31 août 2023 | International, C4ISR
Marines overhaul approach to smart robots, eye new military job
Now, Marine leaders want to bring all of the service’s unmanned systems efforts under one roof.
6 mai 2019 | International, Naval
BY MARCUS WEISGERBER
Even decades-old aircraft carriers are being mapped onto digital models at Newport News Shipbuilding.
NEWPORT NEWS, Va. — When the USS George Washington took shape here in the late 1980s, endless paper blueprints guided the welders and shipfitters of Newport News Shipbuilding. Now, with the aircraft carrier back in a drydock for its midlife overhaul, shipyard workers are laser-scanning its spaces and bulkheads.
They're compiling a digital model of the 104,000-ton carrier, which will allow subsequent Nimitz-class projects to be designed and planned on computers. That will help bring the shipyard's carrier-overhaul work in line with its digital design-and-manufacturing processes that are already speeding up construction and maintenance on newer vessels.
Newport News executives say these digital shipbuilding concepts are revolutionizing the way ships are designed and built.
“We want to leverage technology, learn by doing and really drive it to the deckplates,” Chris Miner, vice president of in-service carriers, said during a tour of the shipyard. This is the future. This isn't about if. This is where we need to go.”
This storied shipyard, now a division of Huntington Ingalls Industries, has been building warships for the U.S. Navy for more than 120 years. Some of its buildings are nearly that old, and some of its employees are fifth-generation shipbuilders. But the technology they use to design, build, and overhaul submarines and mammoth aircraft carriers is rapidly changing. Paper schematics are quickly becoming a thing of the past, being replaced by digital blueprints easily accessible to employees on handheld tablets.
“The new shipbuilders coming in, they're not looking for you to hand them a 30-page or a 200-page drawing,” Miner said. “We're really transitioning how we train folks and how we do things as far as getting them proficient.”
This digital data will “transform the business,” said Miner.
The technology is spreading beyond the shipbuilding sector. Boeing used digital tools to design a new pilot training jet for the Air Force and an aerial refueling drone from the Navy. The Air Force is planning to evaluate new engines for its B-52 bombers, nearly six-decade-old planes, using digital tools. The technology is allowing companies to build weapons faster than traditional manufacturing techniques.
Engineers here at Newport News Shipbuilding are already using digital blueprints to design ships, but they plan to expand the use of the technology into manufacturing in the coming years.
“We want to be able to leverage off all that data and use it,” Miner said. “There's lots of things we can do with that [data].”
The USS Gerald Ford — the Navy's newest aircraft carrier and first in its class — was designed using digital data. The Navy's new Columbia-class nuclear submarines are being digitally designed as well.
Parts for the future USS Enterprise (CVN 80) — the third Ford-class carrier — are being built digitally. Data from the ship's computerized blueprints are being fed into machines that fabricate parts.
“We're seeing over 20 percent improvement in performance,” Miner said.
When the Navy announced it would buy two aircraft carriers at the same time, something not done since the 1980s, James Geurts, the head Navy acquisition, said digital design would contribute to “about an 82 percent learning from CVN79 through to CVN 81” — the second through fourth Ford ships. Geurts called the savings “a pretty remarkable accomplishment for the team.”
In the future, even more of that data will be pumped directly into the manufacturing robots that cut and weld more and more of a ship's steel parts.
“That's the future,” Miner said. “No drawings. They get a tablet. They can visualize it. They can manipulate it, see what it looks like before they even build it.”
As shipyard workers here give the George Washington a thorough working-over, they are using laser scanners to create digital blueprints of the ship. These digital blueprints are creating a more efficient workforce and reducing cutting as many as six months from a three-year overhaul, Miner said.
The top of its massive island — where sailors drive the ship and control aircraft — has been sliced off. It will be rebuilt in the coming months with a new design that will give the crew a better view of the flight deck.
The island already sports a new, sturdier mast that can hold larger antennas and sensors. Shipyard workers lowered it into place in early March.
The yard is also combining its digital ship designs with augmented reality gear to allow its designers and production crews to virtually “walk through” the Ford class's spaces. This helped the yard figure out, for example, whether the ship's sections were designed efficiently for maintenance.
In addition to robots, the additive manufacturing techniques, like 3D printing, could speed shipbuilding even more and reduce the Navy's need for carrying spare parts on ships. The Navy is testing a valve 3D-printed here.
