufacturing, 3D Printing, Modeling, Simulation, Analysis
▼ NSRP - Ship Warfare Systems Integration Panel Back to top
TRITON: Dynamic Network Paradigm Analysis and Demonstration
John Mazurowski, Harold Howard, Sarry Habiby, Jason Farmer, Greg Stevens
Abstract
Present ship cabling connecting supplied equipment is "build-to-print" according to supplier specifications. This causes cabling to be a major part of shipbuilding. Cabling is complex, costly, and heavy. Excessive numbers of parts and installation methods, some proprietary, are difficult to manage. This project and others before it propose to use common Wavelength Division Multiplexed (WDM) optical networks installed by the shipyard, using NAVSEA standard components and installation methods. Data communicated between equipment rides on the network. The networks are configured to make data available to all relevant compartments, making mission preparation and upgrades less difficult. Estimated cost savings is substantial, and comes from a) the use of common parts and installation methods, and b) use of WDM to greatly reduce the number of cables required.
Presented by
John Mazurowski 2
Institution
Penn State Applied Research Laboratory
Keywords
Fiber Optics, Optical Networks, Cabling, Ship Networks
▼ NSRP - Welding Technology Panel Back to top
Deep Penetration Laser-GMAW (HLAW) Welding
Jacob Hay, Stan Ream
Abstract
Laser and gas metal arc welding (GMAW) have been combined in several industries to produce synergistic welding performance. Commonly called “laser-hybrid” welding (see figure 1 below), the combination of the two processes enhances weld joint gap tolerance, joint geometry, weld nugget metallurgy, and heat input management. In shipyard applications the laser-hybrid process is currently being used successfully to perform panel welding on up to ½” thick steels. The success of this shipyard application has led to an interest in advancing the process to enable thicker weld joints, up to 1” total thickness.
Presented by
Jake Hay
<jhay@ewi.org>
Institution
EWI (Edison Welding Institute)
Keywords
Hybrid Laser GMAW, HLAW, Hybrid Laser Gas Metal Arc Welding, Thick Section Welding
Chat with Presenter
Available Call or Email anytime Phone: 614-688-5202
Join the Discussion
▼ NSRP - Workforce Development Panel Back to top
Certificate Program: Shipbuilding Industry Marine Designer Training
Kyle Jellison, General Dynamics, Bath Iron Works
Abstract
This project culminates into the development of an Instructor’s Guide for facilitating Marine Designer Training. Targeting new hires as well as the general public, the training will include computer literacy skills, draftsmanship, print reading, marine design concepts, shipbuilding methods, and computer aided design training (AutoCAD). The Instructor’s Guide will include specific course materials and resources to aid facilitation by any company or community college.
The curriculum itself is structured as a one-year apprenticeship program that can be registered in any state’s DOL. It includes approximately 144 hours of specific training for the shipbuilding designers, and is intended to coincide with a learner’s work experience once hired. Used as a one-year apprenticeship or just a 3-week training program, this training is designed for the attendee to earn a certificate distinguishing him or her as a knowledgeable and competent shipyard marine designer.
The curriculum itself is structured as a one-year apprenticeship program that can be registered in any state’s DOL. It includes approximately 144 hours of specific training for the shipbuilding designers, and is intended to coincide with a learner’s work experience once hired. Used as a one-year apprenticeship or just a 3-week training program, this training is designed for the attendee to earn a certificate distinguishing him or her as a knowledgeable and competent shipyard marine designer.
Presented by
Kyle Jellinson
Institution
Austal USA, Electric Boat, NASSCO, & NMEC
Keywords
Certificate Program: Shipbuilding Industry Manufacturing Technician Training
J. Scott Christman, Ph.D.
Abstract
This project culminates into the development of an Instructor’s Guide for facilitating Manufacturing Technician Training. Targeting new hires as well as the general public, the curriculum for Manufacturing Technician Training will include: shipbuilding basics, introduction to hand and power tools, basic blueprint reading, technical math and measurements, safety and lean training, as well as plasma cutting and tack welding. The Instructor’s Guide will include specific course materials and resources to aid facilitation by any company or community college.
The curriculum itself is structured as a one-year apprenticeship program that can be registered in any state’s DOL. It includes approximately 144 hours of specific training for the “desk plate”, and is designed to coincide with a learner’s work experience once hired. Used as a one-year apprenticeship or just a 3-week training program, it is intended for the attendee to earn a certificate distinguishing him or her as a knowledgeable and competent shipyard production craft mechanic.
The curriculum itself is structured as a one-year apprenticeship program that can be registered in any state’s DOL. It includes approximately 144 hours of specific training for the “desk plate”, and is designed to coincide with a learner’s work experience once hired. Used as a one-year apprenticeship or just a 3-week training program, it is intended for the attendee to earn a certificate distinguishing him or her as a knowledgeable and competent shipyard production craft mechanic.
Presented by
J. Scott Christman, Ph.D
Institution
General Dynamics Bath Iron Works
Keywords
Certificate Program, Manufacturing, Trades Training