Right now, at a time when the Navy is planning to drastically expand its fleet size, shipyards like Newport News are expanding, but not yet to the levels of the Reagan military buildup of the 1980s. Despite the technology advantages, Miner said people still play essential roles in the manufacturing process.
“It's really not about reducing our workforce as much it is about doing more with the workforce we have,” he said. “We're still going to hire people. We still have to ramp up. There's still hands-on things that are always going to have to be done. But it definitely helps us with cycle time to be able to build things quicker” and “enable our workforce to be more efficient.”
31 août 2023 | International, C4ISR
Now, Marine leaders want to bring all of the service’s unmanned systems efforts under one roof.
28 juillet 2024 | International, Aérospatial
The study could drive changes to future tranches of Space Development Agency and Space Systems Command satellites.
11 février 2020 | International, Naval
By: David B. Larter WASHINGTON — U.S. Defense Secretary Mark Esper is calling for a 355-ship fleet by 2030, but for fiscal 2021, shipbuilding took a big hit in the Defense Department's budget request. The Navy's FY21 budget request asked for $19.9 billion for shipbuilding; that's $4.1 billion less than enacted levels for 2020. The ask also seeks in total four fewer ships than the service requested in its 2020 budget. The hefty slice out of shipbuilding comes in the first year the Navy requested full funding for the first Columbia-class submarine, which Navy leaders have warned for years would take up an enormous portion of the shipbuilding account. The Department of the Navy's total budget request (including both base funding and overseas contingency operations funding) is $207.1 billion, approximately split $161 billion for the Navy and $46 billion for the Marine Corps. News of the cuts come a day after Defense News held an exclusive interview with Esper during which he backed a larger, 355-ship fleet, but said the Navy must refocus around smaller, lighter ships to fit within budget constraints. In total, the Navy requested two Arleigh Burke-class destroyers, one Columbia-class submarine, one Virginia-class submarine, one FFG(X) future frigate, one LPD-17 amphibious transport dock, and two towing and salvage ships. The budget reflected a cut to the Virginia-class sub and FFG(X) programs, each of which were supposed to be two ships in 2021, according to last year's 30-year shipbuilding plan. Both cuts were forecast in a memo from the White House's Office of Management and Budget obtained by Defense News in December. The memo also called for cutting an Arleigh Burke destroyer, but it appears to have been restored in trade-offs. Another controversial move in the budget is the decommissioning of the first four littoral combat ships, likewise a move forecast in the OMB memo, as well as the early decommissioning of a dock landing ship. The budget also requests a $2.5 billion cut to aircraft procurement over 2020's enacted levels, requesting $17.2 billion. The budget calls for 24 F/A-18E/F Super Hornets fighter jets, 21 F-35C jets (between the Navy and Marine Corps), and four E-2D Hawkeye aircraft. The budget also funds $160 million in shipyard upgrades, as well as research into the Common Hull Auxiliary Multi-Mission Platform to the tune of $17 million. There is also $208 million in research and development for the DDG-1000 class, as well as $216 million for the Ford class. It also funds the procurement of two new large unmanned surface vessels. Columbia cuts? For years the Navy has warned that once the service starts buying the Columbia class, it's going to have a significant impact on everything else the Navy wants to buy. In a 2013 hearing before the House Armed Service Committee's sea power subpanel, then-Navy Director of Undersea Warfare Rear Adm. Richard Breckenridge testified that failure to realign the Department of Defense's budget by even 1 percent would have a devastating impact on the Navy's shipbuilding program. "The Navy recognizes that without a supplement this is going to have a devastating impact on our other general-purpose ships and is working with the [Office of the Secretary of Defense] and with Congress to identify the funds necessary, which I mentioned earlier represent less than 1 percent of the DoD budget for a 15-year period, to provide relief and fund this separately above and beyond our traditional norms for our shipbuilding budget,” Breckenridge said. But with the rubber meeting the road, the Navy's budget instead went down by almost 20 percent. In an interview with Defense News, Esper rejected the idea of moving Columbia out of the Navy's shipbuilding account, even as he called for a much larger fleet in the future. The Navy must tighten its belt to reduce the impact on the budget, Esper said, adding that the Air Force is in a similar financial bind. “Clearly the Columbia is a big bill, but it's a big bill we have to pay,” Esper said. “That's the Navy's bill. The Air Force has a bill called bombers and ground-based strategic deterrent, so that's a bill they have to pay. “We all recognize that. Acting Secretary [of the Navy Thomas] Modly and I have spoken about this. He believes, and I think he's absolutely correct, that there are more and more efficiencies to be found within the department, the Navy and the Marine Corps, that they can free up money to invest into ships, into platforms.” It is unclear, however, where the Navy will be able to find that money. Despite years of record defense budgets under the Trump administration, the Navy — at its current size of 294 ships — is struggling to field sufficient manpower. It has also struggled with the capacity of its private shipyards and is scouring the country for new places to fix its ships. Furthermore, there are questions about whether the Navy is adequately funding its surge forces, given that the Abraham Lincoln Carrier Strike Group was stranded on a Middle East deployment for more than 10 months because the carrier relieving it had a casualty. The Navy declined to use its surge forces and instead extended Abraham Lincoln's deployment, according to Chief of Naval Operations Adm. Michael Gilday. Esper said the Navy must look to smaller ships to grow, even though the current budget also defunds a second FFG(X) planned for this year. The FFG(X) was developed to field significant capabilities for about half the price of an Arleigh Burke so they could be bought in greater number. “We need to move away from large platforms,” Esper said. “We need to move to smaller and more ships. We need to move to optionally manned.” The idea of moving to a more lightly manned fleet with an unmanned option is currently en vogue with the Navy, and it's partly driven by the fact that 35-40 percent of the shipbuilding budget is eaten up by the Columbia class for the foreseeable future. That's something that all parties are coming around to, Esper said. “[Acting Secretary Modly] agrees, so there's no doubt he's on board," Epser said. “I know the chairman and I have had the same conversations. I've heard from members of Congress. If you go look at the think tank literature that's out there, they will tell you generally the same thing. We need to move forward in that direction.” Optionally manned vs. optionally unmanned Experts disagree over the degree to which the Navy should pursue a more lightly manned construct, and the difference appears to be philosophical: The Navy is developing an “optionally manned” ship; a recent Center for Strategic and Budgetary Assessments study led by analyst Bryan Clark is proposing an “optionally unmanned” ship. It may seem like a small difference, but building a ship designed from the ground up to support humans is a major difference from a boat that can accommodate a few humans if the operators want to. The Navy is currently pursuing a large unmanned surface vessel, or LUSV, which is based on a commercial offshore support vessel, as part of an effort that started in the aegis of the Office of the Secretary of Defense's Special Capabilities Office and is now run by the Navy. The service describes its planned LUSV as an external missile magazine that can significantly boost the number of missile tubes fielded for significantly less money than buying Arleigh Burke-class destroyers, which cost nearly $2 billion per hull. The Navy has discussed equipping the LUSV with the ability to house sailors, but the vessel would be largely designed as an unmanned platform, which would save money because there likely won't be a need for structure that supports human habitation. Sailors supporting an LUSV might use a port-a-potty and eat MREs rather than building an at-sea septic system and galley, for example. But therein lies the problem with the LUSV, according to the study by CSBA: What would the Navy do with those vessels, which it intends to buy in mass, when it's not trading missiles with China? Before the Navy gets too far down the road of fielding an optionally manned LUSV, the Navy should pony up for a more expensive but more useful corvette that, in the event of war, could be unmanned and used as the envisioned external missile magazine, the study said. “The Navy's planned LUSV would also be an approximately 2,000-ton ship based on an [offshore support vessel] design,” the study read. “In contrast to the optionally manned LUSV, the DDC [corvette] would be an optionally unmanned vessel that would normally operate with a crew. By having small crews, DDCs could contribute to peacetime training, engagement, maritime security, and deterrence.” In other words, for every scenario short of war, there would be a small warship that can execute normal naval missions — missions that ideally deter conflict from occurring in the first place. The study described a vessel that would be crewed with as many as 24 sailors, but would retain the ability to be unmanned in a crisis. “Instead of procuring an optionally manned LUSV that may be difficult to employ throughout the spectrum of competition and conflict, CSBA's plan introduces a similarly designed DDC that is designed to be, conversely, optionally unmanned and would normally operate with small crews of around 15–24 personnel,” the report read. “DDCs primarily armed with offensive weapons would serve as offboard magazines for force packages.” https://www.defensenews.com/naval/2020/02/10/355-as-secdef-backs-a-bigger-fleet-dod-moves-to-cut-shipbuilding-by-20-percent/